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SECTION : 100-00 General Information VEHICLE APPLICATION : 2003.0 BA Falcon CONTENTS
PAGE
DESCRIPTION AND OPERATION About this Manual .................................................................................................................100-00-3 Introduction ..........................................................................................................................100-00-3 Replacement Parts ...............................................................................................................100-00-3 Special Tools ........................................................................................................................100-00-3 Important Safety Instructions ...............................................................................................100-00-3 Warnings, Cautions and Notes in This Manual ....................................................................100-00-3 How to Use This Manual ......................................................................................................100-00-3 Samples ...............................................................................................................................100-00-4 Health and Safety Precautions .............................................................................................100-00-4 Introduction ..........................................................................................................................100-00-4 Acids and Alkalis ..................................................................................................................100-00-4 Air Bags ................................................................................................................................100-00-4 Air Conditioning Refrigerant .................................................................................................100-00-5 Adhesives and Sealers ........................................................................................................100-00-5 Antifreeze .............................................................................................................................100-00-6 Asbestos ..............................................................................................................................100-00-6 Battery Acids ........................................................................................................................100-00-6 Brake and Clutch Linings and Pads .....................................................................................100-00-6 Brakes Fluids (Polyalkylene Glycols) ...................................................................................100-00-6 Brazing .................................................................................................................................100-00-6 Chemical Materials ...............................................................................................................100-00-6 Chlorofluorocarbons (CFC) ..................................................................................................100-00-7 Clutch Fluids ........................................................................................................................100-00-7 Clutch Linings and Pads ......................................................................................................100-00-7 Corrosion Protection Materials .............................................................................................100-00-7 Cutting ..................................................................................................................................100-00-7 Dewaxing .............................................................................................................................100-00-7 Dusts ....................................................................................................................................100-00-7 Electric Shock ......................................................................................................................100-00-7 Engine Oils ...........................................................................................................................100-00-7 Exhaust Fumes ....................................................................................................................100-00-8 Fibre Insulation .....................................................................................................................100-00-8 Fire .......................................................................................................................................100-00-8 First Aid ................................................................................................................................100-00-8 Fluoroelastomer ...................................................................................................................100-00-8 Foams - Polyurethane ..........................................................................................................100-00-8 Freon ....................................................................................................................................100-00-8 Fuels ....................................................................................................................................100-00-8 Gas Cylinders .......................................................................................................................100-00-9 Gases ...................................................................................................................................100-00-9 Gaskets (Fluoroelastomer) ...................................................................................................100-00-9 General Workshop Tools and Equipment ............................................................................100-00-9 High Pressure Air, Lubrication and Oil Test Equipment ....................................................100-00-10 Halon ..................................................................................................................................100-00-10 Legal Aspects .....................................................................................................................100-00-10 Lubricants and Greases .....................................................................................................100-00-10 Noise ..................................................................................................................................100-00-10 Noise Insulation Materials ..................................................................................................100-00-10 01/2003 2003.0 BA Falcon
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(Continued) O-Rings (Fluoroelastomer) .................................................................................................100-00-10 Paints .................................................................................................................................100-00-10 Pressurized Equipment ......................................................................................................100-00-11 Solder .................................................................................................................................100-00-11 Solvents .............................................................................................................................100-00-11 Sound Insulation ................................................................................................................100-00-11 Suspended Loads ..............................................................................................................100-00-11 Transmission Brake Bands ................................................................................................100-00-11 Underseal ...........................................................................................................................100-00-11 Viton ...................................................................................................................................100-00-11 Welding ..............................................................................................................................100-00-12 Warning Symbols on Vehicles ...........................................................................................100-00-12 White Spirit .........................................................................................................................100-00-13 Standard Workshop Practices ............................................................................................100-00-13 Vehicle in Workshop ..........................................................................................................100-00-13 Alternative Fuel ..................................................................................................................100-00-14 Alternative Fuel — Do’s .....................................................................................................100-00-14 Alternative Fuel — Do Nots ...............................................................................................100-00-14 Towing the Vehicle .............................................................................................................100-00-14 Connecting a Slave Battery Using Jumper Cables ............................................................100-00-14 Component Cleaning .........................................................................................................100-00-15 Calibration of Essential Measuring Equipment ..................................................................100-00-15 Solvents, Sealers and Adhesives .......................................................................................100-00-15 Introduction ........................................................................................................................100-00-15 General Specifications .......................................................................................................100-00-16 Road/Roller Testing ............................................................................................................100-00-16 Pre-Test Checks ................................................................................................................100-00-16 Starting the Engine ............................................................................................................100-00-16 On Road or Roller Test Check: ..........................................................................................100-00-17 Brake Testing .....................................................................................................................100-00-17
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DESCRIPTION AND OPERATION
About this Manual Introduction This manual has been written in a format that is designed to meet the needs of Ford technicians worldwide. The objective is to use common formats and include similar content in each manual worldwide. This manual provides general descriptions for accomplishing service and repair work with tested, effective techniques. Following them will help assure reliability.
NOTE: Notes are used to provide additional essential information required to carry out a complete and satisfactory repair. As you read through this manual, you will come across WARNINGS, CAUTIONS and NOTES. A warning, caution or note is placed at the beginning of a series of steps if it applies to multiple steps. If the warning, caution or note only applies to one step, it is placed at the beginning of the specific step (after the step number).
How to Use This Manual
Replacement Parts
This manual covers service and repair procedures. This manual is structured into groups and sections, with specific system sections collected together under their relevant group. A group covers a specific portion of the vehicle. The manual is divided into five groups, General Information, Chassis, Powertrain, Electrical and Body Special Tools and Paint. The number of the group is the first The Special Tool(s) Table provided at the beginning number of a section number. of each procedure shows all special tools required to Pages at the start of the manual list all sections carry out a repair. Where possible, illustrations are available. Each section has a contents list detailing provided to assist in identifying the special tool General Specifications, Description and Operation required. and Service Adjustment and Checks. Special tools may be ordered from: If components need to be removed or disassembled in sequence, the sequence will be identified Australia numerically in a graphic and the corresponding text SPX AUSTRALIA will be numbered accordingly (refer to ‘Samples’). Tel: +61 (03) 9544 6222 All left and right-hand references to the vehicle are Fax: +61 (03) 9544 5222 taken from a position sitting in the driver seat looking forward. Important Safety Instructions All left and right-hand references to the engine are taken from a position at the flywheel looking towards Appropriate service methods and correct repair the front camshaft pulley. procedures are essential for the safe, reliable operation of all motor vehicles as well as the personal Where appropriate, instructions will be given for the use of WDS, diagnostic equipment. safety of the individual carrying out the work. Inspection and Verification This manual cannot possibly anticipate all such variations and provide advice or cautions as to each. Visual Inspection Charts, Symptom Charts and other Anyone who departs from the instructions provided in information charts (such as diagnostic routines), this manual must first establish that he compromises supplement test procedures with technical neither his personal safety nor the vehicle integrity by specifications, or navigate the user to a specific test his choice of methods, tools or parts. procedure. Sympton Chart Warnings, Cautions and Notes in This The symptom chart indicates symptoms, sources and Manual actions to address a condition. Pinpoint Tests WARNING: Warnings are used to indicate that failure to follow a procedure correctly may For electrical systems, pinpoint test steps are used to result in personal injury. identify the source of a concern in a logical, step-by-step manner. Pinpoint tests have two CAUTION: Cautions are used to indicate that columns: CONDITIONS and DETAILS/RESULTS/ACTIONS. failure to follow a procedure correctly may result in damage to the vehicle or equipment being The CONDITIONS column is used exclusively for used. graphics and icons (with or without captions) and the DETAILS/RESULTS/ACTIONS column provides Ford and Motorcraft parts are made to the same exacting standards as the original factory fitted components. For this reason, it is recommended that only genuine Ford or Motorcraft parts are installed during service or repair.
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DESCRIPTION AND OPERATION (Continued) direction to another test step or specific corrective actions. The boxed numbers indicate the order in which the described action is to be performed. Component Tests A component test is used when a component is tested in multiple pinpoint tests, or if a procedure is too complicated to be formatted within a single page of the pinpoint test. Graphics Test graphics show the measurement or test to be performed in a test step. A representative tester graphic is used for voltmeters and ohmmeters. If multiple measurements are made in a single graphic, the test leads are drawn with a solid line until the test lead splits to indicate the multiple measurements, at which point dashed lines are used. Breakout box-type testers are represented by a double circle test pin. Test pins are labelled with the pin number.
Samples Special Tools and Torque Figures Any requirement for special tools will picture the tool, showing it in use and with its tool number shown. Torque settings will be given at the relevant point in the procedure.
Health and Safety Precautions Introduction Many of the procedures associated with vehicle maintenance and repair involve physical hazards or other risks to health. This subsection lists, alphabetically, some of these hazardous operations and the materials and equipment associated with them. Precautions necessary to avoid these hazards are identified. The list is not exhaustive and all operations and procedures, and the handling of materials, should be carried out with health and safety in mind.
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Before using any product the Materials Safety Data Sheet supplied by the manufacturer or supplier should be consulted.
Acids and Alkalis See also Battery Acids. For example caustic soda, sulphuric acid. Used in batteries and cleaning materials. Irritant and corrosive to the skin, eyes, nose and throat. Cause burns. Can destroy ordinary protective clothing. Avoid splashes to the skin, eyes and clothing. Wear suitable protective impervious apron, gloves and goggles. Do not breath mists. Make sure access to eye wash bottles, shower and soap are readily available for splashing accidents. Display Eye Hazard sign.
Air Bags See also Fire, Chemical Materials Highly flammable, explosive – observe No Smoking policy. Used as a safety restraint system mounted in the steering wheel and passenger side of the instrument panel and side impact Airbags. The inflator contains a high-energetic propellant which, when ignited, produces a VERY HOT GAS (2500°C). The gas generant used in air bags is Sodium Azide. This material is hermetically sealed in the module and is completely consumed during deployment. No attempt should be made to open an air bag inflator as this will lead to the risk of exposure to Sodium Azide. If a gas generator is ruptured, full protective clothing should be worn when dealing with the spillage. After normal deployment, gloves and safety goggles should be worn during the handling process. Deployed air bags should be disposed of in a plastic bag in accordance with local regulations at an approved chemical waste site. Following any direct contact with gas generant. wash affected areas thoroughly with water. seek medical assistance if necessary. Air Bags - Do’s do store modules in an upright position. do keep modules dry. do carry modules with the cover side pointing away from the body. do place modules with their cover side upwards. do carefully inspect modules for damage. do stand to one side when connecting modules. do make sure all test equipment is properly calibrated and maintained. do wash hands after handling deployed air bags. 01/2003 2003.0 BA Falcon
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DESCRIPTION AND OPERATION (Continued) Air Bags - Do Nots do not store highly flammable material together with modules or gas generators. do not store gas generators at temperatures exceeding 80°C. do not store modules upside down. do not attempt to open a gas generator housing. do not expose gas generators to open flame or sources of heat. do not place anything on top of a module cover. do not use damaged modules. do not touch a fired module or gas generator for at least 10 minutes. do not use any electrical probes on the wiring circuit.
Air Conditioning Refrigerant See also Chlorofluorocarbon, Chemical Materials Highly flammable, combustible – observe No Smoking policy. Skin contact may result in frostbite. Instructions given by the manufacturer must be followed. Avoid naked lights, wear suitable protective gloves and goggles. If refrigerant comes into contact with the skin or eyes, rinse the affected areas with water immediately. Eyes should also be rinsed with an appropriate irrigation solution and should not be rubbed. SEEK MEDICAL ASSISTANCE IF NECESSARY.
Air Conditioning Refrigerant - Do Nots do not expose refrigerant bottles to sunlight or heat. do not stand refrigerant bottles upright; when filling, hold them with the valve downwards. do not expose refrigerant bottles to frost. do not drop refrigerant bottles. do not vent refrigerant to atmosphere under any circumstance. do not mix refrigerants, for example R12 (Freon) and R134a.
Adhesives and Sealers See also Fire, Chemical Materials Highly flammable, flammable, combustible – observe No Smoking policy. Generally should be stored in No Smoking areas. Cleanliness and tidiness in use should be observed, for example disposable paper covering benches; should be dispensed from applicators where possible; containers, including secondary containers, should be labelled appropriately.
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Solvent-based Adhesives/Sealers - See Solvents Follow manufacturers instructions.
Water-based Adhesives/Sealers Those based on polymer emulsions and rubber latexes may contain small amounts of volatile toxic and harmful chemicals. Skin and eye contact should be avoided and adequate ventilation provided during use.
Hot Melt Adhesives In the solid state, they are safe. In the molten state they may cause burns and health hazards may arise from the inhalation of toxic fumes. Use appropriate protective clothing and a thermostatically controlled heater with a thermal cut-out and adequate extraction.
Resin-based Adhesives/Sealers, for example Epoxide and Formaldehyde Resin-based Mixing should be carried out in well ventilated areas, as harmful or toxic volatile chemicals may be released. Skin contact with uncured resins and hardeners can result in irritation, dermatitis, and absorption of toxic or harmful chemicals through the skin. Splashes can damage the eyes. Provide adequate ventilation and avoid skin and eye contact.
Anaerobic, Cyanoacrylate (super-glues) and other Acrylic Adhesives Many are irritant, sensitizing or harmful to the skin and respiratory tract. Some are eye irritants. Skin and eye contact should be avoided and the manufacturers instructions followed. Cyanoacrylate adhesives (super-glues) MUST NOT contact the skin or eyes. If skin or eye tissue is bonded, cover with a clean moist pad and SEEK IMMEDIATE MEDICAL ATTENTION. Do not attempt to pull tissue apart. Use in well ventilated areas as vapours can cause irritation to the nose and eyes. For two-pack systems see Resin-based and Isocyanate Adhesives/Sealers.
Isocyanate (Polyurethane) Adhesives/Sealers See also Resin-based Adhesives Individuals suffering from asthma or respiratory allergies should not work with or near these materials as sensitivity reactions can occur. Over exposure is irritating to the eyes and respiratory system. Excessive concentrations may produce effects on the nervous system including drowsiness. In extreme cases, loss of consciousness may result. Long term exposure to vapour concentrations may result in adverse health effects. 01/2003 2003.0 BA Falcon
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DESCRIPTION AND OPERATION (Continued) Prolonged contact with the skin may have a defatting effect which may lead to skin irritation and in some cases, dermatitis. Splashes entering the eye will cause discomfort and possible damage. Any spraying should preferably be carried out in exhaust ventilated booths, removing vapours and spray droplets from the breathing zone. Wear appropriate gloves, eye and respiratory protection.
Antifreeze See also Fire, Solvents. For example isopropanol, ethylene glycol, methanol. Highly flammable, flammable, combustible. Used in vehicle coolant systems, brake air pressure systems, screenwash solutions. Vapours may be given off from coolant antifreeze (glycol) when heated. Avoid breathing these vapours. Antifreeze may be absorbed through the skin in toxic or harmful quantities. Antifreeze, if swallowed, can be fatal and MEDICAL ATTENTION SHOULD BE SOUGHT IMMEDIATELY. These products must not be used in any cooling or industrial water system which is connected or linked to general, food preparation or drinking water supplies.
Asbestos See also Warning Symbols on Vehicles at the end of this subsection. Breathing asbestos dust may cause lung damage or, in some cases, cancer. Used in brake and clutch linings, transmission brake bands and gaskets. Ford original production and genuine replacement items for this model are asbestos free. The use of drum cleaning units, vacuum cleaning or damp wiping is preferred. Asbestos dust waste should be dampened, placed in a sealed container and marked for safe disposal. If any cutting or drilling is attempted on materials containing asbestos the item should be dampened and only hand tools or low speed power tools used.
Battery Acids See also Acids and Alkalis. Gases released during charging are explosive. Never use naked flames or allow sparks near charging or recently charged batteries. Make sure there is adequate ventilation.
Brake and Clutch Linings and Pads See Asbestos.
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Brakes Fluids (Polyalkylene Glycols) See also Fire. Splashes to the skin and eyes are extremely irritating. Avoid skin and eye contact as far as possible. Inhalation vapour hazards do not arise at ambient temperatures because of the very low vapour pressure.
Brazing See Welding.
Chemical Materials See also Legal Aspects. Chemical materials such as solvents, sealers, adhesives, paints, resin foams, battery acids, antifreeze, brake fluids, fuels, oils and grease should always be used with caution and stored and handled with care. They may be toxic, harmful, corrosive, irritant or highly flammable and give rise to hazardous fumes and dusts. The effects of excessive exposure to chemicals may be immediate or delayed; briefly experienced or permanent; cumulative; superficial; life threatening; or may reduce life expectancy.
Chemical Materials - Do’s Do carefully read and observe hazard and precaution warnings given on material containers (labels) and in any accompanying leaflets, posters or other instructions. Material health and safety data sheets can be obtained from manufacturers. Do remove chemical materials from the skin and clothing as soon as practicable after soiling. Change heavily soiled clothing and have it cleaned. Do organise work practices and protective clothing to avoid soiling of the skin and eyes; breathing vapours, aerosols, dusts or fumes; inadequate container labelling; fire and explosion hazards. Do wash before job breaks, before eating, smoking, drinking or using toilet facilities when handling chemical materials. Do keep work areas clean, uncluttered and free of spills. Do store chemical materials according to national and local regulations. Do keep chemical materials out of the reach of children.
Chemical Materials - Do Nots Do not mix chemical materials except under the manufacturers instructions; some chemicals can form other toxic or harmful chemicals, give off toxic or harmful fumes or become explosive when mixed together. Do not spray chemical materials, particularly 01/2003 2003.0 BA Falcon
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DESCRIPTION AND OPERATION (Continued) those based on solvents, in confined spaces, for example when people are inside a vehicle. Do not apply heat or flame to chemical materials except under the manufacturers instructions. Some are highly flammable and some may release toxic or harmful fumes. Do not leave containers open. Fumes given off can build up to toxic, harmful or explosive concentrations. Some fumes are heavier than air and will accumulate in confined areas such as pits. Do not transfer chemical materials to unlabelled containers. Do not clean hands or clothing with chemicals. Chemicals, particularly solvents and fuels, will dry skin and may cause irritation leading to dermatitis or be absorbed through the skin in toxic or harmful quantities. Do not use emptied containers for other materials except when they have been cleaned under supervised conditions. Do not sniff or smell chemical materials. Brief exposure to high concentrations of fumes can be toxic or harmful.
Cutting See Welding.
Dewaxing See Solvents and Fuels (Kerosene).
Dusts Powder, dusts or clouds may be irritant, harmful or toxic. Avoid breathing dusts from powdery chemical materials or those arising from dry abrasion operations. Wear respiratory protection if ventilation is inadequate. Fine dusts of combustible material can present an explosion hazard. Avoid explosive limits and sources of ignition.
Electric Shock
Electric shock can result from the use of faulty electrical equipment or from the misuse of equipment in good condition. Make sure that electrical equipment is maintained in good condition and frequently tested. Faulty equipment should be labelled and preferably removed from the work station. Chlorofluorocarbons (CFC) Make sure that flexes, cables, plugs and sockets are not frayed, kinked, cut, cracked or otherwise There is concern in the scientific community that damaged. CFCs and Halons are depleting the upper ozone layer Make sure that electrical equipment and flexes do not which filters out harmful ultraviolet radiation. Decreased filtration of ultraviolet radiation may result come into contact with water. in increases in skin cancer, cataracts and immune Make sure that electrical equipment is protected by system suppression in humans, as well as decreased the correct rated fuse. productivity of crops and aquatic systems. Never misuse electrical equipment and never use CFCs are used primarily as refrigerants in vehicle air equipment which is in any way faulty. The results conditioning systems and as aerosol propellants. could be fatal. Halons are used as fire extinguishants. Make sure that the cables of mobile electrical Ford supports worldwide elimination of CFC usage equipment cannot get trapped and damaged, such as and it is recommended that Company subsidiaries in a vehicle hoist. and affiliates should phase out CFC usage as soon as Make sure that the designated electrical workers are acceptable substitutes are commercially available. trained in basic First Aid. In cases of electrocution: Clutch Fluids switch off the power supply before approaching See Brake fluids. the victim. Clutch Linings and Pads if this is not possible push or drag the victim from the source of electricity using dry non-conductive See Asbestos. material. Corrosion Protection Materials commence resuscitation if trained to do so. SUMMON MEDICAL ASSISTANCE. See also Solvents, Fire. Highly flammable, flammable – observe No Smoking Engine Oils policy. See Lubricants and Grease. These materials are varied and the manufacturers instructions should be followed. They may contain Exhaust Fumes solvents, resins or petroleum products. Skin and eye These contain asphyxiating, harmful and toxic contact should be avoided. They should only be sprayed in conditions of adequate ventilation and not chemicals and particles such as carbon oxides, nitrogen oxides, aldehydes, lead and aromatic in confined spaces. G17372 en
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DESCRIPTION AND OPERATION (Continued) hydrocarbons. Engines should be run only under conditions of adequate exhaust extraction or general ventilation and not in confined spaces.
Foams - Polyurethane
First Aid
Avoid skin contact with fuel where possible. Should contact occur, wash the affected skin with soap and water.
See also Fire. Used in sound and noise insulation. Cured foams Gasolene (petrol) engine used in seat and trim cushioning. There may not be adequate warning of odour or of Follow manufacturers instructions. irritation before toxic or harmful effects arise. These Unreacted components are irritating and may be may be immediate or delayed. harmful to the skin and eyes. Wear gloves and goggles. Diesel engine Individuals with chronic respiratory diseases, asthma, Soot, discomfort and irritation usually give adequate bronchial medical problems, or histories of allergic warning of hazardous fume concentrations. diseases should not work in or near uncured materials. Fibre Insulation The components, vapours or spray mists can cause See also Dusts. direct irritation, sensitivity reactions and may be toxic Used in noise and sound insulation. or harmful. The fibrous nature of surfaces and cut edges can Vapours and spray mists must not be inhaled. These cause skin irritation. This is usually a physical and not materials must be applied with adequate ventilation a chemical effect. and respiratory protection. Do not remove the respirator immediately after spraying, wait until the Precautions should be taken to avoid excessive skin contact through careful organization of work practices vapour/mists have cleared. and the use of gloves. Burning of the uncured components and the cured foams can generate toxic and harmful fumes. Fire Smoking, naked flames or the use of electrical equipment during foaming operations and until See also Welding, Foams, Legal Aspects. Many of the materials found on or associated with the vapours/mists have cleared should not be allowed. repair of vehicles are highly flammable. Some give off Any heat cutting of cured foams or partially cured foams should be conducted with extraction ventilation. toxic or harmful fumes if burnt. See also the vehicle Body Repair Manual. Observe strict fire safety when storing and handling flammable materials or solvents, particularly near Freon electrical equipment or welding processes. See Air Conditioning Refrigerant. Make sure, before using electrical or welding equipment, that there is no fire hazard present. Fuels Have a suitable fire extinguisher available when using See also, Fire, Legal Aspects, Chemicals and welding or heating equipment. Solvents. Apart from meeting any legal requirements it is desirable for someone in the workshop to be trained in First Aid procedures. Splashes in the eye should be flushed carefully with clean water for at least ten minutes. Soiled skin should be washed with soap and water. In case of cold burns, from alternative fuels, place affected area in cool to cold water. Individuals affected by inhalation of gases and fumes should be removed to fresh air immediately. If effects persist, consult a doctor. If liquids are swallowed inadvertently, consult a doctor giving him the information on the container or label. Do not induce vomiting unless this action is indicated on the label.
Fluoroelastomer See Viton.
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Gasoline (Petrol) Highly flammable - observe No Smoking policy. Swallowing can result in mouth and throat irritation and absorption from the stomach can result in drowsiness and unconsciousness. Small amounts can be fatal to children. Aspiration of liquid into the lungs, through vomiting, is a very serious hazard. Gasolene dries the skin and can cause irritation and dermatitis on prolonged or repeated contact. Liquid in the eye causes severe smarting. Motor gasolene may contain appreciable quantities of benzene, which is toxic upon inhalation, and the concentration of gasolene vapours must be kept very low. High concentrations will cause eye, nose and throat irritation, nausea, headache, depression and symptoms of drunkenness. Very high concentrations will result in rapid loss of consciousness. 01/2003 2003.0 BA Falcon
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DESCRIPTION AND OPERATION (Continued) Make sure there is adequate ventilation when handling and using gasolene. Great care must be taken to avoid the serious consequences of inhalation in the event of vapour build up arising from spillages in confined spaces. Special precautions apply to cleaning and maintenance operations on gasolene storage tanks. Gasolene should not be used as a cleaning agent. It must not be siphoned by mouth. See First Aid.
checked for integrity following the specified procedures. If the fuel tank is to be removed for service or repair the fuel must be evacuated using dedicated equipment and following the specified procedures.
Gas Cylinders
See also Fire. Gases such as oxygen, acetylene, argon and propane are normally stored in cylinders at pressures of up to Gas-oil (Diesel Fuel) 138 bar (2000 psi) and great care should be taken in Combustible. handling these cylinders to avoid mechanical damage Gross or prolonged skin contact with high boiling point to them or to the valve gear attached. The contents of each cylinder should be clearly identified by gas oils may also cause serious skin disorders appropriate markings. including skin cancer. Cylinders should be stored in well ventilated Kerosene (Paraffin) enclosures, and protected from ice and snow, or Used also as heating fuel, solvent and cleaning agent. direct sunlight. Fuel gases, for example acetylene and propane, should not be stored in close proximity to Flammable - observe No Smoking policy. oxygen cylinders. Irritation of the mouth and throat may result from swallowing. The main hazard from swallowing arises if Care should be exercised to prevent leaks from gas cylinders and lines, and to avoid sources of ignition. liquid aspiration into the lungs occurs. Only trained personnel should undertake work Liquid contact dries the skin and can cause irritation involving gas cylinders. or dermatitis. Splashes in the eye may be slightly irritating. Gases In normal circumstances the low volatility does not See Gas Cylinders. give rise to harmful vapours. Exposure to mists and vapours from kerosene at elevated temperature Gaskets (Fluoroelastomer) should be avoided (mists may arise in dewaxing). See Viton. Avoid skin and eye contact and make sure there is adequate ventilation.
Alternative Fuel Highly flammable. Observe “NO SMOKING” signs. Make sure there is adequate ventilation when working on alternative fuelled vehicles. Great care must be taken to avoid the serious consequences of inhalation in the event of vapour build up in confined spaces. Inhalation in high concentrations may cause dizziness, headache, nausea and loss of co-ordination. Very high concentrations may result in loss of consciousness. Contact with liquidified petroleum gas (LPG) or compressed natural gas (CNG) to skin may cause cold burns and may cause frost bite. Long sleeved cotton overalls, steel toe capped safety boots and rubber neoprene gloves should be worn during removal and installation of LPG/CNG fuel system components. LPG/CNG fuel leaks could cause a fire and be a hazard to health that can lead to personal injury, illness or even death. If a leak is detected, under no circumstances attempt to seal the leak by tightening the union/connection until the fuel in the system or component is depressurised. Once tightened the system should be G17372 en
General Workshop Tools and Equipment
It is essential that all tools and equipment are maintained in good condition and the correct safety equipment is used where required. Never use tools or equipment for any purpose other than that for which they were designed. Never overload equipment such as hoists, jacks, axle and chassis stands or lifting slings. Damage caused by overloading is not always immediately apparent and may result in a fatal failure the next time that the equipment is used. Do not use damaged or defective tools or equipment, particularly high speed equipment such as grinding wheels. A damaged grinding wheel can disintegrate without warning and cause serious injury. Wear suitable eye protection when using grinding, chiselling or sand blasting equipment. Wear a suitable breathing mask when using abrasive blasting equipment, working with asbestos-based materials or using spraying equipment. Make sure there is adequate ventilation to control dusts, mists and fumes.
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DESCRIPTION AND OPERATION (Continued) High Pressure Air, Lubrication and Oil Test Equipment See also Lubricants and Greases. Always keep high pressure equipment in good condition, and regularly maintained, particularly at joints and unions. Never direct a high pressure nozzle, for example diesel injector, at the skin as the fluid may penetrate to the underlying tissue, and cause serious injury.
Halon See CFCs.
Legal Aspects There are many laws and regulations relating to health and safety in the use and disposal of materials and equipment in a workshop. For a safe working environment and to avoid environmental pollution, workshops should be familiar, in detail, with the many health and safety laws and regulations within their country, published by both national and local authorities.
Wash with soap and water to make sure all oil is removed (skin cleansers and nail brushes will help). Preparations containing lanoline replace the natural skin oils which have been removed. Do not use gasolene (petrol), kerosene (paraffin), diesel fuel (gas oil), thinners or solvents for cleaning skin. If skin disorders develop, obtain medical advice without delay. Where practicable, degrease components prior to handling. Where there is a risk of eye contact, eye protection should be worn, for example chemical goggles or face shields; in addition an eye wash facility should be provided.
Environmental Precautions
Burning used engine oil in small space heaters or boilers can be recommended only for units of approved design. If in doubt check with the appropriate local authority and manufacturer of approved appliances. Dispose of used oil and used oil filters through authorized waste disposal contractors or licensed Lubricants and Greases waste disposal sites, or to the waste oil reclamation Avoid all prolonged and repeated contact with mineral trade. If in doubt, contact the relevant local authority oils. All lubricants and greases may be irritating to the for advice on disposal facilities. eyes and skin. It is illegal to pour used oil on to the ground, down sewers or drains, or into water courses. Used Engine Oil Prolonged and repeated contact with mineral oil will result in the removal of natural fats from the skin, leading to dryness, irritation and dermatitis. In addition, used engine oil contains potentially harmful contaminants which may cause skin cancer. Adequate means of skin protection and washing facilities must be provided. Do not employ used engine oils as lubricants or for any application where appreciable skin contact is likely to occur.
Health Protection Precautions Avoid prolonged and repeated contact with oils, particularly used engine oils. Wear protective clothing, including impervious gloves where practicable. Do not put oily rags into pockets. Avoid contaminating clothes, particularly underpants, with oil. Heavily soiled clothing and oil-impregnated footwear should not be worn. Overalls must be cleaned regularly. First Aid treatment should be obtained immediately for open cuts and wounds. Use barrier creams, applying them before each work period, to help the removal of oil from the skin. G17372 en
Noise Some operations may produce high noise levels which could, in time, damage hearing. In these cases, suitable ear protection must be worn.
Noise Insulation Materials See Foams, Fibre Insulation.
O-Rings (Fluoroelastomer) See Viton.
Paints See also Solvents, Chemical Materials. Highly flammable, flammable - observe No Smoking policy
One Pack Can contain harmful or toxic pigments, driers and other components as well as solvents. Spraying should be carried out only with adequate ventilation.
Two Pack Can also contain harmful and toxic unreacted resins and resin hardening agents. The manufacturers instructions should be followed. See also Resin-based Adhesives and Isocyanate Adhesives and Sealers under Adhesives and Sealers. 01/2003 2003.0 BA Falcon
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DESCRIPTION AND OPERATION (Continued) Spraying should preferably be carried out in exhausted ventilated booths removing vapour and spray mists from the breathing zone. Individuals working in booths should wear appropriate respiratory protection. Those doing small scale repair work in the open workshop should wear air-fed respirators.
Pressurized Equipment See High Pressure Air, Lubrication and Oil Test Equipment.
Solder Solders are mixtures of metals such that the melting point of the mixture is below that of the constituent metals (normally lead and tin). Solder application does not normally give rise to toxic lead fumes, provided a gas/air flame is used. Oxy-acetylene flames should not be used, as they are much hotter and will cause lead fumes to be produced. Some fumes may be produced by the application of any flame to surfaces coated with grease, and inhalation of these should be avoided. Removal of excess solder should be undertaken with care, to make sure that fine lead dust is not produced, which can give toxic effects if inhaled. Respiratory protection may be necessary. Solder spillage and filings should be collected and removed promptly to prevent general air contamination by lead. High standards of personal hygiene are necessary in order to avoid ingestion of lead or inhalation of solder dust from clothing.
Avoid splashes to the skin, eyes and clothing. Wear protective gloves, goggles and clothing if necessary. Make sure there is good ventilation when in use, avoid breathing fumes, vapours and spray mists and keep containers tightly sealed. Do not use in confined spaces. When spraying materials containing solvents, for example paints, adhesive, coatings, use extraction ventilation or personal respiratory protection in the absence of adequate general ventilation. Do not apply heat or flame except under specific and detailed manufacturers instructions.
Sound Insulation See Fibre Insulation, Foams.
Suspended Loads CAUTION: Never improvise lifting tackle. There is always a danger when loads are lifted or suspended. Never work under an unsupported, suspended or raised load, for example a suspended engine. Always make sure that lifting equipment such as jacks, hoists, axle stands and slings are adequate and suitable for the job, in good condition and regularly maintained.
Transmission Brake Bands See Asbestos.
Underseal
Solvents
See Corrosion Protection.
See also Chemical Materials, Fuels (Kerosene), Fire. For example acetone, white spirit, toluene, xylene, trichloroethane. Used in cleaning and dewaxing materials, paints, plastics, resins and thinners. Some may be highly flammable or flammable. Skin contact will degrease the skin and may result in irritation and dermatitis following repeated or prolonged contact. Some can be absorbed through the skin in toxic or harmful quantities. Splashes in the eye may cause severe irritation and could lead to loss of vision. Brief exposure of high concentrations of vapours or mists will cause eye and throat irritation, drowsiness, dizziness, headaches and, in the worst circumstances, unconsciousness. Repeated or prolonged exposure to excessive but lower concentrations of vapours or mists, for which there might not be adequate warning indications, can cause more serious toxic or harmful effects. Aspiration into the lungs, for example through vomiting, is the most serious consequence of swallowing.
Viton
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In common with many other manufacturers vehicles, some components fitted to the Ford range have O-rings, seals or gaskets which contain a material known as ‘Viton’. Viton is a fluoroelastomer, that is a synthetic rubber type which contains Fluorine. It is commonly used for O-rings, gaskets and seals of all types. Although Viton is the most well known fluoroelastomer, there are others, including Fluorel and Tecmoflon. When used under design conditions fluoroelastomers are perfectly safe. If, however, they are exposed to temperatures in excess of 400°C, the material will not burn, but will decompose, and one of the products formed is hydrofluoric acid. This acid is extremely corrosive and may be absorbed directly, through contact, into the general body system. O-rings, seals or gaskets which have been exposed to very high temperatures will appear charred or as a black sticky substance. DO NOT, under any circumstances touch them or the attached components. 01/2003 2003.0 BA Falcon
100-00-12
General Information
100-00-12
DESCRIPTION AND OPERATION (Continued) Enquiries should be made to determine whether Viton or any other fluoroelastomer has been used in the affected O-ring, seal or gasket. If they are of natural rubber or nitrile there is no hazard. If in doubt, be cautious as the material may be Viton or any fluoroelastomer. If Viton or any other fluoroelastomers have been used, the affected area should be decontaminated before the commencement of work. Disposable heavy duty plastic gloves should be worn at all times, and the affected area washed down using wire wool and a limewater (calcium hydroxide) solution to neutralise the acid before disposing of the decomposed Viton residue and final cleaning of the area. After use, the plastic gloves should be discarded carefully and safely.
Gas Welding (and Cutting)
This process may cause particles of molten metal to be emitted at a high velocity, and the eyes and skin must be protected.
Oxy-acetylene torches may be used for welding and cutting, and special care must be taken to prevent leakage of these gases, with consequent risk of fire and explosion. The process will produce metal spatter and eye and skin protection is necessary. The flame is bright, and eye protection should be used, but the ultra-violet emission is much less than that from arc welding, and lighter filters may be used. The process itself produces few toxic fumes, but such fumes and gases may be produced from coatings on the work, particularly during cutting away of damaged body parts, and inhalation of the fumes should be avoided. In brazing, toxic fumes may be produced from the metals in the brazing rod, and a severe hazard may arise if brazing rods containing cadmium are used. In this event particular care must be taken to avoid inhalation of fumes and expert advice may be required. Special precautions must be taken before any welding or cutting takes place on vessels which have contained combustible materials, for example boiling or steaming out of fuel tanks .
Arc Welding
Warning Symbols on Vehicles
This process emits a high level of ultra-violet radiation which may cause arc-eye and skin burns to the operator and to other persons nearby. Gas-shielded welding processes are particularly hazardous in this respect. Personal protection must be worn, and screens used to shield other people. CONTACT LENS WEARERS ARE ADVISED TO REVERT TO ORDINARY SPECTACLES WHEN ARC WELDING as the arc spectrum is believed to emit microwaves which dry out the fluid between the lens and the eye. This may result in blindness when the lens is removed from the eye. Metal spatter will also occur, and appropriate eye and skin protection is necessary. The heat of the welding arc will produce fumes and gases from the metals being welded, the rods and from any applied coatings or contamination on the surfaces being worked on. These gases and fumes may be toxic and inhalation of these should be avoided. The use of extraction ventilation to remove the fumes from the working area may be necessary particularly in cases where the general ventilation is poor, or where considerable welding work is anticipated. In extreme cases or confined spaces where adequate ventilation cannot be provided, air-fed respirators may be necessary.
Decals showing warning symbols will be found on various vehicle components. These decals must not be removed. The warnings are for the attention of owners/operators and persons carrying out service or repair operations on the vehicle. The most commonly found decals are reproduced below together with an explanation of the warnings.
Welding See also Fire, Electric Shock, Gas Cylinders. Welding processes include Resistance Welding (Spot Welding), Arc Welding and Gas Welding.
Resistance Welding
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1. Components or assemblies displaying the caution triangle and open book symbol advise consultation of the relevant section of the owners handbook before touching or attempting adjustments of any kind.
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General Information
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DESCRIPTION AND OPERATION (Continued)
2. Components or assemblies displaying the warning 5. Displaying this symbol (normally in conjunction triangle with the ‘electrified’ arrow and open book with 5 above) warn of the presence of potentially symbol give warning of inherent high voltages. explosive matter within the immediate vicinity. Never touch these with the engine running or the ignition switched on. See Electric Shock in this subsection.
6. Displaying this symbol warn that children should not be allowed in the immediate vicinity unsupervised.
3. Components or assemblies displaying this symbol White Spirit give warning that the component contains a corrosive substance. See Acids and Alkalis in this See Solvents. subsection.
Standard Workshop Practices Vehicle in Workshop
When working on a vehicle in the workshop always make sure that: the parking brake is applied or the wheels are securely chocked to prevent the vehicle moving forwards or backwards. the key is removed from key operated hood locks before any work is carried out around the front of the vehicle. if the engine is to be run, there is adequate ventilation, or an extraction hose to remove exhaust fumes. 4. Displaying the caution circle with a deleted lighted there is adequate room to raise the vehicle and match symbol, caution against the use of naked remove the wheels, if necessary. lights or flames within the immediate vicinity due fender covers are always fitted if any work is to be to the presence of highly flammable or explosive carried out in the engine compartment. liquids or vapours. See Fire in this subsection.
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General Information
100-00-14
DESCRIPTION AND OPERATION (Continued) the battery is disconnected if working on the engine.
do not work on the fuel lines or system components unless the alternative fuel has been evacuated and the pressure in the system is reduced to atmospheric, or less CAUTION: When electric arc welding on a vehicle, always disconnect the generator wiring to do not use anything other than the specified leak prevent the possibility of a surge of current detector fluid to trace fuel leaks causing damage to the internal components of the Be aware of situations that may cause the LPG or generator. CNG fuel system to vent off fuel, such as: If using welding equipment on the vehicle, a extremely hot days suitable fire extinguisher is readily available. parking by a space heater Alternative Fuel hoisting a vehicle up near a ceiling heater Only personnel fully trained to Ford and local WARNING: When servicing the fuel system standards are to work on alternative fuel vehicles. always follow the recommended procedures. Towing the Vehicle Failure to follow these instructions may result in personal injury. If the odour of liquified petroleum gas (LPG) or WARNING: When the vehicle is being towed compressed natural gas (CNG) is present in the air in the ignition switch must be in position II (steering the workshop, warn all persons in the area to: lock released and warning lights illuminated). Only then will the steering, turn signal lamps, extinguish all flames and lighted tobacco. horn and stop lamps be operational. Failure to shut off electrical and air powered equipment. follow these instructions may result in personal evacuate the area. injury. ventilate the area. When a vehicle with automatic transmission is towed, the gear selector must be in position N (Neutral). contact fire control authorities. Never tow a vehicle with automatic transmission remove the vehicle to a dedicated, ventilated faster than 30 mph (50 km/h) or further than 30 miles area. (50 km). If it is necessary to tow the vehicle a greater distance, the drive wheels must be lifted clear off the Alternative Fuel — Do’s ground. do work on the vehicle in a designated area that Alternatively the vehicle can be transported on a low is well ventilated and its access restricted to loader or a trailer. qualified personnel only install new warning labels to their original Connecting a Slave Battery Using Jumper locations Cables if possible always isolate the alternative fuel tank, run the vehicle on the alternative fuel until it WARNING: If the slave battery has recently automatically switches to its normal fuel prior to been charged and is gassing, cover the vent plugs taking the vehicle into the workshop/service area or covers with a damp cloth to reduce the risk of only use tested and approved components and explosion should arcing occur when connecting pipes when repairing or servicing LPG and CNG the jumper cables. Failure to follow these systems instructions may result in personal injury.
Alternative Fuel — Do Nots do not vent off LPG fuel do not use shop air pressure to force LPG fuel from the fuel tank do not use paint drying ovens above 40°C for any alternative fuel vehicles. LPG and CNG fuel tanks should be removed from the vehicles prior to being put into paint drying ovens above 40°C do not modify the system or install new components with parts not designed for gas vehicles do not evacuate fuel tanks unless there is repair that requires removed of the fuel tank
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CAUTION: A discharged battery condition may have been caused by an electrical short circuit. If this condition exists there will be an apparently live circuit on the vehicle even when all normal circuits are switched off. This can cause arcing when the jumper cables are connected. CAUTION: While it is not recommended that the vehicle is jump started, it is recognized that this may occasionally be the only practical way to mobilize a vehicle. In such an instance the discharged battery must be recharged immediately after jump starting to avoid permanent damage.
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100-00-15
General Information
100-00-15
DESCRIPTION AND OPERATION (Continued) Always make sure that the jumper cables are adequate for the task. Heavy duty cables must be used. Always make sure that the slave battery is of the same voltage as the vehicle battery. The batteries must be connected in parallel. Always make sure that switchable electric circuits are switched off before connecting jumper cables. This reduces the risk of arcing occurring when the final connection is made.
Component Cleaning To prevent ingress of dirt, accumulations of loose dirt and greasy deposits should be removed before disconnecting or dismantling components or assemblies. Components should be thoroughly cleaned before inspection prior to reassembly.
Cleaning Methods: dry cleaning removal of loose dirt with soft or cable brushes scraping dirt off with a piece of metal or wood wiping off with a rag CAUTION: Compressed air is sometimes ‘wet’ so use with caution, especially on hydraulic systems. blowing dirt off with compressed air. (Eye protection must be worn when using this method) removal of dry dust using vacuum equipment. This method should always be used to remove friction lining material dust (asbestos particles) steam cleaning
WARNING: Make sure that the ends of the jumper cables do not touch each other or ground against the vehicle body at any time while the cables are attached to the battery. A fully charged battery, if shorted through jumper cables, can discharge at a rate well above 1000 amps causing violent arcing and very rapid heating of the jumper cables and terminals, and can even cause the battery to explode. Failure to follow these instructions may result in personal injury. Always connect the jumper cables in the following sequence: slave battery positive first then vehicle battery positive slave battery negative next and then vehicle ground at least 12 inches (300 mm) from the battery terminal, for example engine lifting eye Always reduce the engine speed to idle before disconnecting the jumper cables. Before removing the jumper cables from the vehicle that had the discharged battery, switch on the heater blower (high) or the heated rear window, to reduce the voltage peak when the cables are removed. Always disconnect the jumper cables in the reverse order to the connecting sequence and do not short the ends of the cables. Do not rely on the generator to restore a discharged battery. For a generator to recharge a battery, it would take in excess of eight hours continuous driving with no additional loads placed on the battery.
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WARNING: Most solvents require careful handling and some are harmful. Refer to Health and Safety Precautions and to the manufacturers literature for safety precautions. Failure to follow these instructions may result in personal injury. Various solvents are available which are suitable for component cleaning. Some components such as brake hydraulic parts and electrical assemblies should be cleaned only with recommended solvents — refer to Solvents, Sealers and Adhesives or to the section of the manual relevant to the component.
Calibration of Essential Measuring Equipment WARNING: Failure to follow these instructions may result in personal injury or damage to components. It is of fundamental importance that certain essential equipment, for example torque wrenches, multimeters, exhaust gas analysers or rolling roads, are regularly calibrated in accordance with the manufacturers instructions.
Solvents, Sealers and Adhesives Introduction WARNING: Always handle all solvents, sealers and adhesives with extreme care. Some contain chemicals or give off fumes which can be dangerous to health. Always follow the manufacturers instructions. If in doubt about any 01/2003 2003.0 BA Falcon
100-00-16
General Information
100-00-16
DESCRIPTION AND OPERATION (Continued) substance, particularly a solvent, DO NOT use it. CAUTION: If in doubt about the suitability of any proprietary solvent or sealer for a particular application, contact the manufacturer of the product for information regarding storage, handling and application. The Health and Safety Precautions subsection refers to some commonly used chemicals and materials, hazards associated with their use, and safety measures to be taken. Some of these chemicals may be included in the following list either in their own right or as an ingredient in a sealer or adhesive.
General Specifications Anti-Seize Compound Ford Spec. SAM-1C-9107A SAM-1C-9107A ESE-M1244-A
General Spark plug threads Sealers Application For camshaft bearing caps For cylinder block For fitting rear lamp assembly For transmission housing (80 gram can)
Ford Spec. ESK-M4G260-A WSK-M4G320-A WSK-M4G329-ABC Finis Code 6 160 443
Manufacturer and Identification Loctite 518 Hylosil 502
Adhesives Application PU for windscreen, side and rear glass
Road/Roller Testing Road or roller testing may be carried out for various reasons and a procedure detailing pre-test checks, through engine starting and stopping, pre-driving checks, on-test checks to final checks on completion of the test is given overleaf. Unless complete vehicle performance is being checked, the full road test procedure need not be carried out. Instead, those items particularly relevant to the system/s being checked can be extracted.
Pre-Test Checks WARNING: If the brake system hydraulic fluid level is low, pedal travel is excessive or a hydraulic leak is found, do not attempt to road test the vehicle until the reason for the low fluid level, excessive pedal travel or hydraulic leak is found and rectified. It is suggested that pre-test checks, and functional tests of those systems/circuits which affect the safe and legal operations of the vehicle, such as brakes, lights and steering, should always be carried out before the road or roller test. G17374 en
Ford Spec. Finis Code 6 997 259 Engine oil level Engine coolant level Tires, for correct pressure, compatible types and tread patterns, and wear within limits. There is sufficient fuel in the tank to complete the test. All around the engine, transmission and under the vehicle for oil, coolant, hydraulic and fuel leaks. Make a note of any apparent leaks and wipe off the surrounding areas to make it easier to identify the extent of the leak on completion of the test.
Starting the Engine NOTE: On initial drive away from cold and within the first 1.5 km (1 mile), do not depress accelerator pedal beyond half travel until the vehicle has attained a minimum speed of 25 km/h (15 miles/h). Never operate at high engine speed or with the accelerator pedal at full travel whilst the engine is cold. With the ignition switched off, check: The handbrake is applied. The gear lever is in neutral.
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General Information
100-00-17
DESCRIPTION AND OPERATION (Continued) All instrument gauges (except fuel gauge) read zero. With the ignition switched on, check: Ignition controlled warning lights come on. Engine temperature gauge registers a reading compatible with the engine temperature. Fuel gauge registers a reading appropriate to the fuel level in the tank. The operation of the handbrake warning light and fluid level warning indicator light.
On Road or Roller Test Check: CAUTION: If road testing, check the brake operation while still travelling at low speed before continuing with the test. If the brakes pull to one side, or appear to be otherwise faulty, do not continue with the road test until the fault has been found and rectified. Clutch pedal operation is not stiff or heavy. Initial gear engagement is smooth and there is no evidence of clutch drag. Handbrake control operates smoothly and the handbrake releases quickly and completely. Clutch takes up the drive smoothly, without slip or judder. Gear changing is smooth, and there are no abnormal noises or vibrations from the transmission. The engine power output is satisfactory, full power is achieved, acceleration is smooth and pedal operation not stiff or heavy, and engine speed returns to idle correctly. There is no excessive or abnormally colored smoke from the engine under normal driving, heavy load or overrun conditions. Steering operation, including power steering where fitted, is smooth, accurate, not excessively heavy or with excessive free play or vibration. Does not pull to one side and self centres smoothly after cornering. Speedometer, oil pressure warning lamp, coolant temperature gauge and tachometer (where fitted) register the correct readings or operate correctly. Switches and controls operate smoothly and positively, warning or indicator lights operate correctly and the direction indicator control self cancels when the steering is returned to the straight ahead position. Heating and ventilation systems work correctly and effectively. Brake operation and efficiency.
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Brake Testing WARNING: When brake testing, avoid breathing the smoke or fumes from hot brakes, this may contain asbestos dust which is hazardous to health, see Health and Safety Precautions. Avoid brake testing on busy roads where it can cause inconvenience or danger to other road users. CAUTION: Brake testing which includes heavy brake applications should not be carried out with new brake pads/discs or linings/drums until the components have bedded-in. New brake friction components will not reach full efficiency until the bedding-in process is complete. Test the brakes at several speeds within the normal operating range using both light and heavy pedal pressure. Note any tendency to snatch, pull or drag, and any undue delay in application or release. Allow the vehicle to coast and note any tendency to pull to one side, or evidence that the brakes are binding. After stopping the vehicle (not immediately after a period of heavy braking), carefully check the brake temperature. A disc which feels hot, or appreciably hotter than the others, indicates that the brake is binding. After completion of the test, check for: Oil, coolant, hydraulic, air and fuel leaks. Abnormal temperature of any moving components or assemblies, e.g. wheel hubs, transmission, axle etc., which might indicate overtightness or lack of lubrication.
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100-01-1
Identification Codes
100-01-1
SECTION : 100-01 Identification Codes VEHICLE APPLICATION : 2003.0 BA Falcon CONTENTS
PAGE
DESCRIPTION AND OPERATION Identification Codes ..............................................................................................................100-01-2 Vehicle Identification Number ..............................................................................................100-01-2 Vehicle Compliance (VC) Label .............................................................................................100-01-5 Emission Decal ....................................................................................................................100-01-6
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Identification Codes
100-01-2
DESCRIPTION AND OPERATION
Identification Codes Vehicle Identification Number The vehicle identification number (VIN) is a seventeen-digit combination of letters and numbers. The VIN is printed on a label located in the engine compartment or on the driver’s side A-pillar as shown. The VIN number is also found on the vehicle compliance (VC) label located in the same area. Typical Identification Plate Locations
Identification Label (engine bay)
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Identification Codes
100-01-3
DESCRIPTION AND OPERATION (Continued) Identification Label (A-pillar)
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Identification Codes
100-01-4
DESCRIPTION AND OPERATION (Continued) Body Style Code BODY TYPE XT Sedan XT Wagon Futura Sedan Futura Wagon XR Sedan XR Ute GT Sedan Fairmont Sedan Fairmont Wagon Fairmont Ghia Sedan Fairlane Ghia LTD XL Ute XLS Ute Model Code Body Type Sedan Wagon Sedan Wagon Sedan Sedan Wagon Sedan Sedan Sedan Ute Ute Ute Ute Ute
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Body Style XT XT Futura Futura XR FMT FMT FMT Ghia Fairlane Ghia LTD XL Tray XL SSB XR Tray XLS Tray XLS SSB
CODE SW WA SW WA SW CM SW SW WA SW LW LW CM CM Model Code 18333 18363 18334 18364 18335 18332 18332 18338 18349 18346 45313 45373 45375 45314 45374
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Identification Codes
100-01-5
DESCRIPTION AND OPERATION (Continued)
Paint Colour and Code Colour Winter White Venom Ice Mint Silver Barossa Reb Congo Green Silhouette Blue Print Narooma Blue Phantom Mercury Silver Blue Pearl Acid Rush Citric Acid Blood Orange Victorian Taxi Yellow Taxi Orange Trim Colour and Code Colour Stone Warm Charcoal
Code A1 VF EI B7 DG ST UU NR P3 M7 CP RH JA HO 44 22
with the Design Rules referred to on the compliance label of the vehicle. Such Laws must be complied with at all times. Failure to do so may result in Substantial Financial Penalties. Where State/Territory Laws differ from the repair manual procedures, the Laws MUST take precedence. To ensure continuing compliance it is imperative that the engine/emission system is serviced according to the specified procedure. A typical compliance plate is shown below. Compliance Plate (engine bay)
Code S1 B1
Vehicle Compliance (VC) Label Australian Design Rules (A.D.R.) reuire vehicle manufacturere to comply with specific requirements regarding consumer, environment protection, and safety devices. A compliance plate is fitted to the vehicle and this contains codes which relate to specific design rules in effect at the time of vehicle manufacture. Legiclation requires that no alteration be made to a vehicle that would result in the vehicle not complying G86657 en
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Identification Codes
100-01-6
DESCRIPTION AND OPERATION (Continued) Compliance Plate (A-pillar)
Emission Decal Emission Control Information Decal is affixed to the underside of the bonnet. Should this decal become mutilated or unreadable, a new decal must be obtained and affixed to the vehicla. To ensure contained compliance it is imperative that the engine and emission system is serviced according to the service procedures outlined in this manual. Should it become necessary to replace a component which affects vehicle emissions, it is mandatory that the replacement part be of the same calibration as the original part. No circumstances would permit the disconnection, alteration or modification of any emission related component on vehicles marketed by Ford Sales Company of Australia Limited, except in accordance with the diagnostic, maintenance and repair procedures specified in the Company’s service materials. Any person who removes, modifies or otherwise renders ineffective any emission control components fitted to a vehicle could be contravening the relevant regulations and be guilty of an offence under the regulations. Any person who owns and/or operates such a vehicle could also be guilty of an offence under the regulations.
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Jacking and Lifting
100-02-1
SECTION : 100-02 Jacking and Lifting VEHICLE APPLICATION : 2003.0 BA Falcon CONTENTS
PAGE
DESCRIPTION AND OPERATION Jacking ..................................................................................................................................100-02-2 Jacking/Lifting Points - Sedan/Wagon .................................................................................100-02-2 Jacking/Lifting Points - Ute ..................................................................................................100-02-2
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Jacking and Lifting
100-02-2
DESCRIPTION AND OPERATION
Jacking
Jacking/Lifting Points - Ute
WARNING: Do not run the engine when jacking the vehicle. The wheels contacting the ground could cause the vehicle to move. Failure to follow these instructions may result in personal injury. WARNING: Make sure the jack and jack stands are correctly located to prevent the vehicle from falling. Failure to follow these instructions may result in personal injury. WARNING: Wheel chocks should be used to prevent the vehicle from rolling and falling off the jack. Failure to follow these instructions may result in personal injury.
1. The front jacking\lifting point for the ute is on the sill at the point where the rocker moulding has been cut away to expose the sill. CAUTION: The service jack provided with the 2. The rear jacking\lifting point for the ute is on the vehicle is only intended to be used in an leaf spring hanger bracket. emergency for changing a deflated tire. Never use the service jack to hoist the vehicle for any other service. Refer to the Owner Guide when using the jack supplied with the vehicle.
Jacking/Lifting Points - Sedan/Wagon
1. The front jacking\lifting point for sedan and wagon is on the sill at the point where the rocker moulding has been cut away to expose the sill. 2. The rear jacking\lifting point for the sedan and wagon is on the sill at the point where the rocker moulding has been cut away to expose the sill.
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Noise, Vibration and Harshness
100-04-1
SECTION : 100-04 Noise, Vibration and Harshness VEHICLE APPLICATION : 2003.0 BA Falcon CONTENTS
PAGE
DESCRIPTION AND OPERATION Noise, Vibration and Harshness (NVH) ................................................................................100-04-2 Acceptable Noise, Vibration and Harshness .......................................................................100-04-2 Diagnostic Theory ................................................................................................................100-04-2 Glossary of Terms ................................................................................................................100-04-2 DIAGNOSIS AND TESTING Noise, Vibration and Harshness (NVH) ................................................................................100-04-7 1: Customer Interview ........................................................................................................100-04-10 2: Pre-Drive Check .............................................................................................................100-04-10 3: Preparing for the Road Test ..........................................................................................100-04-10 4: Verify the Customer Concern ........................................................................................100-04-10 5: Road Test ......................................................................................................................100-04-10 6: Check OASIS/TSBs/Repair History ...............................................................................100-04-12 7: Diagnostic Procedure .....................................................................................................100-04-12 NVH Condition and Symptom Categories .........................................................................100-04-13 Symptom Charts ................................................................................................................100-04-14 Pinpoint Tests ....................................................................................................................100-04-35 Component Tests ...............................................................................................................100-04-49 GENERAL PROCEDURES Brake Disc Machining .........................................................................................................100-04-55 Powertrain/Drivetrain Mount Neutralizing ...........................................................................100-04-55 Exhaust System Neutralizing ..............................................................................................100-04-55 Wheel Bearing Check .........................................................................................................100-04-56
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Noise, Vibration and Harshness
100-04-2
DESCRIPTION AND OPERATION
Noise, Vibration and Harshness (NVH) Noise is any undesirable sound, usually unpleasant in nature. Vibration is any motion, shaking or trembling, that can be felt or seen when an object moves back and forth or up and down. Harshness is a ride quality issue where the vehicle’s response to the road transmits sharply to the customer. Harshness normally describes a firmer than usual response from the suspension system. Noise, vibration and harshness (NVH) is a term used to describe these conditions, which result in varying degrees of dissatisfaction. Although, a certain level of NVH caused by road and environmental conditions is normal. This section is designed to aid in the diagnosis, testing and repair of NVH concerns.
within an acceptable range.
Glossary of Terms Acceleration-Light An increase in speed at less than half throttle. Acceleration-Medium An increase in speed at half to nearly full throttle, such as 0-97 km/h (0-60 mph) in approximately 30 seconds. Acceleration-Heavy An increase in speed at one-half to full throttle, such as 0-97 km/h (0-60 mph) in approximately 20 seconds.
Acceptable Noise, Vibration and Harshness
Ambient Temperature The surrounding or prevailing temperature.
All internal combustion engines and drivelines produce some noise and vibration; operating in a real world environment adds noise that is not subject to control. Vibration isolators, mufflers and dampers reduce these to acceptable levels. A driver who is unfamiliar with a vehicle can think that some sounds are abnormal when actually the sounds are normal for the vehicle type. For example, Traction-Lok® differentials produce a slight noise on slow turns after extended highway driving. This is acceptable and has no detrimental effect on the locking axle function. As a technician, it is very important to be familiar with vehicle features and know how they relate to NVH concerns and their diagnosis. If, for example, the vehicle has automatic overdrive it is important to test drive the vehicle both in and out of overdrive mode.
Amplitude The quantity or amount of energy produced by a vibrating component (G force). An extreme vibration has a high amplitude. A mild vibration has a low amplitude.
Diagnostic Theory The shortest route to an accurate diagnosis results from: system knowledge, including comparison with a known good system. system history, including repair history and usage patterns. condition history, especially any relationship to repairs or sudden change. knowledge of possible sources. using a systematic diagnostic method that divides the system into related areas. The diagnosis and correction of noise, vibration and harshness concerns requires: a road or system test to determine the exact nature of the concern. an analysis of the possible causes. testing to verify the cause. repairing any concerns found. a road test or system test to make sure the concern has been corrected or brought back to G72678 en
Backlash Gear teeth clearance. Boom Low frequency or low pitched noise often accompanied by a vibration. Also refer to Drumming. Bound Up An overstressed isolation (rubber) mount that transmits vibration/noise instead of absorbing it. Brakes Applied When the service brakes are applied with enough force to hold the vehicle against movement with the transmission in gear. Buffet/Buffeting Strong noise fluctuations (less than 1000 Hz) caused by gusting winds. An example would be wind gusts against the side glass. Buzz A low-pitched sound (200-5000 Hz) like that from a bee. Often a metallic or hard plastic humming sound. Also describes a high frequency (200–800 Hz) vibration. Vibration feels similar to an electric razor. Camber The angle of the wheel in relation to the true vertical as measured looking from the front of the vehicle. Camber is positive when the wheel angle is offset so that the top of the wheel is positioned away from the vehicle.
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100-04-3
Noise, Vibration and Harshness
100-04-3
DESCRIPTION AND OPERATION (Continued) Clonk A hydraulic knocking sound. Sound occurs with air pockets in a hydraulic system. Also described as hammering. Clunk/Driveline Clunk A heavy or dull, short-duration, low-frequency sound. Occurs mostly on a vehicle that is accelerating or decelerating abruptly. Also described as a thunk. Coast/Deceleration Releasing the accelerator pedal at cruise, allowing the engine to reduce vehicle speed without applying the brakes. Caster The angle of the steering knuckle in relation to the true vertical as measured looking from the side of the vehicle.
Coast/Neutral Coast Placing the transmission range selector in NEUTRAL (N) or depressing the clutch pedal while at cruise. Constant Velocity (CV) Joint A joint used to absorb vibrations caused by driving power being transmitted at an angle. Controlled Rear Suspension Height The height at which a designated vehicle element must be when driveline angle measurements are made. Coupling Shaft The shaft between the transfer case and the front drive axle or, in a two-piece rear driveshaft, the front section.
Item 1 2 3
Description True vertical Positive caster Steering axis
Chatter A pronounced series of rapidly repeating rattling or clicking sounds. Chirp A short-duration high-pitched noise associated with a slipping drive belt. Chuckle A repetitious low-pitched sound. A loud chuckle is usually described as a knock. Click A sharp, brief, non-resonant sound, similar to actuating a ball point pen.
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CPS Cycles per second. Same as hertz (Hz). Cracks A mid-frequency sound, related to squeak. Sound varies with temperature conditions. Creak A metallic squeak. Cruise Constant speed on level ground; neither accelerating nor decelerating. Cycle The process of a vibrating component going through a complete range of motion and returning to the starting point. Decibel A unit of measurement, referring to sound pressure level, abbreviated dB. Drive Engine Run-Up (DERU) Test The operation of the engine through the normal rpm range with the vehicle standing still, the brakes 01/2003 2003.0 BA Falcon
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DESCRIPTION AND OPERATION (Continued) applied and the transmission engaged. This test is used for noise and vibration checks.
from side-to-side (wobble). Dynamically unbalanced wheel and tyre assemblies can cause wheel shimmy.
Driveline Angles The differences of alignment between the transmission output shaft, the driveshaft, and the rear axle pinion centerline.
Engine Imbalance A condition in which an engine’s center mass is not concentric to the rotation center, causing excessive motion. Engine Misfire When combustion in one or more cylinders does not occur or occurs at the wrong time. Engine Shake An exaggerated engine movement or vibration that directly increases in frequency as the engine speed increases. It is caused by non-equal distribution of mass in the rotating or reciprocating components. Flexible Coupling A flexible joint.
Item 1 2 3
Description Engine Driveshaft Differential
Driveshaft The shaft that transmits power to the rear axle input shaft (pinion shaft). In a two-piece driveshaft, it is the rearmost shaft. Drivetrain All power transmitting components from the engine to the wheels; includes the clutch or torque converter, the transmission, the transfer case, the driveshaft, and the front or rear drive axle.
Float A drive mode on the dividing line between cruise and coast where the throttle setting matches the engine speed with the road speed. Flutter Mid to high (100-200 Hz) intermittent sound due to air flow. Similar to a flag flapping in the wind. Frequency The rate at which a cycle occurs within a given time. Gravelly Feel A grinding or growl in a component, similar to the feel experienced when driving on gravel. Grind An abrasive sound, similar to using a grinding wheel, or rubbing sand paper against wood.
Drivetrain Damper A weight attached to the engine, the transmission, the Hiss transfer case, or the axle. It is tuned by weight and Steady high frequency (200–800 Hz) noise. Vacuum placement to absorb vibration. leak sound. Drone A low frequency (100-200 Hz) steady sound, like a freezer compressor. Also described as a moan.
Hoot A steady low frequency tone (50-500 Hz), sounds like blowing over a long neck bottle.
Drumming A cycling, low-frequency (20–100 Hz), rhythmic noise often accompanied by a sensation of pressure on the ear drums. Also described as a low rumble, boom, or rolling thunder.
Howl A mid-range frequency (200-800 Hz) noise between drumming and whine. Also described as a hum.
Dynamic Balance The equal distribution of weight on each side of the centerline, so that when the wheel and tyre assembly spins, there is no tendency for the assembly to move G72678 en
Hum Mid-frequency (200-800 Hz) steady sound, like a small fan motor. Also described as a howl. Hz Hertz; a frequency measured in cycles per second. 01/2003 2003.0 BA Falcon
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DESCRIPTION AND OPERATION (Continued) Imbalance Out of balance; heavier on one side than the other. In a rotating component, imbalance often causes vibration. Inboard Toward the centerline of the vehicle. Intensity The physical quality of sound that relates to the strength of the vibration (measured in decibels). The higher the sound’s amplitude, the higher the intensity and vice versa. Isolate To separate the influence of one component to another. Knock A heavy, loud, repetitious sound, like a knock on the door. Moan A constant, low-frequency (100–200 Hz) tone. Also described as a hum.
Item 1 2
Description Lateral runout Radial runout
Rattle A random and momentary or short duration noise.
Neutral Engine Run-Up (NERU) Test The operation of the engine through the normal rpm range with the vehicle standing still and the transmission disengaged. This test is used to identify engine related vibrations.
Rotary Blade Coupling (RBC) This part is attached to the rear axle on 4WD vehicles. It includes an internal hydraulic pump and clutch pack to control the torque supplied to the rear axle/wheels. It also has an internal electromagnetic clutch to lock to the RCB for the 4WD ON mode. This unit is not to be disassembled and if necessary a new unit must be installed.
Neutralize/Normalize To return to an unstressed position. Used to describe mounts. Refer to Bound Up.
Ring Gear The large, circular, driven gear in a ring and pinion gearset.
Outboard Away from the centerline of the vehicle.
Road Test The operation of the vehicle under conditions intended to produce the concern under investigation.
Ping A short duration, high-frequency sound, which has a slight echo. Pinion Shaft The input shaft in a driving axle that is usually a part of the smaller driving or input hypoid gear of a ring and pinion gearset. Pitch The physical quality of sound that relates to its frequency. Pitch increases as frequency increases and vice versa. Pumping Feel A slow, pulsing movement. Radial/Lateral Radial is in the plane of rotation; lateral is at 90 degrees to the plane of rotation. G72678 en
Roughness A medium-frequency vibration. A slightly higher frequency (20 to 50 Hz) than a shake. This type of vibration is usually related to drivetrain components. Runout Lateral runout means measuring the movement or “wobble” of a wheel or tyre at the sidewall. Radial runout means measuring the out-of-round of the tyre tread surface. Rustling Intermittent sound of varying frequency (100-200 Hz), sounds similar to shuffling through leaves. Shake A low-frequency vibration (5–20 Hz), usually with visible component movement. Usually relates to tyres, wheels, brake drums or brake discs if it is vehicle 01/2003 2003.0 BA Falcon
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DESCRIPTION AND OPERATION (Continued) speed sensitive, or engine if it is engine speed sensitive. Also referred to as a shimmy or wobble.
warm. Also, irregular tyre wear patterns in the tyre tread resulting from wheel-locked skids.
Shimmy An abnormal vibration or wobbling, felt as a side-to-side motion of the steering wheel in the driveshaft rotation. Also described as waddle. Shudder A low-frequency vibration that is felt through the steering wheel or seat during light brake application.
Tyre Force Vibration A tyre vibration caused by variations in the construction of the tyre that is noticeable when the tyre rotates against the pavement. This condition can be present on perfectly round tyres because of variations in the inner tyre construction. This condition can occur at wheel rotation frequency or twice rotation frequency.
Slap A resonance from flat surfaces, such as safety belt webbing or door trim panels.
Transient A noise or vibration that is momentary, a short duration.
Slip Yoke/Slip Spline The driveshaft coupling that allows length changes to occur while the suspension articulates and while the driveshaft rotates.
Two-Plane Balance Radial and lateral balance.
Squeak A high-pitched transient sound, similar to rubbing fingers against a clean window. Squeal A long-duration, high-pitched noise. Static Balance The equal distribution of weight around the wheel. Statically unbalanced wheel and tyre assemblies can cause a bouncing action called wheel tramp. This condition will eventually cause uneven tyre wear. Tap A light, rhythmic, or intermittent hammering sound, similar to tapping a pencil on a table edge. Thump A dull beat caused by two items striking together.
Vibration Any motion, shaking or trembling, that can be felt or seen when an object moves back and forth or up and down. Whine A constant, high-pitched noise. Also described as a screech. Whistle High-pitched noise (above 500 Hz) with a very narrow frequency band. Examples of whistle noises are a turbocharger or airflow around an antenna. Wind Noise Any noise caused by air movement in, out or around the vehicle. WOT The acronym wide-open throttle is WOT.
Tick A rhythmic tap, similar to a clock noise. Tip-In Moan A light moaning noise heard during light vehicle acceleration, usually between 40-100 km/h (25-65 mph). TIR The acronym for the total indicated runout is TIR. Tyre Deflection The change in tyre diameter in the area where the tyre contacts the ground. Tyre Flat Spots A condition commonly caused by letting the vehicle stand while the tyres cool off. This condition can be corrected by driving the vehicle until the tyres are G72678 en
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DIAGNOSIS AND TESTING
Noise, Vibration and Harshness (NVH) To assist the service advisor and the technician, a Write-up Job Aid and an NVH Diagnostic Guide are included with this material. The Write-up Job Aid serves as a place to record all important symptom information. NHV Diagnostic Guide serves as a place to record information reported on the Write-up Job Aid as well as data from the testing to be carried out. To begin a successful diagnosis, fill out the NVH Diagnostic Guide, record the reported findings, then proceed to each of the numbered process steps to complete the diagnosis.
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DIAGNOSIS AND TESTING (Continued)
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DIAGNOSIS AND TESTING (Continued)
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DIAGNOSIS AND TESTING (Continued) 1: Customer Interview The diagnostic process starts with the customer interview. The service advisor must obtain as much information as possible about the concern and take a test drive with the customer. There are many ways a customer will describe NVH concerns and this will help minimize confusion arising from descriptive language differences. It is important that the concern is correctly interpreted and the customer descriptions are recorded. During the interview, ask the following questions: When was the concern first noticed? Did the concern appear suddenly or gradually? Did any abnormal occurrence coincide with or proceed its appearance? Use the information gained from the customer to accurately begin the diagnostic process.
2: Pre-Drive Check It is important to do a pre-drive check before road testing the vehicle. A pre-drive check verifies that the vehicle is relatively safe to drive and eliminates any obvious faults on the vehicle. The pre-drive check consists of a brief visual inspection. During this brief inspection, take note of anything that will compromise safety during the road test and make those repairs or adjustments before taking the vehicle on the road.
The engine speed is an important factor in arriving at a final conclusion. Therefore, connect an accurate tachometer to the engine, even if the vehicle has a tachometer. Use a tachometer that has clearly defined increments of less than 50 rpm. This ensures an exact engine speed reading.
4: Verify the Customer Concern Verify the customer concern by carrying out a road test, an engine run-up test, or both. The decision to carry out a road test, an engine run-up test, or both depends on the type of NVH concern. A road test may be necessary if the symptom relates to the suspension system or is sensitive to torque. A drive engine run-up (DERU) or a neutral engine run-up (NERU) test identifies noises and vibrations relating to engine and drivetrain rpm. Remember, a condition will not always be identifiable by carrying out these tests, however, they will eliminate many possibilities if carried out correctly.
5: Road Test NOTE: It may be necessary to have the customer ride along or drive the vehicle to point out the concern. During the road test, take into consideration the customer’s driving habits and the driving conditions. The customer’s concern just may be an acceptable operating condition for that vehicle.
The following is a brief overview of each test in the order in which it appears. A review of this information 3: Preparing for the Road Test helps to quickly identify the most appropriate process necessary to make a successful diagnosis. After Observe the following when preparing for the road reviewing this information, select and carry out the test: appropriate test(s), proceeding to the next step of this Review the information recorded on the NVH process. Diagnostic Guide. It is important to know the The Slow Acceleration Test is normally the first specific concern the customer has with the test to carry out when identifying an NVH concern, vehicle. especially when a road test with the customer is Do not be misled by the reported location of the not possible. noise or vibration. The cause can actually be The Heavy Acceleration Test helps to determine if some distance away, transferred from another the concern is torque-related. part of the vehicle. The Neutral Coast Down Speed Test helps to Remember that the vibrating source component determine if the concern is vehicle speed-related. (originator) may only generate a small vibration. This small vibration can in turn cause a larger The Downshift Speed Test helps to determine if vibration or noise to emanate from another the concern is engine speed-related. receiving component (reactor), due to contact with The Steering Input Test helps to determine how other components (transfer path). the wheel bearings and other suspension Conduct the road test on a quiet street where it is components contribute to a vehicle speed-related safe to duplicate the vibration or noise. The ideal concern. testing route is an open, low-traffic area where it The Brake Test helps to identify vibrations or is possible to operate the vehicle at the speed in noise that are brake-related. which the condition occurs. The Road Test Over Bumps helps isolate a noise If possible, lower the radio antenna in order to that occurs when driving over a rough or bumpy minimize turbulence. Identify anything that could surface. potentially make noise or be a source of wind The Engine Run-Up Tests consist of the Neutral noise. Inspect the vehicle for add-on items that Run-up Test and the Engine Load Test. These create vibration/noise. Turn off the radio and the heating and cooling system blower. G72679 en
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DIAGNOSIS AND TESTING (Continued) tests help to determine if the concern is engine speed-related. The Neutral Run-up Test is used as a follow-up test to the Downshift Speed Test when the concern occurs at idle. The Engine Load Test helps to identify vibration/noise sensitive to engine load or torque. It also helps to reproduce engine speed-related concerns that cannot be duplicated when carrying out the Neutral Run-up Test or the Neutral Coast Down Test. The Engine Accessory Test helps to locate faulty belts and accessories that cause engine speed-related concerns. The Vehicle Cold Soak Procedure helps to identify concerns occurring during initial start-up and when an extended time lapse occurs between vehicle usage.
Downshift Speed Test To carry out this test, proceed as follows: Shift into a lower gear than the gear used when carrying out the Slow Acceleration Test. Drive at the engine rpm where the concern occurs. The concern is engine speed related if duplicated while carrying out this test. This eliminates the tyres, wheels, brakes and the suspension components as sources. If necessary, repeat this test using other gears and NEUTRAL to verify the results. Proceed as necessary.
Steering Input Test
To carry out this test, proceed as follows: Drive at the speed where the concern occurs, while making sweeping turns in both directions. Slow Acceleration Test If the concern goes away or gets worse, the To carry out this test, proceed as follows: wheel bearings, hubs, U-joints (contained in the Slowly accelerate to the speed where the reported axles of 4WD applications), and tyre tread wear concern occurs. Note the vehicle speed, the are all possible sources. engine rpm and, if possible, determine the Proceed as necessary. vibration frequency. Brake Test Attempt to identify from what part of the vehicle the concern is coming. To carry out this test, proceed as follows: Attempt to identify the source of the concern. Warm the brakes by slowing the vehicle a few Proceed as necessary. times from 80–32 km/h (50–20 mph) using light braking applications. At highway speeds of 89–97 Heavy Acceleration Test km/h (50–60 mph), apply the brake using a light pedal force. To carry out this test, proceed as follows: Accelerate to 89–97 km/h (55–60 mph). Accelerate hard from 0-64 km/h (0-40 mph). Lightly apply the brakes and slow the vehicle to Decelerate in a lower gear. 30 km/h (20 mph). The concern is torque-related if duplicated while A brake vibration noise can be felt in the steering carrying out this test. wheel, seat or brake pedal. A brake noise can be Proceed as necessary. heard upon brake application and diminish when Neutral Coast Down Speed Test the brake is release. To carry out this test, proceed as follows: Drive at a higher rate of speed than where the concern occurred when carrying out the Slow Acceleration Test. Place the transmission in NEUTRAL and coast down past the speed where the concern occurs. The concern is vehicle speed-related if duplicated while carrying out this test. This eliminates the engine and the torque converter as sources. If the concern was not duplicated while carrying out this test, carry out the Downshift Speed Test to verify if the concern is engine speed-related. Proceed as necessary.
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Road Test Over Bumps To carry out this test, proceed as follows: Drive the vehicle over a bump or rough surface one wheel at a time to determine if the noise is coming from the front or the back and the left or the right side of the vehicle. Proceed as necessary.
Neutral Engine Run-up (NERU) Test To carry out this test, proceed as follows: Install a tachometer. Increase the engine rpm up from an idle to approximately 3,500 rpm while in PARK on front wheel drive vehicles with automatic transmissions, or NEUTRAL for all other vehicles. Note the
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DIAGNOSIS AND TESTING (Continued) engine rpm and, if possible, determine the vibration frequency. Attempt to identify what part of the vehicle the concern is coming from. Attempt to identify the source of the concern. Proceed as necessary.
Drive Engine Run-Up (DERU) Load Test To carry out this test, proceed as follows: WARNING: Block the front and rear wheels, and apply the parking brake and the service brake, or injury to personnel can result. CAUTION: Do not carry out the Engine Load Test for more than five seconds or damage to the transmission or transaxle can result. Block the front and rear wheels. Apply the parking brake and the service brake. Install a tachometer. Shift the transmission into DRIVE, and increase and decrease the engine rpm between an idle to approximately 2,000 rpm. Note the engine rpm and, if possible, determine the vibration frequency. Repeat the test in REVERSE. If the vibration or noise is duplicated when carrying out this test, inspect the engine and transmission or transaxle mounts. If the concern is definitely engine speed-related, carry out the Engine Accessory Test to narrow down the source. Proceed as necessary.
Engine Accessory Test To carry out this test, proceed as follows: WARNING: Block the front and rear wheels, and apply the parking brake and the service brake, or injury to personnel can result. CAUTION: Limit engine running time to one minute or less with belts removed or serious engine damage will result. NOTE: A serpentine drive belt decreases the usefulness of this test. In these cases, use a vibration analyzer, such as the EVA, to pinpoint accessory vibrations. An electronic listening device, such as an EngineEAR, will also help to identify noises from specific accessories. Remove the accessory drive belts. Increase the engine rpm to where the concern occurs.
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If the vibration/noise is duplicated when carrying out this test, the belts and accessories are not sources. If the vibration/noise was not duplicated when carrying out this test, install each accessory belt, one at a time, to locate the source.
Vehicle Cold Soak Procedure To carry out this procedure, proceed as follows: Test preparations include matching customer conditions (if known). If not known, document the test conditions: gear selection and engine rpm. Monitor the vibration/noise duration with a watch for up to three minutes. Park the vehicle where testing will occur. The vehicle must remain at or below the concern temperature (if known) for 6-8 hours. Before starting the engine, conduct a visual inspection under the hood. Turn the key on, but do not start the engine. Listen for the fuel pump, anti-lock brake system (ABS) and air suspension system noises. Start the engine. CAUTION: Never probe moving parts. Isolate the vibration/noise by carefully listening. Move around the vehicle while listening to find the general location of the vibration/noise. Then, search for a more precise location by using a stethoscope or EngineEAR. Refer to Idle Noise/Vibration in the Symptom Chart to assist with the diagnosis.
6: Check OASIS/TSBs/Repair History After verifying the customer concern, check for OASIS reports, TSBs and the vehicle repair history for related concerns. If information relating to a diagnosis/repair is found, carry out the procedure(s) specified in that information. If no information is available from these sources, carry out the vehicle preliminary inspection to eliminate any obvious faults.
7: Diagnostic Procedure Qualifying the concern by the particular sensation present can help narrow down the concern. Always use the “symptom” to “system” to “component” to “cause” diagnosis technique. This diagnostic method divides the problem into related areas to correct the customer concern. Verify the “symptom”. Determine which “system(s)” can cause the “symptom”. If a vibration concern is vehicle speed related, the tyre and wheel rpm/frequency or driveshaft frequency should be calculated.
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DIAGNOSIS AND TESTING (Continued) If a vibration concern is engine speed related, the engine, engine accessory or engine firing frequencies should be calculated. After determining the “system”, use the diagnostic tools to identify the worn or damaged “components”. After identifying the “components”, try to find the “cause” of the failure. Once the concern is narrowed down to a symptom/condition, proceed to NVH Condition and Symptom Categories.
2.
NVH Condition and Symptom Categories Operating Condition—Vehicle is Not Moving 1. Static operation Noise occurs during part/system functioning. Goto Squeak and Rattle. 2. While cranking 1. Grinding or whine, differential ring gear or starter motor pinion noise. Goto Engine Noise/Vibration. 2. Rattle. Exhaust hanger, exhaust heat shield or A/C line noise. Goto Squeak and Rattle. 3. Vibration. Acceptable condition. 3. At idle Idle noise. Goto Idle Noise/Vibration. Idle vibration or shake. Goto Idle Noise/Vibration. 4. During gear selection 1. Vehicle parked on a steep incline. Acceptable noise. 2. Vehicle parked on a flat surface. Goto Driveline Noise/Vibration. 3. Vehicle with a manual transmission. Goto Transmission (Manual) and Transfer Case Noise/Vibration.
3. 4.
5.
Operating Condition—Vehicle is Moving 1. Depends more on how the vehicle is operated 1. Speed-related Related to vehicle speed Pitch increases with vehicle speed. Goto Tire Noise/Vibration. Noise occurs at specific vehicle speed. A high-pitch noise (whine). Goto Drivline Noise/Vibration. Loudness proportional to vehicle speed. Low-frequency noise at high speeds, noise and loudness increase with speed. Goto Driveline Noise/Vibration. A low-pitched noise (drumming). Goto Engine Noise/Vibration. Vibration occurs at a particular speed (mph) regardless of acceleration or G72679 en
6.
7. 8.
deceleration. Goto Tire Noise/Vibration. Noise varies with wind/vehicle speed and direction. Goto Air Leak and Wind Noise. Related to engine speed. Noise varies with engine rpm. Goto Engine Noise/Vibration. Vibration occurs at a particular speed (mph) regardless of engine speed (rpm). Acceleration Wide open throttle (WOT) Engine induced contact between components. Inspect and repair as necessary. Noise is continuous throughout WOT. Exhaust system or engine ground out. Goto Engine Noise/Vibration. Light/moderate acceleration Tip-in moan. Engine/exhaust noise. Goto Engine Noise/Vibration. Knock-type noise. Goto Engine Noise/Vibration. Driveline shudder. Goto Driveline Noise/Vibration. Engine vibration. Goto Engine Noise/Vibration. Turning noise. Goto Steering Noise/Vibration. Braking. Clicking sound is signaling ABS is active. Acceptable ABS sound. A continuous grinding/squeal. Goto Brake Noise/Vibration. Brake vibration/shudder. Goto Brake Noise/Vibration. Clutching. A noise occurring during clutch operation. Goto Transmission (Manual) and Transfer Case Noise/Vibration. Vibration. Goto Transmission (Manual) and Transfer Case Noise/Vibration. Shifting Noise or vibration condition related to the transmission (automatic). Goto Transmission (Automatic) Noise/Vibration. Noise or vibration related to the transmission (manual). Goto Transmission (Manual) and Transfer Case Noise/Vibration. Engaged in four-wheel drive. Goto Transmission (Manual) and Transfer Case Noise/Vibration. Cruising speeds Accelerator pedal vibration. Goto Engine Noise/Vibration. Driveline vibration. Goto Driveline Noise/Vibration.
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DIAGNOSIS AND TESTING (Continued) A shimmy or shake. Goto Tire Noise/Vibration. 9. Driving at low/medium speeds A wobble or shudder. Goto Tire Noise/Vibration. 2. Depends more on where the vehicle is operated 1. Bump/pothole, rough road or smooth road. Goto Suspension Noise/Vibration. Noise is random or intermittent occurring from road irregularities. Goto Squeak and Rattle. Noise or vibration changes from one road surface to another. Normal sound changes. Noise or vibration associated with a hard/firm ride. Goto Suspension Noise/Vibration.
Symptom Charts Symptom Chart — Air Leak and Wind Noise Condition Air leak around door perimeter
Air leak around glass run
Air leak at inner belt line
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Source
Action
Loose fit seal.
PINCH the seal carrier to improve retention on the seal flange.
Seal installed incorrectly.
REINSTALL the seal.
Door misaligned.
REALIGN the door. CHECK door gaps and fit in the door opening and ADJUST as necessary.
Scuff plate installed incorrectly.
REINSTALL the scuff plate.
Seal or seal push pins damaged.
INSTALL a new seal.
Door glass misaligned.
ADJUST the door glass.
Glass run installed incorrectly.
ADJUST the glass run. INSERT foam in the glass run carrier.
Leak path behind glass run.
INSTALL foam rope behind the glass run.
Glass run channel spread wide.
PINCH the glass run channel to reduce the size of the opening.
Blow-out clip bent or contacting door glass.
ADJUST the blow-out clip or INSTALL a new glass run/blow-out clip molding assembly.
Glass run damaged.
INSTALL a new glass run.
Belt line seal installed incorrectly on flange.
ADJUST the seal. (Do not bend the flange.)
Belt line seal integrated with door trim installed incorrectly (no glass contact).
REINSTALL the door trim.
No contact with side glass.
ADJUST the door glass.
No contact with glass runs at both ends of belt line seal.
ADJUST the belt line seal or ADD foam at the seal ends.
Belt line seal damaged.
INSTALL a new seal.
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DIAGNOSIS AND TESTING (Continued) Condition
Source
Action
Belt line seal installed incorrectly on flange (no glass contact).
ADJUST the seal.
Belt line seal does not contact the glass.
ADJUST the door glass.
No contact with glass runs at both ends of belt line seal.
ADJUST the belt line seal/ADD foam at the seal ends.
Belt line seal damaged.
INSTALL a new seal.
Hole in watershield.
SEAL the hole with a suitable tape.
Watershield misaligned.
REALIGN the watershield. INSTALL a new watershield if the pressure sensitive adhesive fails.
Exterior door handle seal misaligned/damaged.
REALIGN or INSTALL a new seal as necessary.
Exterior mirror housing misaligned.
REALIGN with the edges shingled correctly and no gaps.
Mirror sail gasket folded/misaligned.
REINSTALL with the gasket unfolded and aligned correctly.
Mirror housing trim cap installed incorrectly.
REINSTALL with the edges shingled to the air flow.
Air leak through mirror housing hinge.
Fully ENGAGE the mirror into its operating position/USE foam to block the air path through the hinge.
Inner sail trim installed incorrectly.
REINSTALL the sail trim/ADJUST the door trim.
Inner sail gasket/barrier installed incorrectly.
REINSTALL the trim cover with the gasket/barrier aligned correctly.
Air path through wiring bundle/fastener access holes.
BLOCK the air path(s) with foam/tape.
Exposed fastener access hole on mirror housing/sail.
INSTALL a new cap if it is missing.
Gaps in the sealant bead.
APPLY approved sealant.
Air traveling up windshield molding along A-pillar.
INSTALL foam rope the full length of the A-pillar.
Windshield/backlite misaligned or not installed correctly.
REINSTALL the windshield/backlite.
Rear hood seal at base of windshield misaligned/damaged.
REALIGN or INSTALL a new seal as necessary.
Air leak at cowl
Cowl gasket misaligned/damaged.
REALIGN or INSTALL a new seal as necessary.
Air leak around liftgate perimeter
Loose fit seal.
PINCH the seal carrier to improve retention on the seal flange or INSERT foam in the carrier.
Seal misaligned.
REINSTALL the seal.
Liftgate misaligned.
REALIGN the liftgate. CHECK the liftgate fit in the body opening and ADJUST as necessary.
Scuff plate misaligned.
REINSTALL the scuff plate.
Seal or seal push pins damaged.
INSTALL a new seal.
Air leak at outer belt line
Draft at inner door handle/speaker opening
Wind noise from exterior rear view mirror
Air leak around perimeter of fixed glass
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DIAGNOSIS AND TESTING (Continued) Condition Air leak around the liftgate flip window perimeter
Wind noise from antenna
Air leak from closed roof opening panel
Buffeting from an open roof opening panel
Wind noise created by airflow over or behind body panels
Wind noise created by grille opening panel
Wind noise from air extractor
Noise from roof rack
Wind noise from bug shield/exterior windshield sun visor
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Source
Action
Loose fit seal.
PINCH the seal carrier to improve the retention to the seal flange.
Seal misaligned.
REINSTALL the seal.
Glass misaligned.
REALIGN the glass.
Seal damaged.
INSTALL a new seal.
Shape of antenna.
INSTALL an antenna boot or a spiral antenna.
Air leak around antenna cable access hole.
INSPECT the antenna access hole grommet. REPAIR as necessary.
Seal installed incorrectly.
REINSTALL the seal.
Roof opening panel glass/door misaligned.
REALIGN the roof opening panel glass/door.
Roof opening panel damaged.
INSTALL a new roof opening panel. REFER to Section 501-17 .
Wind deflector inoperative/damaged.
REPAIR or INSTALL a new wind deflector as necessary. REFER to Section 501-17 .
Wind deflector height incorrect.
ADJUST the wind deflector higher.
Fender splash shield misaligned.
REALIGN the fender splash shield.
Body panel misaligned (exposed edge).
REALIGN the appropriate body panel.
Hood misaligned (front margin).
CHECK hood gaps and fit. ADJUST the hood as necessary.
Front grille edge noise.
APPLY foam in the hollow areas behind the louvers.
Grille relationship to leading edge on hood.
ADJUST the grille opening panel forward to eliminate wind noise.
Sharp edges due to material imperfections.
REMOVE the sharp edges (no damage to visible surface).
Air extractor housing seated incorrectly.
REINSTALL the air extractor housing.
Air extractor housing or flaps damaged.
INSTALL a new air extractor.
Roof rack rails or crossbars loose.
TIGHTEN the fasteners.
Roof rack fasteners missing.
INSTALL the approved fasteners.
Roof rack crossbars installed backward.
REINSTALL the crossbars.
Roof rack rub strips partially lifting from roof.
REAPPLY adhesive or fasteners or INSTALL new rub strips as necessary.
Roof rack gaskets loose or misaligned.
REINSTALL the gasket.
Turbulence created by location and shape.
REMOVE per customer direction if it is a dealer installed option.
01/2003 2003.0 BA Falcon
100-04-17
Noise, Vibration and Harshness
100-04-17
DIAGNOSIS AND TESTING (Continued) Symptom Chart — Brake Noise/Vibration Condition
Source
Action
Caliper mounting bolts loose.
CHECK the caliper bolts. TIGHTEN to specifications. REFER to Section 206-03 .
Damaged or worn caliper pins or retainers.
CHECK the caliper pins and retainers for lubrication and correct fit. LUBRICATE or INSTALL new components as necessary.
Missing or damaged anti-rattle clips or springs.
CHECK the brake pads for missing clips or broken springs. INSTALL new components as necessary. REFER to Section 206-03 .
Loose brake disc shield.
TIGHTEN the brake disc shield bolts to specification. REFER to Section 206-03 .
Clicking noise—with brakes applied with ABS brakes
ABS hydraulic control unit.
Acceptable condition.
Squealing noise—occurs on first (morning) brake application
Disc brake pads.
Acceptable condition. Caused by humidity and low disc brake pad temperature.
Squealing noise—a continuous squeal
Disc brake pads worn below minimum thickness.
INSTALL new disc brake pads. REFER to Section 206-03 .
Squealing noise—an intermittent squeal brought on by cold, heat, water, mud or snow
Disc brake pads.
Acceptable condition.
Groaning noise—occurs at low speeds with brake lightly applied (creeping)
Disc brake pads.
Acceptable condition.
Grinding noise—continuous
Disc brake pads worn below minimum thickness.
INSPECT the brake pads, shoes, brake discs and attaching hardware for damage. REPAIR or INSTALL new components as necessary. REFER to Section 206-03 for front disc brakes or Section 206-02 for rear disks.
Moaning noise
Brake linings contaminated with grease or oil.
INSPECT the brake pads and shoes for contamination. REPAIR or INSTALL new components as necessary. REFER to Section 206-03 for front disc brakes or Section 206-04 for rear disks.
Brake vibration/shudder—occurs when brakes are applied
Uneven disc or drum wear. Uneven disc brake pad or lining transfer. Suspension components.
Go to PinPoint Test A .
Brake vibration/shudder—occurs when the brake pedal is released
Brake drag.
INSPECT the brake pads and shoes for premature wear. REPAIR or INSTALL a new caliper or wheel cylinder as necessary. REFER to Section 206-03 for front disc brakes or Section 206-04 for rear disk brakes.
Rattling noise
Symptom Chart—Driveline Noise/Vibration Condition Axle howling or whine—rear axle or transfer case
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Source Axle lubricant low.
Action CHECK the lubricant level. FILL the axle to specification.
01/2003 2003.0 BA Falcon
100-04-18
Noise, Vibration and Harshness
100-04-18
DIAGNOSIS AND TESTING (Continued) Condition
Driveline clunk—loud clunk when shifting from reverse to drive
Driveline clunk—occurs as the vehicle starts to move forward following a stop
Clicking, popping or grinding—occurs while vehicle is turning
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Source
Action
Axle housing damage.
INSPECT the axle housing for damage. REPAIR or INSTALL a new axle as necessary. REFER to Section 205-02 .
Damaged or worn wheel bearings or axle bearings.
CHECK for abnormal wheel bearing play or roughness. REFER to Wheel Bearing Check in this section. ADJUST or INSTALL new wheel bearings as necessary. REFER to Section 204-01 for front bearings or Section 204-02 for rear bearings.
Damaged or worn differential ring and pinion.
INSPECT the ring and pinion ring for abnormal wear patterns or broken teeth. INSTALL a new ring and pinion as necessary. REFER to Section 205-02 .
Damaged or worn differential side or pinion bearings.
CHECK for abnormal bearing play or roughness. INSTALL new bearings as necessary. REFER to Section 205-02 .
Damaged or worn differential side gears and pinion gears.
DISASSEMBLE the differential carrier. INSPECT the side and pinion gears for abnormal wear patterns or broken teeth. INSTALL new gears as necessary. REFER to Section 205-02 .
Transfer case housing or internal gear damage or low lubricant.
INSPECT the transfer case for damage. CHECK the lubricant level and fill transfer case to specification. REFER to Section 308-07b .
Incorrect axle lubricant level.
CHECK the lubricant level. FILL the axle to specification.
Excessive backlash in the axle or transmission.
CARRY OUT a total backlash check.
Damaged or worn pinion bearings.
CHECK for abnormal bearing play or roughness. INSTALL new bearings as necessary. REFER to Section 205-02 .
Damaged or worn universal joints (U-joints).
INSPECT the U-joints for wear or damage. INSTALL new U-joints as necessary. REFER to Section 205-01 .
Loose suspension components.
INSPECT the suspension for damage or wear. REPAIR or INSTALL new components as necessary. REFER to Section 204-00 .
Broken powertrain mounts.
INSPECT the powertrain mounts. INSTALL new mounts as necessary. REFER to Section 303-01a for 2.0L Zetec engine or Section 303-01b for 3.0L (4V) engine.
Idle speed too high.
CHECK for the correct idle speed.
Worn driveshaft constant velocity (CV) joint or U-joints with excessive play.
INSPECT the CV joint and U-joints for a worn condition. INSTALL a new Driveshaft as necessary. REFER to Section 205-01 .
Loose rear axle mount.
CHECK the axle for loose bolts. TIGHTEN to specification.
Inadequate or contaminated lubrication in the CV joints.
CHECK the CV joint boots and joints for wear or damage. REPAIR or INSTALL new components as necessary. REFER to Section 205-04 .
01/2003 2003.0 BA Falcon
100-04-19
Noise, Vibration and Harshness
100-04-19
DIAGNOSIS AND TESTING (Continued) Condition
High pitched chattering—noise from the rear axle when the vehicle is turning
Buzz—buzzing noise is the same at cruise or coast/deceleration
Rumble or boom—noise occurs at coast/deceleration, usually driveshaft speed related and noticeable over a wide range of speeds
Grunting—normally associated with a shudder experienced during acceleration from a dead stop
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Source
Action
Another component contacting the halfshaft.
CHECK the halfshafts and the area around the halfshafts. REPAIR as necessary.
Brake components.
INSPECT the front brakes for wear or damage. REPAIR as necessary. REFER to Section 206-03 .
Steering components.
INSPECT the drag link, inner and outer tie-rods or idler arm for wear or damage. REPAIR as necessary. REFER to Section 211-00 .
Suspension components.
INSPECT the upper and lower ball joints for wear or damage. REPAIR as necessary. REFER to Section 204-01 for front ball joints or Section 204-02 for rear ball joints.
Damaged or worn wheel bearings.
CHECK for abnormal wheel bearing play or roughness. REFER to Wheel Bearing Check in this section. ADJUST or INSTALL new wheel bearings as necessary. REFER to Section 204-01 for front wheel bearings or Section 204-02 for rear wheel bearings.
Incorrect or contaminated lubricant.
CHECK the vehicle by driving in tight circles (5 clockwise, 5 counterclockwise). FLUSH and REFILL with the specified rear axle lubricant and friction modifier as necessary.
Damaged or worn differential (differential side gears and pinion gears).
DISASSEMBLE the differential assembly. INSPECT the differential case, pin and gears for wear or damage. REPAIR or INSTALL a new differential as necessary. REFER to Section 205-02 .
Damaged or worn tyres.
CHECK for abnormal tyre wear or damage. INSTALL a new tyre as necessary. REFER to Section 204-04 .
Incorrect driveline angles.
CHECK for correct driveline angles. REPAIR as necessary. REFER to Section 205-00 .
Driveshaft is out-of-balance.
CHECK the driveshaft for damage, missing balance weights or undercoating. Using the Driveline balancer, CHECK the driveshaft balance. CARRY OUT a driveline vibration test. REFER to Section 205-00 . REPAIR as necessary.
U-joints binding or seized.
ROTATE the driveshaft and CHECK for rough operation or seized U-joints. INSTALL new U-joints as necessary. REFER to Section 205-01 .
Excessive pinion flange runout.
CARRY OUT a runout check. REPAIR as necessary.
Driveshaft CV joint binding.
CLEAN the CV joint and INSTALL a new driveshaft as necessary. REFER to Section 205-01 .
Loose rear axle mount bolts or suspension fasteners
INSPECT the rear suspension and axle. TIGHTEN the fasteners to specification.
01/2003 2003.0 BA Falcon
100-04-20
Noise, Vibration and Harshness
100-04-20
DIAGNOSIS AND TESTING (Continued) Condition
Source
Howl—can occur at various speeds and driving conditions—affected by acceleration and deceleration
Incorrect ring and pinion contact, incorrect bearing preload or gear damage.
CHECK the ring and pinion and bearings for damage. INSPECT the ring and pinion wear pattern. REFER to Checking Tooth Contact Pattern and Condition of the Ring and Pinion component test in this section. ADJUST or INSTALL new components as necessary. REFER to Section 205-02 .
Chuckle—heard at coast/deceleration—also described as a knock
Incorrect ring and pinion contact or by damaged teeth on the coast side of the ring and pinion.
CHECK the ring and pinion for damage. INSPECT the ring and pinion wear pattern. REFER to Checking Tooth Contact Pattern and Condition of the Ring and Pinion component test in this section. ADJUST or INSTALL new components as necessary. REFER to Section 205-02 .
Knock—noise occurs at various speeds—not affected by acceleration or deceleration
Gear tooth damage to the ring and pinion.
CHECK the differential case and ring and pinion for damage. INSTALL new components as necessary. REFER to Section 205-02 .
Excessive axle shaft end play (vehicles with integral axles).
CHECK the axle end play using a dial indicator. INSTALL a new axle shaft or side gears as necessary. REFER to Section 205-02 .
Scraping noise—a continuous low pitched noise starting at low speeds
Worn or damaged pinion bearings.
CHECK the pinion bearings. INSTALL new pinion bearings as necessary. REFER to Section 205-02 .
Driveline shudder—occurs during acceleration from a slow speed or stop
Rear drive axle assembly mispositioned.
CHECK the axle mounts and the rear suspension for damage or wear. REPAIR as necessary.
Loose rear axle bolts.
INSPECT the bolts. TIGHTEN the bolt nuts to specification.
Incorrect or high CV joint operating angle.
CHECK vehicle ride height is within limits. REPAIR as necessary.
Damaged or worn front suspension components.
CHECK for a loose stabilizer bar, damaged or loose strut/strut bushings or loose or worn ball joints. INSPECT the steering linkage for wear or damage. REPAIR or INSTALL new components as necessary. REFER to Section 204-00 .
Driveline angles out of specification.
CHECK for correct driveline angles. REPAIR as necessary. REFER to Section 205-00 .
U-joints binding or seized.
ROTATE the driveshaft and CHECK for rough operation or seized U-joints. INSTALL new U-joints as necessary. REFER to Section 205-01 .
Binding the driveshaft CV joint.
INSPECT the driveshaft shaft CV joint and coupling shaft for a worn, or damaged condition. INSTALL a new or driveshaft assembly as necessary. REPAIR as necessary. REFER to Section 205-01 . REPAIR as necessary.
Loose rear axle bolts.
INSPECT the bolts. TIGHTEN the bolts to specification.
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01/2003 2003.0 BA Falcon
100-04-21
Noise, Vibration and Harshness
100-04-21
DIAGNOSIS AND TESTING (Continued) Condition Driveline vibration—occurs at cruising speeds
Source
Action
U-joints are worn.
CHECK for wear or incorrect seating. INSTALL new driveshaft as necessary. REFER to Section 205-01 .
Worn or damaged driveshaft center bearing support.
CHECK the insulator for damage or wear. ROTATE the driveshaft and CHECK for rough operation. INSTALL a new center bearing support as necessary. REFER to Section 205-01 .
Loose axle pinion flange bolts.
INSPECT the axle pinion flange. TIGHTEN the pinion flange bolts to specification. REFER to Section 205-01 .
Excessive axle pinion flange runout.
CARRY OUT a Runout Check. REFER to Section 205-01 . REPAIR as necessary.
Driveshaft is out-of-balance.
CHECK the driveshaft for damage, missing balance weights or undercoating. CHECK driveshaft balance. CARRY OUT a driveline vibration test. REFER to Section 205-01 . REPAIR as necessary.
Binding or damaged driveshaft CV joint.
INSPECT the driveshaft CV joint for wear or damage. INSTALL a new driveshaft assembly as necessary. REFER to Section 205-01 . REPAIR as necessary.
Driveshaft runout.
CARRY OUT a runout check. REFER to Section 205-01 . REPAIR as necessary.
Incorrect lateral and radial tyre/wheel runout.
INSPECT the tyre and wheels. MEASURE tyre runouts. REPAIR or INSTALL new components as necessary. REFER to Section 204-04 .
Driveline angles out of specification.
CHECK for correct driveline angles. REPAIR as necessary. REFER to Section 205-00 .
Incorrectly seated CV joint in the front wheel hub.
CHECK the outer CV joint for correct seating into the hub. REPAIR as necessary. REFER to Section 205-04 for front CV joints or Section 205-05 for rear CV joints.
Symptom Chart — Engine Noise/Vibration Condition Grinding noise—occurs during engine cranking
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Source
Action
Incorrect starter motor mounting.
INSPECT the starter motor for correct mounting. REPAIR as necessary. REFER to Section 303-06 .
Starter motor.
CHECK the starter motor. REPAIR or INSTALL a new starter motor as necessary. REFER to Section 303-06 .
Incorrect starter motor drive engagement.
INSPECT the starter motor drive and flexplate/flywheel for wear or damage. If necessary, INSTALL a new starter motor drive. REFER to Section 303-06 . If necessary, INSTALL a new flexplate/flywheel. REFER to Section 303-01a for 2.0L Zetec engine or Section 303-01b for 3.0L (4V) engine.
01/2003 2003.0 BA Falcon
100-04-22
Noise, Vibration and Harshness
100-04-22
DIAGNOSIS AND TESTING (Continued) Condition
Source
Action
Engine ticking noise
Fuel injector. Fuel line. Oil pump. Valve lifter. Belt tensioner. Water pump. Obstruction of cooling fan.
Go to PinPoint Test B .
Engine drumming noise—normally accompanied by vibration
Powertrain mount.
CARRY OUT Powertrain/Drivetrain Mount Neutralizing in this section.
Damaged or misaligned exhaust system.
INSPECT the exhaust system for loose or broken clamps and brackets, flex coupling or damper (2.0L Zetec). CARRY OUT Exhaust System Neutralizing in this section.
Whistling noise—normally accompanied with poor idle condition
Air intake system.
CHECK the air intake ducts, air cleaner, throttle body and vacuum hoses for leaks and correct fit. REPAIR or ADJUST as necessary. REFER to Section 303-12 .
Clunking noise
Water pump has excessive end play or imbalance.
CHECK the water pump for excessive end play. INSPECT the water pump with the drive belt off for imbalance. INSTALL a new water pump as necessary. REFER to Section 303-03 .
Alternator has excessive end play.
CHECK the generator for excessive end play. REPAIR or INSTALL a new alternator. REFER to Section 414-02 .
Exhaust system leak.
INSPECT the exhaust system for leaks. REPAIR as necessary.
Gasoline octane too low.
VERIFY with customer the type of gasoline used. CORRECT as necessary.
Knock sensor operation.
CHECK the knock sensor. INSTALL a new knock sensor as necessary. REFER to Section 303-14 .
Incorrect spark timing.
CHECK the spark timing. REPAIR as necessary.
High operating temperature.
INSPECT cooling system for leaks. CHECK the coolant level. REFILL as necessary. CHECK the coolant for the correct mix ratio. DRAIN and REFILL as needed. CHECK engine operating temperature is within specifications. REPAIR as necessary.
Foul-out spark plug.
CHECK the spark plugs. REPAIR or INSTALL new spark plugs as necessary.
Catalytic converter.
Acceptable noise.
Excessive clearance between the piston and the cylinder wall.
Engine cold and at high idle. Using an EngineEAR, pull a spark plug or fuel injector connector until the noise goes away. CARRY OUT a cylinder bore clearance to piston check. INSTALL a new piston.
Pinging noise
Knocking noise—light knocking noise, also described as piston slap—noise is most noticeable when engine is cold with light to medium acceleration—noise disappears as engine warms
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01/2003 2003.0 BA Falcon
100-04-23
Noise, Vibration and Harshness
100-04-23
DIAGNOSIS AND TESTING (Continued) Condition
Source
Action
Knocking noise—light double knock or sharp rap sound—occurs mostly with warm engine at idle or low speeds in DRIVE—increases in relation to engine load—associated with poor lubrication history
Excessive clearance between the piston and the piston pin.
INSTALL a new piston or piston pin.
Knocking noise—light knocking noise is most noticeable when engine is warm—noise tends to decrease when vehicle is coasting or in neutral
Excessive clearance between the connecting rod bearings and the crankshaft.
Engine warm and at idle. PULL a spark plug or fuel injector connector until the noise goes away. INSTALL new bearings.
Knocking—deep knocking noise—noise is most noticeable when engine is warm, at lower rpm and under a light load and then at float
Worn or damaged crankshaft main bearings.
CARRY OUT DERU test. CHECK for noise with vehicle at operating temperature, during medium to heavy acceleration. CHECK at idle with injector disconnected, noise does not change. INSTALL new main bearings.
Knocking noise—occurs mostly with warm engine at light/medium acceleration
Spark plugs.
CHECK the spark plug for damage or wear. INSTALL new spark plugs as necessary.
Carbon accumulation in combustion chamber.
REMOVE carbon from combustion chamber.
Air intake system.
CHECK the air cleaner and ducts for correct fit. INSPECT the air intake system for leaks or damage. REPAIR as necessary. REFER to Section 303-12 .
Alternator electrical field or bearings.
CARRY OUT alternator load test. REPAIR or INSTALL a new alternator as necessary. REFER to Section 412-02 .
Exhaust system.
CARRY OUT the Exhaust System Neutralizing in this section. REPAIR as necessary.
A/C compressor.
CHECK for noise with vehicle at constant speeds. CYCLE the compressor on and off and listen for a change in pitch. REPAIR as necessary. REFER to Section 412-03 .
Powertrain mounts.
CARRY OUT the Exhaust System Neutralizing in this section.
Sputter type noise—noise worse when cold, lessens or disappears when vehicle is at operating temperature
Damaged or worn exhaust system components.
INSPECT the exhaust system for leaks or damage. REPAIR as necessary. REFER to Section 309-00 .
Rattling noise—noise from the upper engine (valve train)—worse when engine is cold
Low oil level.
CHECK oil level. FILL as necessary.
Thin or diluted oil.
INSPECT the oil for contamination. If oil is contaminated, CHECK for the source. REPAIR as necessary. CHANGE the oil and filter.
Low oil pressure.
CARRY OUT an oil pressure test. If not within specifications, REPAIR as necessary. REFER to Section 303-00 .
Worn rocker arms/fulcrums or followers.
CARRY OUT a valve train analysis. INSTALL new valve train components as necessary. REFER to Section 303.
Worn valve guides.
CARRY OUT a valve train analysis. INSTALL new valve guides as necessary. REFER to Section 303.
Whine or moaning noise
Drone type noise
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01/2003 2003.0 BA Falcon
100-04-24
Noise, Vibration and Harshness
100-04-24
DIAGNOSIS AND TESTING (Continued) Condition
Source
Action
Excessive runout of valve seats on the valve face.
CARRY OUT a valve seat runout test. INSPECT the valve face and seat. INSTALL new valves as necessary. REFER to Section 303.
Rattling noise—from the bottom of the vehicle
Loose muffler shields or catalytic converter shields.
CHECK the exhaust system for loose shields. REPAIR as necessary.
Thumping noise—from the bottom of the vehicle, worse at acceleration
Exhaust pipe/muffler grounded to chassis.
CHECK the exhaust system to chassis clearance. CHECK the exhaust system hangers for damage. REPAIR as necessary.
Engine vibration—increases intensity as engine rpm is increased
Engine out-of-balance.
CARRY OUT Neutral Engine Run-up (NERU) Test. ROTATE the torque converter, 120° for 3 bolt and 180° for 4 bolt. INSPECT the torque converter pilot outer diameter to crankshaft pilot inner diameter.
Engine vibration—is felt with increases and decreases in engine rpm
Strain on exhaust mounts.
CARRY OUT the Exhaust System Neutralizing procedure in this section. REPAIR as necessary.
Damaged or worn powertrain/drivetrain mounts.
CHECK the powertrain/drivetrain mounts for damage. REPAIR as necessary.
Engine or transmission grounded to chassis.
INSPECT the powertrain/drivetrain for correct clearances. REPAIR as necessary.
Excessive engine pulley runout.
CARRY OUT Engine Accessory Test. INSTALL a new engine pulley as necessary. REFER to Section 303.
Damaged or worn accessory component.
CARRY OUT Engine Accessory Test. REPAIR or INSTALL a new component as necessary. REFER to Section 303-05.
Engine vibration—mostly at coast/neutral coast—condition improves with vehicle accelerating
Combustion instability.
CHECK the ignition system. INSTALL new components as necessary.
Engine vibration or shudder—occurs with light to medium acceleration above 56 km/h (35 mph)
Worn or damaged spark plugs.
INSPECT the spark plugs for cracks, high resistance or broken insulator. INSTALL a new spark plug(s) as necessary.
Plugged fuel injector.
REPAIR or INSTALL a new injector as necessary.
Damaged spark plug wire.
INSPECT the spark plug wires for damage. INSTALL a new spark plug wire(s) as necessary.
Contaminated fuel.
INSPECT the fuel for contamination. DRAIN the fuel system and refill.
Worn or damaged torque converter.
CHECK the torque converter. INSTALL a new torque converter as necessary. REFER to Section 307-01 .
Engine vibration—vibration felt at all times
Symptom Chart—Idle Noise/Vibration Condition
Source
Idle air control (IAC) valve moan — occurs on throttle tip-out
IAC valve is contaminated with oil.
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Action GO to Component Tests in this section.
01/2003 2003.0 BA Falcon
100-04-25
Noise, Vibration and Harshness
100-04-25
DIAGNOSIS AND TESTING (Continued) Condition
Source
Action
Accessory drive belt chirp — occurs at idle or high idle, cold or hot—most common occurrence is during humid weather
Accessory drive belt worn, or pulley is misaligned or loose.
INSPECT for loose or misaligned pulleys. CHECK the drive belt for wear or damage. INSTALL new pulley(s) or accessory drive belt, as necessary. REFER to Section 303-05 .
Accessory drive bearing hoot — occurs at idle or high idle in cold temperatures of approximately +4°C (+40°F) or colder at first start of the day
Accessory drive idler or tensioner pulley bearing is experiencing stick/slip between ball bearings and bearing race.
Go to PinPoint Test C .
Power steering moan — occurs at high idle and possibly at idle during the first cold start of the day in temperatures of approximately -18°C (0°F) or colder—noise can even be a severe screech for less than one minute in very cold temperatures of approximately -29°C (-20°F) or colder
High fluid viscosity, or plugged reservoir screen in power steering reservoir starves pump causing cavitation.
Go to PinPoint Test D .
Alternator whine — during high electrical loads at idle or high idle, a high pitch whine or moan is emitted from the alternator
Alternator electrical field noise.
CHECK for changes in the noise level while changing electrical loads (such as rear defrost, headlamps etc.). CARRY OUT a alternator load test. REFER to Section 414-00 . If the system passes the load test, the noise is from the alternator bearings, INSTALL new bearings. If the system fails the load test, INSTALL a new alternator. REFER to Section 414-02 .
Drumming noise — occurs inside the vehicle during idle or high idle, hot or cold—very low-frequency drumming is very rpm dependent
Exhaust system vibration excites the body resonances inducing interior noise. Engine vibration excites the body resonances inducing interior noise.
Go to PinPoint Test E .
Hissing noise — occurs during idle or high idle that is apparent with the hood open
Vacuum leak or idle air control (IAC) valve flow noise.
CHECK the air intake system from the inlet to each cylinder intake port. DISCARD the leaking parts, and INSTALL a new component.
Automatic transmission buzz or hiss
Incorrect driveline angles.
CHECK for correct driveline angles. REPAIR as necessary. REFER to Section 205-00 .
Worn or damaged main control solenoids or valves.
Using a transmission tester, ACTIVATE the solenoids to duplicate sound. INSTALL new components as necessary. REFER to Section 307-01 .
Manual Transmission Clutch throw-out bearing whine—a change in noise pitch or loudness while depressing the clutch pedal
Worn throw-out bearing.
INSTALL a new throw-out bearing. REFER to Section 308-01 .
Heating, vacuum and air conditioning (HVAC) system chirp — most audible inside the vehicle—listen for a change in noise pitch or loudness while changing the HVAC system blower speed
Damaged or worn HVAC blower bearing.
INSTALL a new blower motor. REFER to Section 412-02 .
Air conditioning (A/C) clutch ticking — occurs when the compressor clutch engages
Acceptable noise. Incorrect air gap.
LISTEN to the clutch to determine if the noise occurs with clutch engagement. A small amount of noise is acceptable. If the noise is excessive, CHECK the A/C clutch air gap. INSPECT the A/C clutch for wear or damage. INSTALL a new clutch as necessary. REFER to Section 412-03 .
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01/2003 2003.0 BA Falcon
100-04-26
Noise, Vibration and Harshness
100-04-26
DIAGNOSIS AND TESTING (Continued) Condition Intermittent rattle, or scraping/rubbing noise
Source
Action
Loose exhaust heat shield(s).
INSPECT the exhaust system for loose parts using a glove or clamps to verify cause. REPAIR as necessary. REFER to Section 309-00 .
Wiring, hose or other part interfering with the accessory drive belt or pulley.
INSPECT the accessory drive system closely verifying there is adequate clearance to all rotating components. REPAIR as necessary.
Engine ticking or knocking noise — occurs during idle or high idle during the first cold start of the day
Piston noise or valvetrain noise (bled down lifter/lash adjuster).
Go to PinPoint Test F .
A continuous, speed-dependent rattle from the engine — occurs during idle or high idle during the first cold start of the day and disappears as the engine warms up
Piston noise or valvetrain noise (bled down lifter/lash adjuster).
Go to PinPoint Test F .
Idle vibration—a low-frequency vibration (5-20 Hz) or mild shake that is felt through the seat/floorpan
Cylinder misfire.
Using the diagnostic tool, CHECK the ignition system. CARRY OUT a cylinder power test. REFER to Section 303-00 .
Engine or torque converter out of balance.
VERIFY the torque converter to crankshaft pilot clearance is correct, REPAIR as necessary. RE-INDEX the torque converter on the flex plate by 120° on a 3-bolt converter or 180° for a 4-bolt converter. REFER to Section 307-01 . RETEST the vehicle.
Exhaust system mounts bound up.
VERIFY concern occurs at engine firing frequency. CHECK that the exhaust system vibrates at the same frequency as the engine. ADD 9–14 km (20–30 lb.) to the tail pipe to test, CARRY OUT Exhaust System Neutralizing in this section.
Power steering lines grounded out.
INSPECT that the power steering lines are not contacting the chassis or each other. REPAIR as necessary.
Engine mounts binding.
NEUTRALIZE the powertrain/drivetrain mounts. CARRY OUT Powertrain/Drivetrain Mount Neutralizing in this section.
Idle vibration—a high-frequency vibration (20–80 Hz) or buzz, that is felt through the steering wheel or seat
Symptom Chart—Squeak and Rattle Condition
Source
Squeak—heard inside the vehicle when closing/opening the door
Insufficient lubrication on the door hinge or check strap.
LUBRICATE the hinge or check strap.
Internal door components loose, rubbing or misaligned.
CHECK the inside of the door. TIGHTEN or ALIGN as necessary. USE the Rotunda Squeak and Rattle Kit to ISOLATE any rubbing components.
Squeak—heard inside the vehicle when closing/opening the window
Worn or damaged glass run/channel.
REPAIR or INSTALL a new glass run/channel. REFER to Section 501-11 .
Squeak—heard outside of vehicle when closing/opening the door
Exhaust shield rubbing against the chassis or exhaust pipe.
CHECK the exhaust system. REPAIR as necessary. REFER to Section 309-00 .
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01/2003 2003.0 BA Falcon
100-04-27
Noise, Vibration and Harshness
100-04-27
DIAGNOSIS AND TESTING (Continued) Condition
Source
Action
Squeak—occurs with initial brake pedal application
Disc brake pads.
Under certain conditions, asbestos free pads can generate a squeak noise. This noise is normal and does not indicate a concern.
Squeak—a constant noise that occurs with brake pedal applications
Damaged or worn disc brake pads.
INSPECT the pads for oil, grease or brake fluid contamination. CHECK for glazed linings. A brake disc with hard spots will also cause a squeak type noise. REPAIR or INSTALL new brake pads as necessary. REFER to Section 206-03 .
Squeak—noise occurs over bumps or when turning
Worn control arm bushings.
INSPECT the control arm bushings. Spray with lubricant and CARRY OUT a “bounce test” to determine which bushing. REPAIR as necessary. REFER to Section 204-01 for front bushings or Section 204-02 for rear bushings.
Worn or damaged shock absorber/strut.
INSPECT the shock absorber for damage. CARRY OUT a “bounce test” to isolate the noise. INSTALL a new shock absorber/strut as necessary. REFER to Section 204-01 for front shock absorber/strut or Section 204-02 for rear shock absorber/strut.
Rattle—heard when closing/opening the door or window
Loose internal door mechanism, bracket or attachment.
REPEAT the motion or CARRY OUT a “tap test” to duplicate the noise. INSPECT the door for loose components. TIGHTEN loose components.
Squeak or rattle—heard inside the vehicle over rough roads/bumps
Misaligned glove compartment door/hinge.
ALIGN the glove compartment door.
Instrument panel trim loose or misaligned.
INSPECT the instrument panel trim for missing or loose clips or screws. REPAIR as necessary.
Loose interior component or trim.
CARRY OUT a “touch test”. ELIMINATE the noise by pressing or pulling on interior trim and components.
Damaged or worn sub-frame mounts.
INSPECT the upper and lower absorbers for damage or wear. CHECK the sub-frame for damage. CHECK the nuts and bolts are tightened to specifications. TIGHTEN as necessary.
Squeak or rattle—noise with a vibration concern
Symptom Chart—Steering Noise/Vibration Condition
Source
Action
Steering grunt or shudder — occurs when turning into or out of a turn at low speeds (temperature sensitive)
Steering gear or power steering hoses.
GO to Steering Gear Grunt/Shudder Test component test in this section.
Steering System clonk—hydraulic knocking sound
Air in the steering hydraulic system.
CHECK for leaks in the system. PURGE the air from the system. REFER to Section 211-00 .
Power steering pump moan — loud humming noise occurs when the steering wheel is rotated to the stop position. Produces a 120-600 Hz frequency that changes with rpm
Power steering hose grounded out to chassis.
INSPECT the power steering hoses. REPAIR as necessary.
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DIAGNOSIS AND TESTING (Continued) Condition
Source
Action
Aerated fluid.
CHECK for leaks in the system. PURGE the air from the system. REFER to Section 211-00 .
Steering gear isolators.
INSPECT the isolators for wear or damage. REPAIR as necessary.
Low fluid.
CHECK the fluid level. REFILL as necessary.
Power steering pump brackets loose or misaligned.
CHECK bolts, brackets and bracket alignment. TIGHTEN bolts to specification. REPAIR or INSTALL new brackets as necessary. REFER to Section 211-02.
Steering gear clunk — occurs only while cornering over a bump (can be temperature sensitive)
Steering gear.
INSPECT the steering gear for loose mounting bolts. TIGHTEN as necessary. REFER to Section 211-02 .
Feedback (rattle, chuckle or knocking noise in the steering gear) — a condition where roughness is felt in the steering wheel when the vehicle is driven over rough surfaces
Column intermediate/flexible shaft joints damaged or worn.
INSTALL a new intermediate/flexible shaft. REFER to Section 211-04 .
Loose, damaged or worn tie-rod ends.
TIGHTEN the nuts to specification or INSTALL new tie-rod ends as necessary. REFER to Section 211-03 .
Steering gear insulators or mounting bolts loose or damaged.
TIGHTEN the bolts or INSTALL new bolts as necessary. REFER to Section 211-02 .
Steering column intermediate shaft bolts are loose.
TIGHTEN the bolts to specification.
Steering column damaged or worn.
REPAIR or INSTALL a new steering column as necessary. REFER to Section 211-04 .
Loose suspension bushings, bolts or ball joints.
INSPECT the suspension system. TIGHTEN or INSTALL new components as necessary. REFER to Section 204-01 for front suspension or Section 204-02 for rear suspension.
Feedback (nibble at the steering wheel) — a condition where slight rotational movement is felt in the steering wheel when the vehicle is driven over rough or grooved surfaces
Lateral runout in the tyre or wheel.
GO to Pinpoint Test G.
Accessory drive belt squeal/chirp—when rotating the steering wheel from stop to stop
Loose or worn accessory drive belt.
ADJUST or INSTALL a new accessory belt as necessary. REFER to Section 303-05 .
Power steering gear hiss
Steering column intermediate/flexible shaft-to-steering gear is binding or misaligned.
REPAIR or INSTALL a new intermediate/flexible shaft as necessary. REFER to Section 211-04 .
Grounded or loose steering column boot at the dash panel.
REPAIR as necessary.
Damaged or worn steering gear input shaft and valve.
REPAIR or INSTALL a new steering gear as necessary. REFER to Section 211-02 .
Steering column rattle
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Loose bolts or attaching brackets.
TIGHTEN the bolts to specifications.
Loose, worn or insufficiently lubricated column bearings.
LUBRICATE or INSTALL new steering column bearings as necessary. REFER to Section 211-04 .
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DIAGNOSIS AND TESTING (Continued) Condition
Source
Action
Steering shaft insulators damaged or worn.
INSTALL new insulators. REFER to Section 211-04 .
Intermediate/flexible shaft compressed or extended.
INSTALL a new intermediate/flexible shaft. REFER to Section 211-04 .
Insufficiently lubricated steering shaft bushings.
LUBRICATE the steering shaft and shaft tube seals.
Loose or misaligned steering column shrouds.
TIGHTEN or ALIGN the steering column shrouds.
Steering wheel rubbing against steering column shrouds.
REPOSITION the steering column shrouds.
Insufficient lubricated speed control slip ring.
LUBRICATE the speed control slip ring.
Upper or lower bearing sleeve out of position.
REPOSITION the bearing sleeves.
Power steering pump noisy
Incorrect assembly of components. Imperfections on the outside diameter or end surface of the power steering pump rotor. Damaged or worn power steering pump rotor splines. A crack on the inner surface of the power steering pump cam. Interference between the power steering pump rotor and cam. Damaged or worn power steering pump rotor and pressure plates.
REPAIR or INSTALL a new power steering pump as necessary. REFER to Section 211-02 .
Power steering pump swish noise
Power steering fluid flow into the bypass valve of the pump valve housing with fluid temperature below 54°C (130°F).
Acceptable condition.
Power steering pump whine noise
Aerated fluid.
PURGE the air from the system. REFER to Section 211-00 . CHECK for a leak in the system.
Damaged power steering pump.
REPAIR or INSTALL a new power steering pump as necessary. REFER to Section 211-02 .
Damaged valve cover O-ring seal.
REPAIR or INSTALL a new power steering pump as necessary. REFER to Section 211-02 .
Power steering pump clicking (mechanical) noise
Power steering pump rotor slippers too long, excessive rotor slipper-to-slot clearance or damaged or worn rotor assembly.
REPAIR or INSTALL a new power steering pump as necessary. REFER to Section 211-02 .
Power steering pump clatter noise
Damaged corners on the outside diameter or the power steering rotor or distorted rotor slipper ring.
REPAIR or INSTALL a new power steering pump as necessary. REFER to Section 211-02 .
Steering column squeak or cracks
Symptom Chart—Suspension Noise/Vibration Condition
Source
Action
Squeak or grunt—noise from the front suspension, occurs more in cold ambient temperatures—more noticeable over rough roads or when turning
Front stabilizer bar insulators.
Under these conditions, the noise is acceptable. CHECK TSBs.
Clunk—noise from the front suspension, occurs in and out of turns
Loose front struts or shocks.
INSPECT for loose nuts or bolts. TIGHTEN to specifications. REFER to Section 204-01 .
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DIAGNOSIS AND TESTING (Continued) Condition
Source
Action
Clunk—noise from the rear suspension, occurs when shifting from reverse to drive
Loose rear suspension components.
INSPECT for loose or damaged rear suspension components. REPAIR or INSTALL new components as necessary. REFER to Section 204-02 .
Click or pop—noise from the front suspension—more noticeable over rough roads or over bumps
Worn or damaged ball joints.
CARRY OUT a ball joint inspection. INSTALL new control arm as necessary. REFER to Section 204-01 .
Front suspension noise—a squeak, creak or rattle noise—occurs mostly over bumps or rough roads
Steering components. Loose or bent front struts or shock absorbers. Damaged spring or spring mounts. Damaged or worn control/radius arm bushings. Worn or damaged stabilizer bar bushings or links.
Go to PinPoint Test G .
Rear suspension noise—a squeak, creak or rattle noise—occurs mostly over bumps or rough roads
Loose or bent rear shock absorbers. Damaged spring or spring mounts. Damaged or worn control arm bushings.
Go to PinPoint Test H .
Shudder—occurs during acceleration from a slow speed or stop
Rear drive axle assembly mispositioned.
CHECK the axle mounts and the rear suspension for damage or wear. REPAIR as necessary.
Incorrect or high CV joint operating angle.
CHECK vehicle ride height is within limits. REPAIR as necessary.
Damaged or worn front suspension components.
CHECK for a loose stabilizer bar, damaged or loose strut/strut bushings or loose or worn ball joints. INSPECT the steering linkage for wear or damage. REPAIR or INSTALL new components as necessary.
Excessive positive caster.
CHECK the caster alignment angle. CORRECT as necessary. REFER to Section 204-00 .
Shimmy—most noticeable on coast/deceleration—also hard steering condition
Symptom Chart—Tyre Noise/Vibration Condition
Source
Action
Tyre noise—hum/moan at constant speeds
Abnormal wear patterns.
SPIN the tyre and CHECK for tyre wear. INSTALL a new tyre as necessary. INSPECT for damaged/worn suspension components. CARRY OUT wheel alignment.
Tyre noise—noise tone lowers as the vehicle speed is lowered
Out-of-balance tyre.
BALANCE the tyre and road test. INSTALL a new tyre as necessary. REFER to Section 204-04 .
Tyre noise — ticking noise, changes with speed
Nail puncture or stone in tyre tread.
INSPECT the tyre. REPAIR as necessary.
Wheel and tyre—vibration and noise concern is directly related to vehicle speed and is not affected by acceleration, coasting or decelerating
Damaged or worn tyre.
Go to PinPoint Test I .
Tyre wobble or shudder — occurs at lower speeds
Damaged wheel bearings.
SPIN the tyre and CHECK for abnormal wheel bearing play or roughness. ADJUST or INSTALL new wheel bearings as necessary. REFER to Section 204-01 for front bearings or Section 204-02 for rear bearings.
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DIAGNOSIS AND TESTING (Continued) Condition
Tyre shimmy or shake— occurs at lower speeds
High speed shake or shimmy—occurs at high speeds
Source
Action
Damaged wheel.
INSPECT the wheel for damage. INSTALL a new wheel as necessary. REFER to Section 204-04 .
Damaged or worn suspension components.
INSPECT the suspension components for wear or damage. REPAIR as necessary.
Loose wheel nuts.
CHECK the wheel nuts. TIGHTEN to specification. REFER to Section 204-04 .
Damaged or uneven tyre wear.
SPIN the tyre and CHECK for abnormal tyre wear or damage. INSTALL a new tyre as necessary. REFER to Section 204-04 .
Wheel/tyre out of balance.
BALANCE the wheel/tyre assembly.
Uneven tyre wear.
CHECK for abnormal tyre wear. INSTALL a new tyre as necessary. REFER to Section 204-04 .
Excessive radial runout of wheel or tyre.
CARRY OUT a radial runout test of the wheel and tyre. INSTALL a new tyre as necessary. REFER to Section 204-04 .
Worn or damaged wheel studs or elongated stud holes.
INSPECT the wheel studs and wheels. INSTALL new components as necessary.
Excessive lateral runout of the wheel or tyre.
CARRY OUT a lateral runout test of the wheel and tyre. CHECK the wheel, tyre and hub. REPAIR or INSTALL new components as necessary.
Foreign material between the brake disc and hub or in the brake disc fins.
CLEAN the mounting surfaces of the brake disc and hub. CHECK the brake disc fins for material.
Excessive wheel hub runout. Damaged or worn tyres. Damaged or worn wheel bearings. Worn or damaged suspension or steering linkage components. Brake disc or drum imbalance.
Go to PinPoint Test J .
Symptom Chart—Transmission (Manual) Vibration Condition
Source
Action
Clutch rattling noise—occurs with clutch engaged, noise changes/disappears with clutch pedal depressed
Flywheel bolts, clutch housing bolts or clutch pressure plate bolts loose.
TIGHTEN the bolts to specifications. CHECK the bolts for damage.
Clutch squeaking noise—noise is heard when the clutch is operated—vehicle moves slowly or creeps when the clutch is disengaged—can also be difficult to shift into first and reverse gear
Pilot bearing seized or damaged.
INSTALL a new pilot bearing. REFER to Section 308-01 .
Clutch squeaking noise—occurs with clutch pedal depressed/released
Worn clutch pedal shaft or bushings.
INSPECT the clutch pedal for wear or damage. REPAIR as necessary. REFER to Section 308-02 .
Clutch whirring/rattle noise—occurs when clutch pedal is depressed
Worn, damaged or misaligned clutch release bearing.
INSTALL a new clutch release bearing. REFER to Section 308-02 .
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DIAGNOSIS AND TESTING (Continued) Condition Clutch grating/grinding noise—occurs when clutch pedal is depressed
Source
Action
Clutch pressure plate fingers bent or worn.
INSPECT the clutch pressure plate release fingers. INSTALL a new pressure plate as necessary. REFER to Section 308-01 .
Contact surface of clutch release bearing worn or damaged.
INSTALL a new clutch release bearing. REFER to Section 308-01 .
Clutch chatter—a small amount of noise when clutch pedal is released at initial take-off
Clutch engagement.
Acceptable operating condition.
Clutch chatter/grabs—in some cases a shudder is felt—occurs with clutch pedal depressed/released
Damaged or worn powertrain/driveline mounts.
INSPECT the powertrain/drivetrain mounts. INSTALL new mounts as necessary. REFER to Section 308-03 .
Binding or dragging plunger of the clutch master cylinder or slave cylinder.
CHECK the master and slave cylinder operation. INSPECT the components for damage or wear. INSTALL a new master or slave cylinder as necessary. REFER to Section 308-02 .
Grease or oil on the clutch disc facing.
CHECK the input shaft seal and rear main oil seal. REPAIR as necessary. INSTALL a new clutch disc. REFER to Section 308-03 .
Clutch disc surface glazed or damaged.
INSPECT the clutch disc surface for a glazed, hardened or damage condition. CARRY OUT a disc check. INSTALL a new clutch disc as necessary. REFER to Section 308-01 .
Damaged or worn clutch pressure plate.
INSPECT the clutch pressure plate for wear or damage. INSTALL a new clutch pressure plate as necessary. REFER to Section 308-01 .
Flywheel surface damaged or glazed.
INSPECT the flywheel for damage or wear. CARRY OUT a flexplate/flywheel runout check. INSTALL a new flywheel as necessary. REFER to Section 303-01a for 2.0L Zetec engine or Section 303-01b for 3.0L (4V) engine.
Clutch chatter noise—noise when clutch pedal is released at initial take-off—clutch is hard to engage and disengage
Pilot bearing worn, damaged or not correctly aligned in bore.
INSPECT the clutch pressure plate release fingers for uneven wear, clutch components burnt or a seized pilot bearing. INSTALL a new pilot bearing as necessary. REFER to Section 308-01 .
Clutch vibration
Loose flywheel bolts. Damaged or loose clutch pressure plate. Excessive flywheel runout.
Go to PinPoint Test K .
Transmission rattling/clattering noise—noise at idle or on light acceleration from a stop—gear selection difficult
Gearshift lever joint worn or damaged.
INSTALL a new gearshift lever. REFER to Section 308-06 .
Gearshift lever loose.
TIGHTEN the bolts to specification. REFER to Section 308-06 .
Gearshift linkage rods worn or damaged.
CHECK the linkage bushings for wear. INSTALL new linkage rods as necessary. REFER to Section 308-06 .
Incorrect fluid level or fluid quality.
CHECK that the transmission is filled to the correct level and with the specified fluid. REFER to Section 308-03 .
Transmission rattling/clattering noise—occurs in neutral or in gear, at idle
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DIAGNOSIS AND TESTING (Continued) Condition
Source
Action
Worn or rough reverse idler gear.
CHECK the reverse idler gear. REPAIR as necessary. REFER to Section 308-03 .
Rough running engine, cylinder misfire.
CHECK the ignition system. CARRY OUT a cylinder power test. REFER to Section 303-00 .
Excessive backlash in gears
CHECK the gear backlash. ADJUST as necessary. REFER to Section 308-03 .
Worn countershaft gears.
REPAIR as necessary. REFER to Section 308-03 .
Transmission whine—a mild whine at extreme speeds or high rpm
Rotating gears/geartrain.
Acceptable noise.
Transmission whine—a high pitched whine, also described as a squeal
Transmission gears are worn (high mileage vehicle).
Result of normal gear wear. REPAIR as necessary. REFER to Section 308-03 .
Mismatched gear sets.
INSPECT the gear sets for an uneven wear pattern on the face of the gear teeth. REPAIR as necessary. REFER to Section 308-03 .
Damaged or worn transmission bearing.
INSPECT the transmission bearings. INSTALL new bearings as necessary. REFER to Section 308-03 .
Transmission growling/humming—noise occurs in the forward gears—the noise is more prominent when the gear is loaded—the problem gear can be located as the noise occurs in a specific gear position
Gear is cracked, chipped or rough.
INSPECT the transmission gears for damage or wear. INSTALL new gears as necessary. REFER to Section 308-03 .
Transmission hissing—noise in neutral or in forward gears—as bearings wear or break up, the noise changes to a thumping noise
Damaged or worn bearings.
INSPECT the transmission bearings. INSTALL new bearings as necessary. REFER to Section 308-03 .
Transmission knocking/thudding—noise at low speeds in forward gears
Bearings with damaged balls or rollers or with pitted and spalled races.
INSPECT the transmission bearings. INSTALL new bearings as necessary. REFER to Section 308-03 .
Transmission rumble/growl—noise at higher speeds in forward gears, more pronounced in a coast/deceleration condition
Incorrect driveline angle.
CHECK the driveline angle. REPAIR as necessary. REFER to Section 205-00 .
Driveshaft out of balance or damaged.
CHECK the driveshaft for damage, missing balance weights or undercoating. Using the EVA, CHECK the driveshaft balance. CARRY OUT a driveline vibration test. REFER to Section 205-01 . REPAIR as necessary.
Damaged or worn transmission bearing or gears (high mileage vehicles).
CHECK transmission fluid for excessive metal particles. REPAIR as necessary. REFER to Section 308-03 .
Transmission rattling/clattering noise—noise at idle in neutral
Transmission rumble/growl—noise at all speeds in forward gears, more pronounced in a heavy acceleration condition
Symptom Chart—Transmission (Automatic) Noise/Vibration Condition Rattle—occurs at idle or at light acceleration from a stop
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Source Damaged engine or transmission mounts.
Action CHECK the powertrain/drivetrain mounts for damage. INSTALL new mounts as necessary. REFER to 303.
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DIAGNOSIS AND TESTING (Continued) Condition
Source
Action
A loose front exhaust pipe heat shield.
REPAIR or INSTALL a new heat shield as necessary.
Loose inspection plate or dust cover plate.
CHECK for loose bolts. TIGHTEN to specifications. REFER to Section 307-01 .
Loose flex plate to converter nuts.
CHECK for loose nuts. TIGHTEN to specifications. REFER to Section 307-01 .
Whine—pitch increases with vehicle speed—starts in first and second gear, decreases or goes away at higher gears
Damaged or worn low one-way clutch. Damaged or worn intermediate one-way clutch. Friction elements. Damaged or worn planetary or sun gear.
INSPECT the transmission for wear or damage. REPAIR or INSTALL new components as necessary. REFER to Section 307-01 .
Whine—the pitch changes with engine speed
A worn or damaged accessory drive component.
CARRY OUT the Engine Accessory Test. REPAIR or INSTALL new components as necessary. REFER to Section 303-05 .
Incorrect fluid level.
CHECK that the transmission is filled to the correct level. ADD fluid as necessary. REFER to Section 307-01 .
Partially blocked filter.
INSPECT the filter. CLEAN or INSTALL a new filter as necessary.
Worn or damaged torque converter.
CARRY OUT the torque converter service and replacement check. REFER to Section 307-01 .
Worn or damaged front pump.
INSPECT the front pump. INSTALL a new front pump as necessary. REFER to Section 307-01 .
Whine—pitch changes with vehicle speed
Speedometer gears.
REPAIR or INSTALL new gears as necessary.
Whine/moan type noise—pitch increases or changes with vehicle speed
Damaged engine or transmission mount.
CHECK the powertrain/drivetrain mounts for damage. CARRY OUT Powertrain/Drivetrain Mount Neutralizing in this section.
U-joints worn or damaged.
INSPECT the U-joints for wear or damage. INSTALL new U-joints as necessary. REFER to Section 205-01 .
Damaged or worn differential ring and pinion.
INSPECT the differential ring and pinion for damage. CARRY OUT the Checking Tooth Contact Pattern and Condition of the Ring and Pinion component test in this section. REPAIR or INSTALL a new differential ring and pinion as necessary. REFER to Section 205-02 .
Planetary gears nicked or chipped.
CHECK the planetary gears for damage. INSTALL new components as necessary. REFER to Section 307-01 .
Hydraulic pressure in the main control.
INSPECT the main control. REPAIR or INSTALL new components as necessary. REFER to Section 307-01 .
Incorrect band/clutch apply pressure.
CARRY OUT the line pressure tests. REPAIR or INSTALL components as necessary. REFER to Section 307-01 .
Whistle—noise is high pitched, constant—changes in pitch with throttle position
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DIAGNOSIS AND TESTING (Continued) Condition
Source
Action
Worn or damaged torque converter.
CARRY OUT the torque converter service and replacement check. REFER to Section 307-01 .
Damaged powertrain mounts.
INSPECT the powertrain mounts for damage. INSTALL new mounts as necessary. REFER to Section 307-01 .
Damaged or worn pinion bearings.
CHECK for abnormal bearing play or roughness. INSTALL new bearings as necessary. REFER to Section 205-02 .
Worn driveshaft CV joint.
INSPECT the CV joint. INSTALL a new driveshaft as necessary. REFER to Section 205-01 .
Worn friction elements or excessive clutch pack end plate play.
INSPECT the transmission for wear. CHECK that all end play and clearances are within specification. REPAIR or INSTALL new components as necessary. REFER to Section 307-01 .
Bump—occurs when shifting from PARK to a drive or reverse position—similar to Clunk but with no sound
Initial gear engagement.
Acceptable condition.
Buzz or hiss
Incorrect driveline angles.
CHECK for correct driveline angles. REPAIR as necessary. REFER to Section 205-00 .
Worn or damaged main control solenoids or valves.
INSTALL new components as necessary. REFER to Section 307-01 .
Transmission cooler lines grounded out.
CHECK the transmission cooler lines. REPAIR as necessary.
Flexplate to torque converter nuts loose.
CHECK the flexplate nuts. TIGHTEN to specification. REFER to Section 307-01 .
Fluid filler tube grounded out.
CHECK the fluid filler tube. REPAIR as necessary.
Electrical inputs/outputs. Vehicle wiring harness. Incorrect inputs/outputs from the powertrain control module (PCM), digital transmission range (TR) sensor, brake pedal position (BPP) sensor, throttle position (TP) sensor, transmission speed sensor (TSS), output speed shaft (OSS) sensor or the torque converter clutch (TCC).
CARRY OUT a Torque Converter Clutch Operation Test. RUN on-board diagnostics or self–test. CLEAR the DTCs, ROAD TEST and RERUN on-board diagnostics or self–test.
Clunk—occurs when shifting from PARK to a drive or reverse position
Vibration—a high frequency (20–80 Hz) that is felt through the seat or gear shifter—changes with engine speed
Shutter or chatter—occurs with light to medium acceleration from low speeds or a stop
system for normal operation. Sometimes, it is necessary to remove various vehicle components to The pinpoint tests are a step-by-step diagnostic gain access to the component requiring testing. For process designed to determine the cause of a additional information, refer to the appropriate section condition. It may not always be necessary to follow a for removal and installation procedures. Reinstall all pinpoint test to its conclusion. Carry out only the steps components after verifying system operation is necessary to correct the condition. Then, test the normal.
Pinpoint Tests
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DIAGNOSIS AND TESTING (Continued) PINPOINT TEST A : BRAKE VIBRATION/SHUDDER Test Step A1
Result / Action to Take
ROAD TEST THE VEHICLE—LIGHT BRAKING Check that the wheel and tyres are correct for the vehicle. Inspect the tyres for abnormal wear patterns. Road test the vehicle. Warm the brakes by slowing the vehicle a few times from 80–32 km/h (50 to 20 mph) using light braking applications. At highway speeds of 89–97 km/h (55-60 mph), apply the brake using a light pedal force.
Yes
Go to A4.
No
Go to A2.
Is there a vibration/shudder felt in the steering wheel, seat or brake pedal?
A2
ROAD TEST THE VEHICLE—MODERATE TO HEAVY BRAKING Road test the vehicle. At highway speeds of 89–97 km/h (55-60 mph), Yes apply the brake using a moderate to heavy pedal force. For vehicles with ABS, Go to A3. For vehicles with standard brakes, Go to A4. Is there a vibration/shudder?
No
Vehicle is OK. VERIFY condition with customer. TEST the vehicle for normal operation.
A3
NORMAL ACTUATION OF THE ABS SYSTEM DIAGNOSIS During moderate to heavy braking, noise from the hydraulic control unit (HCU) and pulsation in the brake pedal can be observed. Pedal pulsation coupled with noise during heavy braking or on loose gravel, bumps, wet or snowy surfaces is acceptable and indicates correct functioning of the ABS system. Pedal pulsation or steering wheel nibble whose frequency is proportioned to the vehicle speed indicates a concern with a brake or suspension component.
Yes
Go to A5.
No
The brake system is operating correctly.
Is the vibration/shudder vehicle speed sensitive?
A4
APPLICATION OF THE PARKING BRAKE NOTE: Begin at the front of the vehicle unless the vibration or shudder has been isolated to the rear.
This test is not applicable to vehicles with drum-in-hat type parking brakes. For vehicles with drum-in-hat parking brakes, proceed to the next test. For all other vehicles, apply the parking brake to identify if the problem is in the front or rear brake. At highway speeds of 89–97 km/h (55-60 mph), lightly apply the parking brake until the vehicle slows down. Release the parking brake immediately after the test.
Yes
Go to A8.
No
Go to A5.
Is there a vibration/shudder?
A5
CHECK THE FRONT WHEEL BEARINGS Yes
Check the front wheel bearings. Refer to Wheel Bearing Check in this section.
Go to A6.
Are the wheel bearings OK?
No
INSPECT the wheel bearings. ADJUST or REPAIR as necessary. TEST the system for normal operation.
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DIAGNOSIS AND TESTING (Continued) Test Step A6
Result / Action to Take
CHECK THE FRONT SUSPENSION Check the front suspension for: broken or loose bolts damaged springs worn or damaged lower control arm bushings loose or rough front bearings
Yes
Go to A7.
No
REPAIR or INSTALL new components as necessary. TEST the system for normal operation.
uneven tyre wear Are all the suspension components in satisfactory condition?
A7
RESURFACE THE FRONT BRAKE DISCS CAUTION: Do not use a bench lathe to machine brake discs. NOTE: Follow the manufacturer’s instructions to machine the brake discs. After machining, make sure the brake disc meets the thickness specification.
Yes
Go to A8.
No
Vehicle is OK.
Refer to Brake Disc Machining in this section. Resurface the front brake discs. Road test the vehicle. Is the vibration/shudder present?
A8
CHECK THE REAR SUSPENSION Check the rear suspension for: broken or loose bolts damaged or worn springs or spring bushings worn or damaged upper and lower control arm bushings worn or damaged trailing arms loose or rough rear bearings
Yes
Go to A9.
No
REPAIR or INSTALL new components as necessary. TEST the system for normal operation.
uneven tyre wear Are all the suspension components in satisfactory condition?
A9
RESURFACE THE REAR BRAKE DISC OR DRUM CAUTION: Do not use a bench lathe to machine brake discs.
Yes
CHECK the front suspension for wear or damage, RESURFACE the front brake discs. NOTE: Follow the manufacturers instructions to machine the brake discs. TEST the system for normal operation. After machining, make sure the brake disc meets the thickness specification. No Vehicle is OK. Refer to Brake Disc Machining in this section. Resurface the rear brake disc or drums. Road test the vehicle. Is the vibration/shudder present?
PINPOINT TEST B : ENGINE TICKING NOISE Test Step B1
Result / Action to Take
CHECK FOR TICKING NOISE AT THE FUEL RAIL Disconnect the first fuel line clip. Is the ticking noise gone?
Yes
CHECK for TSB for applicable vehicle. REPAIR as necessary. TEST the system for normal operation.
No
Go to B2.
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DIAGNOSIS AND TESTING (Continued) Test Step B2
Result / Action to Take
CHECK FOR TICKING NOISE AT THE FUEL INJECTOR Using an EngineEAR, listen at the fuel injectors by placing a probe on Yes each injector. To isolate the faulty injector, disconnect the injector INSTALL a new fuel injector. REFER to Section electrical connector and listen for the noise. 303-04a for 2.0L Zetec engine or Section 303-04b for 3.0L (4V) engine. TEST the system Is the fuel injector the source of the ticking noise? for normal operation.
No
Go to B3.
B3
CHECK THE BELT TENSIONER FOR TICKING NOISE Inspect the front engine accessory drive (FEAD). Check for the belt tensioner bottoming at end of travel or not at end of stroke. Using an EngineEAR, listen at the belt tensioner. Is the belt tensioner the source of the noise?
Yes
INSTALL a new belt tensioner. REFER to Section 303-05 . TEST the system for normal operation.
No
Go to B4.
B4
CHECK THE WATER PUMP FOR TICKING NOISE Using an EngineEAR, listen at the water pump for ticking noise. Is the water pump the source of the noise?
Yes
INSTALL a new water pump. REFER to Section 303-03 . TEST the system for normal operation.
No
Go to B5.
B5
CHECK FOR AN OBSTRUCTION OF THE COOLING FAN Inspect the cooling fan for obstructions. Check the cooling fan and shroud for wear or damage. Was there an obstruction or does the cooling fan show signs of damage?
Yes
REPAIR or INSTALL a new cooling fan. REFER to Section 303-03 . TEST the system for normal operation.
No
Go to B6.
B6
CHECK THE OIL PUMP FOR TICKING NOISE Check the oil pump using EngineEARs and probe at the oil filter adapter to verify the oil pump as a source. Is the oil pump the source of the noise?
Yes
INSTALL a new oil pump. REFER to Section 303-01a for 2.0L Zetec engine or Section 303-01b for 3.0L (4V) engine. TEST the system for normal operation.
No
Go to B7.
B7
CHECK VALVE LIFTERS OR LASH ADJUSTERS FOR CORRECT OPERATION Check valve lifter/lash adjuster for correct operation, using EngineEARs. Are the valve lifters/lash adjusters operating correctly?
Yes
VERIFY customer concern. CONDUCT a diagnosis of other suspect components.
No
INSTALL a new valve lifter/lash adjuster(s). TEST the system for normal operation.
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DIAGNOSIS AND TESTING (Continued) PINPOINT TEST C : FRONT ENGINE ACCESSORY DRIVE BEARING HOOT Test Step C1
Result / Action to Take
CHECK THE ACCESSORY DRIVE IDLER AND TENSIONER PULLEY BEARINGS Carry out the Vehicle Cold Soak Procedure in this section.
Yes
INSTALL a new pulley/idler. REFER to Section 303-05 . CARRY OUT the Vehicle Cold Soak Place an EngineEAR probe directly on the pulley center post or bolt to Procedure and TEST the system for normal operation. verify which bearing is making the noise. Key in START position.
Key in OFF position.
No
Is either bearing making the noise?
CONDUCT a diagnosis on other suspect accessory drive components.
PINPOINT TEST D : POWER STEERING MOAN Test Step D1
Result / Action to Take
CHECK THE POWER STEERING SYSTEM Carry out the Vehicle Cold Soak Procedure in this section. Key in START position. Turn the steering wheel while the noise is occurring and listen for changes in sound pitch or loudness. Key in OFF position.
Yes
Go to D2.
No
CONDUCT a diagnosis on other suspect accessory drive components.
Does the sound pitch or loudness change while turning the steering wheel?
D2
VERIFY THE SOURCE Key in START position. Place an EngineEAR probe near the power steering pump/reservoir while the noise is occurring. While an assistant turns the steering wheel, listen for changes in sound pitch or loudness. Key in OFF position. Does the sound pitch or loudness change while turning the steering wheel?
Yes
VERIFY that the supply tube to the pump is unobstructed. CHECK the fluid condition and level. DRAIN the fluid and REFILL. CARRY OUT the Vehicle Cold Soak Procedure and TEST the system for normal operation. REFER to Section 211-02 .
No
Normal system operation.
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DIAGNOSIS AND TESTING (Continued) PINPOINT TEST E : DRUMMING NOISE Test Step E1
Result / Action to Take
CHECK THE EXHAUST SYSTEM Key in START position.
Yes
CARRY OUT Exhaust System Neutralizing in Increase the engine rpm until the noise is the loudest. Note the engine this section. TEST the system for normal rpm. operation. Key in OFF position.
No
Add approximately 9 kg (20 lb) of weight to the exhaust system. Place Go to E2. the weight at the tailpipe and test. Key in START position. Increase the engine rpm and listen for the drumming noise. Note the engine rpm if the noise occurs. Key in OFF position. Using a vibration analyzer, determine the amount of vibration that occurs with the drumming noise. Is the noise/vibration reduced or eliminated, or does the noise/vibration occur at a different rpm?
E2
POWERTRAIN/DRIVETRAIN MOUNT NEUTRALIZING Carry out Powertrain/Drivetrain Mount Neutralizing in this section. Test the system for normal operation. Is the noise reduced or eliminated?
Yes
Vehicle is OK. TEST the system for normal operation.
No
CONDUCT diagnosis of other suspect components.
PINPOINT TEST F : ENGINE TICKING, KNOCKING OR CONTINUOUS RATTLE Test Step F1
Result / Action to Take
CHECK FOR NOISE AT THE VALVE COVERS AND THE FRONT COVERS (OHC ENGINES) Carry out the Vehicle Cold Soak Procedure in this section.
Yes
REMOVE the appropriate cover and INSPECT for loose, worn/broken components. REPAIR as necessary. TEST the system for normal NOTE: For a short-duration ticking noise, multiple engine starts may operation. be necessary. Key in START position.
Using an EngineEAR, listen closely at the valve covers and the front covers by placing the probe near the surface of the valve cover and then on the surface front cover.
No
Go to F2.
Key in OFF position. Is the noise source apparent?
F2
CHECK FOR NOISE AT THE CYLINDER BLOCK Key in START position. Using an EngineEAR, listen closely at the cylinder block by placing a probe on or near each freeze plug. Key in OFF position. Is the noise source apparent?
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Yes
REPAIR or INSTALL new components as necessary.
No
Go to F3.
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DIAGNOSIS AND TESTING (Continued) Test Step F3
Result / Action to Take
CHECK FOR NOISE WHILE DISCONNECTING EACH FUEL INJECTOR ELECTRICAL CONNECTOR, ONE AT A TIME Key in START position.
Yes
Key in OFF position.
INSTALL a new fuel injector. REFER to Section 303-04a for 2.0L Zetec engine or Section 303-04b for 3.0L (4V) engine. TEST the system for normal operation.
Is the noise reduced or eliminated?
No
Disconnect each fuel injector electrical connector, one at a time, to decrease piston force and listen for the noise.
INSPECT accessory drive or the transmission as a possible source.
PINPOINT TEST G : FRONT SUSPENSION NOISE Test Step G1
ROAD TEST THE VEHICLE Test drive the vehicle. During the road test, drive the vehicle over a rough road. Using ChassisEARs, determine from which area/component the noise is originating. Is there a squeak, creak or rattle noise?
G2
Result / Action to Take
Yes
Go to G2.
No
The suspension system is OK. CONDUCT a diagnosis on other suspect systems.
INSPECT THE STEERING SYSTEM Raise and support the vehicle. For additional information, refer to Section 100-02 . Check the steering system for wear or damage. Carry out a steering linkage test. Inspect the tyre wear pattern. Refer to Tyre Wear Patterns chart in this section.
Yes
REPAIR the steering system. INSTALL new components as necessary. TEST the system for normal operation.
No
Go to G3.
Are the steering components worn or damaged?
G3
FRONT SHOCK ABSORBER/STRUT CHECK Check the front shock absorbers/strut mounts for loose bolts or nuts.
Yes
TIGHTEN to specifications if loose. INSTALL Check the front shock absorbers/struts for damage. Carry out a shock new front shock absorbers/struts if damaged. absorber check. TEST the system for normal operation. Are the front shock absorbers/struts loose or damaged?
No
Go to G4.
G4
CHECK THE FRONT SPRINGS Check the front spring and front spring mounts/brackets for wear or damage. Are the front springs or spring mounts/brackets worn or damaged?
Yes
REPAIR or INSTALL new components as necessary. TEST the system for normal operation.
No
Go to G5.
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DIAGNOSIS AND TESTING (Continued) Test Step G5
Result / Action to Take
CHECK THE CONTROL ARMS/RADIUS ARMS Inspect the control arm bushings for wear or damage. Inspect for twisted or bent control arm/radius arm. Are the control arm/radius arms damaged or worn?
Yes
REPAIR or INSTALL new components as necessary. TEST the system for normal operation.
No
Go to G6.
G6
CHECK THE STABILIZER BAR/TRACK BAR Check the stabilizer bar/track bar bushings and links for damage or wear.
Yes
Check the stabilizer bar/track bar for damage.
REPAIR or INSTALL new components as necessary. TEST the system for normal operation.
Check for loose or damaged stabilizer bar/track bar isolators or brackets.
No
Are the stabilizer bar/track bar components loose, worn or damaged?
Suspension system is OK. CONDUCT diagnosis on other suspect systems.
PINPOINT TEST H : REAR SUSPENSION NOISE Test Step H1
ROAD TEST THE VEHICLE Test drive the vehicle. During the road test, drive the vehicle over a rough road. Using ChassisEARs, determine from which area/component the noise is originating. Is there a squeak, creak or rattle noise?
H2
Yes
Go to H2.
No
The suspension system is OK. Conduct a diagnosis on other suspect systems.
REAR SHOCK ABSORBER/STRUT CHECK Raise and support the vehicle. REFER to Section 100-02 . Check the rear shock absorber/strut mounts for loose bolts or nuts. Check the rear shock absorbers/struts for damage. Carry out a shock absorber check. Are the rear shock absorbers/struts loose or damaged?
H3
Result / Action to Take
Yes
TIGHTEN to specifications if loose. INSTALL new rear shock absorbers/struts if damaged. TEST the system for normal operation.
No
Go to H3.
CHECK THE REAR SPRINGS Check the rear springs and rear spring mounts/brackets for wear or damage. Are the rear springs or spring mounts/brackets worn or damaged?
Yes
REPAIR or INSTALL new components as necessary. TEST the system for normal operation.
No
Go to H4.
H4
CHECK THE CONTROL ARMS/TRAILING ARMS Inspect the control arm/trailing arm bushings for wear or damage. Check for loose control arm/trailing arm bolts. Inspect for twisted or bent control arms/trailing arms. Are the control arms/trailing arms loose, damaged or worn?
Yes
REPAIR or INSTALL new components as necessary. TEST the system for normal operation.
No
Suspension system is OK. CONDUCT diagnosis on other suspect systems.
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DIAGNOSIS AND TESTING (Continued) PINPOINT TEST I : WHEEL AND TYRE Test Step I1
Result / Action to Take
ROAD TEST THE VEHICLE NOTE: Wheel or tyre vibrations felt in the steering wheel are most likely related to the front wheel or tyre. Vibration felt through the seat are most likely related to the rear wheel or tyre. This may not always be true, but it can help to isolate the problem to the front or rear of the vehicle. Test drive the vehicle at different speed ranges.
Yes
Go to I2.
No
The wheel and tyres are OK. CONDUCT a diagnosis on other suspect systems.
During the road test, if the vibration can be eliminated by placing the vehicle in neutral or is affected by the speed of the engine, the cause is not the wheels or tyres. Is there a vibration and noise?
I2
CHECK THE FRONT WHEEL BEARINGS Yes
Check the front wheel bearings. Refer to Wheel Bearing Check in this section.
Go to I3.
Are the wheel bearings OK?
No
INSPECT the wheel bearings. ADJUST or REPAIR as necessary. TEST the system for normal operation.
I3
INSPECT THE TYRES Check the tyres for missing weights.
Yes
CORRECT the condition that caused the abnormal wear. INSTALL new tyre(s). TEST the Inspect the tyre wear pattern. Refer to the Tyre Wear Patterns chart in system for normal operation. this section. Check the wheels for damage.
Do the tyres have an abnormal wear pattern?
I4
No
Go to I4.
TIRE ROTATION DIAGNOSIS Spin the tyres slowly and watch for signs of lateral runout. Spin the tyres slowly and watch for signs of radial runout. Are there signs of visual runout?
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Yes
Go to I5.
No
CHECK the wheel and tyre balance. CORRECT as necessary. TEST the system for normal operation.
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DIAGNOSIS AND TESTING (Continued) Test Step I5
Result / Action to Take
RADIAL RUNOUT CHECK ON THE TIRE Measure the radial runout of the wheel and tyre assembly. A typical specification for total radial runout is 1.15mm (0.059inch).
Yes
Go to I8.
No
Go to I6.
Is the radial runout within specifications?
I6
RADIAL RUNOUT CHECK ON THE WHEEL Measure the radial runout of the wheel. A typical specification for total radial runout is 1.14mm (0.045 inch). Is the radial runout within specifications?
Yes
INSTALL a new tyre. TEST the system for normal operation.
No
Go to I7.
I7
CHECK THE HUB/BRAKE DISC OR DRUM PILOT RUNOUT OR BOLT CIRCLE RUNOUT Measure the pilot or bolt circle runout. A typical specification for radial runout is: pilot runout— less than 0.15 mm (0.006 inch) bolt circle runout— less than 0.38 mm (0.015 inch) Is the radial runout within specifications?
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Yes
INSTALL a new wheel. TEST the system for normal operation.
No
REPAIR or INSTALL new components as necessary. REFER to 204-01 for the front suspension or 204-02 for the rear suspension.
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DIAGNOSIS AND TESTING (Continued) Test Step I8
Result / Action to Take
LATERAL RUNOUT CHECK ON THE TIRE Measure the lateral runout of the wheel and tyre assembly. A typical specification for total lateral runout is 2.5mm (0.098inch).
Yes
Wheel and tyres are OK. CONDUCT diagnosis on other suspect systems.
No
Go to I9.
Is the lateral runout within specifications?
I9
LATERAL RUNOUT CHECK ON THE WHEEL Measure the lateral runout of the wheel. A typical specification for total radial runout is 1.2mm (0.047inch). Is the lateral runout within specifications?
Yes
INSTALL a new tyre. TEST the system for normal operation.
No
Go to I10.
I10
CHECK THE FLANGE FACE LATERAL RUNOUT Measure the flange face lateral runout. A typical specification for lateral runout is: hub/brake disc— less than 0.13mm (0.005inch) axle shaft— less than 0.25 mm (0.010 inch) Is the lateral runout within specifications?
Yes
INSTALL a new wheel. TEST the system for normal operation.
No
REPAIR or INSTALL new components as necessary. REFER to Section 204-01 for the front suspension or Section 204-02 for the rear suspension.
PINPOINT TEST J : HIGH SPEED SHAKE OR SHIMMY Test Step J1
Result / Action to Take
CHECK FOR FRONT WHEEL BEARING ROUGHNESS Chock the rear wheels. Raise and support the front end of the vehicle so that the front wheel and tyre assemblies can spin. Refer to Section 100-02 . Spin the front tyres by hand. Do the wheel bearings feel rough?
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Yes
INSPECT the wheel bearings. REPAIR as necessary. TEST the system for normal operation.
No
Go to J2.
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DIAGNOSIS AND TESTING (Continued) Test Step J2
Result / Action to Take
CHECK THE END PLAY OF THE FRONT WHEEL BEARINGS Check the end play of the front wheel bearings. Is the end play OK?
Yes
Go to J3.
No
ADJUST or REPAIR as necessary. TEST the system for normal operation.
J3
MEASURE THE LATERAL RUNOUT AND THE RADIAL RUNOUT OF THE FRONT WHEELS ON THE VEHICLE Measure the lateral runout and the radial runout of the front wheels on Yes the vehicle. Go to Pinpoint Test I. Go to J4. Are the measurements within specifications?
No
INSTALL new wheels as necessary and BALANCE the assembly. TEST the system for normal operation.
J4
MEASURE THE LATERAL RUNOUT OF THE FRONT TIRES ON THE VEHICLE Yes
Measure the lateral runout of the front tyres on the vehicle. Go to Pinpoint Test I.
Go to J5.
Is the runout within specifications?
No
INSTALL new tyres as necessary and BALANCE the assembly. TEST the system for normal operation.
J5
MEASURE THE RADIAL RUNOUT OF THE FRONT TIRES ON THE VEHICLE Measure the radial runout of the front tyres on the vehicle. Go to Pinpoint Test I. Is the runout within specifications?
Yes
BALANCE the front wheel and tyre assemblies. If any tyre cannot be balanced, INSTALL a new tyre. TEST the system for normal operation.
No
Go to J6.
J6
MATCH MOUNT THE TIRE AND WHEEL ASSEMBLY Mark the high runout location on the tyre and also on the wheel. Break the assembly down and rotate the tyre 180 degrees (halfway around) on the wheel. Inflate the tyre and measure the radial runout.
Yes
Is the runout within specifications?
No
BALANCE the assembly. TEST the system for normal operation.
If the high spot is not within 101.6 mm (4 inches) of the first high spot on the tyre, Go to J7.
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DIAGNOSIS AND TESTING (Continued) Test Step J7
Result / Action to Take
MEASURE THE WHEEL FLANGE RUNOUT Dismount the tyre and mount the wheel on a wheel balancer. Measure the runout on both wheel flanges. Go to Pinpoint Test I. Is the runout within specifications?
Yes
LOCATE and MARK the low spot on the wheel. INSTALL the tyre, matching the high spot on the tyre with the low spot on the wheel. BALANCE the assembly. TEST the system for normal operation. If the condition persists, Go to J8.
No
INSTALL a new wheel. CHECK the runout on the new wheel. If the new wheel is within limits, LOCATE and MARK the low spot. INSTALL the tyre, matching the high spot on the tyre with the low spot on the wheel. BALANCE the assembly. TEST the system for normal operation. If the condition persists, Go to J8.
J8
CHECK FOR VIBRATION FROM THE FRONT OF THE VEHICLE Yes WARNING: If only one drive wheel is allowed to rotate, speed SUBSTITUTE known good wheel and tyre
must be limited to 55 km/h (34 mph) using the speedometer reading, since actual wheel speed will be twice that indicated on the speedometer. Exceeding a speed of 55 km/h (34 mph) or allowing the drive wheel to hang unsupported can result in tyre disintegration or differential failure, which can cause serious personal injury and extensive vehicle damage.
Spin the front wheel and tyre assemblies with a wheel balancer while the vehicle is raised on a hoist. Feel for vibration in the front fender or while seated in the vehicle.
assemblies as necessary. TEST the system for normal operation.
No
For front wheel drive vehicles, check the driveline components. TEST the system for normal operation. For rear wheel drive vehicles, Go to J9.
Is the vibration present?
J9
CHECK FOR VIBRATION FROM THE REAR OF THE VEHICLE Yes WARNING: If only one drive wheel is allowed to rotate, speed Go to J10.
must be limited to 55 km/h (34 mph) using the speedometer reading, since actual wheel speed will be twice that indicated on the speedometer. Exceeding a speed of 55 km/h (34 mph) or allowing the drive wheel to hang unsupported can result in tyre disintegration or differential failure, which can cause serious personal injury and extensive vehicle damage.
No
TEST the system for normal operation.
Chock the front wheels. Raise and support the rear end of the vehicle so that the rear wheel and tyre assemblies can spin. Refer to Section 100-02 . Engage the drivetrain and carefully accelerate the drive wheels while checking for vibration. Is the vibration present?
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DIAGNOSIS AND TESTING (Continued) Test Step J10
Result / Action to Take
CHECK THE DRIVETRAIN Yes WARNING: If only one drive wheel is allowed to rotate, speed CHECK/TEST the drivetrain and driveline
must be limited to 55 km/h (34 mph) using the speedometer reading, since actual wheel speed will be twice that indicated on the speedometer. Exceeding a speed of 55 km/h (34 mph) or allowing the drive wheel to hang unsupported can result in tyre disintegration or differential failure, which can cause serious personal injury and extensive vehicle damage.
Remove the rear wheel and tyre assemblies. Refer to Section 204-04 .
components. TEST the system for normal operation.
No
SUBSTITUTE known good wheel and tyre assemblies as necessary. TEST the system for normal operation.
Secure the brake drums (if so equipped), by installing wheel hub bolt nuts, reversed. Carefully accelerate the drivetrain while checking for vibration. Is the vibration present?
PINPOINT TEST K : CLUTCH VIBRATION Test Step K1
Result / Action to Take
CHECK ENGINE COMPONENTS FOR GROUNDING Yes
NOTE: Make sure the clutch is the cause of the vibration concern. The vibration should occur during clutch operation. The clutch can also be difficult to engage or disengage. Eliminate all related systems before checking the clutch components.
REPAIR as necessary. TEST the system for normal operation.
NOTE: Check the driveline angles and driveshaft runout before
Go to K2.
No
disassembling the clutch system. Refer to Section 205-00 for the correct driveline angle specifications. Check the powertrain/drivetrain mounts, exhaust manifolds or other engine components for grounding on the chassis. Are any mounts or engine components grounded?
K2
CHECK THE ACCESSORY DRIVE BELT Remove the accessory drive belt. Does the vibration stop with the accessory drive belt removed?
Yes
DIAGNOSE the accessory drive components.
No
Go to K3.
K3
CHECK FOR LOOSE CLUTCH PRESSURE PLATE BOLTS Check for loose clutch pressure plate bolts. Inspect the clutch pressure plate for damage or for material between the pressure plate and flywheel. Are there any loose bolts or damage?
Yes
TIGHTEN the bolts to specifications or if damaged, INSTALL a new clutch pressure plate. REFER to Section 308-01 . TEST the system for normal operation.
No
Go to K4.
K4
CHECK THE CLUTCH DISC SPRINGS Check for worn, broken or loose clutch disc springs. Are the clutch springs worn, broken or loose?
Yes
INSTALL a new clutch disc. REFER to Section 308-01 . TEST the system for normal operation.
No
Go to K5.
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DIAGNOSIS AND TESTING (Continued) Test Step K5
Result / Action to Take
CHECK THE CLUTCH DISC SPLINES Inspect the clutch disc splines for damage or wear. Is there damage or wear?
Yes
INSTALL a new clutch disc. REFER to Section 308-01 . TEST the system for normal operation.
No
Go to K6.
K6
CHECK THE FLYWHEEL BOLTS Check for loose flywheel bolts. Are the bolts loose?
Yes
TIGHTEN the bolts to specifications. REFER to Section 308-01 . TEST the system for normal operation.
No
Go to K7.
K7
CHECK THE FLYWHEEL SURFACE Inspect the flywheel surface for wear or damage. Check the flywheel runout. Is there any damage or excessive wear?
Yes
INSTALL a new flywheel. REFER to Section 303-01a for 2.0L Zetec engine or Section 303-01b for 3.0L (4V) engine. TEST the system for normal operation.
No
Clutch system is normal. CONDUCT a diagnosis on other suspect systems.
scored or forcibly damaged gear teeth and is usually quite audible over the entyre speed range. The Steering Gear Grunt/Shudder Test second type of ring and pinion noise pertains to the mesh pattern of the gear pattern. This gear noise can 1. Start and run the vehicle to operating be recognized as it produces a cycling pitch or whine. temperature. Ring and pinion noise tends to peak in a narrow 2. Set engine idle speed to 1,200 rpm. speed range or ranges, and will tend to remain CAUTION: Do not hold the steering wheel constant in pitch. 1. Raise and support the vehicle. Refer to Section against the stops for more than three to five 100-02. seconds at a time. Damage to the power steering pump will occur. 2. Drain the axle lubricant. Refer to Section 205-02. 3. Rotate the steering wheel to the RH stop, then 3. Remove the carrier assembly or the axle housing turn the steering wheel 90 degrees back from that cover depending on the axle type. Refer to position. Turn the steering wheel slowly in a 15 to Section 205-02. 30 degree arc. 4. Inspect the gear set for scoring or damage. 4. Turn the steering wheel another 90 degrees. Turn the steering wheel slowly in a 15 to 30 degree arc. 5. Repeat the test with power steering fluid at different temperatures. 6. If a light grunt is heard or a low (50-200 Hz) shudder is present, this is a normal steering system condition. 7. If a loud grunt is heard or a strong shudder is felt, fill and purge the power steering system.
Component Tests
Checking Tooth Contact Pattern and Condition of the Ring and Pinion There are two basic types of conditions that will produce ring and pinion noise. The first type is a howl or chuckle produced by broken, cracked, chipped, G72679 en
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DIAGNOSIS AND TESTING (Continued)
5. In the following steps, the movement of the contact pattern along the length is indicated as toward the “heel” or “toe” of the differential ring gear.
Item 1 2
8. A high, thick contact pattern that is worn more toward the toe. Tooth contact pattern shown on the drive side of the gear teeth. The high contact pattern indicates that the drive pinion is not installed deep enough into the carrier. The differential ring gear backlash is correct, a thinner drive pinion shim is needed. A decrease will move the drive pinion toward the differential ring gear.
Description Heel Toe
6. Apply a marking compound to a third of the gear teeth on the differential ring gear. Rotate the differential ring gear several complete turns in both directions until a good, clear tooth pattern is 9. A high, thin contact pattern that is worn toward the toe. obtained. Inspect the contact patterns on the ring gear teeth. Tooth contact pattern shown on the drive side of the gear teeth. 7. A good contact pattern should be centered on the tooth. It can also be slightly toward the toe. There The drive pinion depth is correct. Increase the should always be some clearance between the differential ring gear backlash. contact pattern and the top of the tooth. Tooth contact pattern shown on the drive side of the gear teeth.
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DIAGNOSIS AND TESTING (Continued)
10. A contact pattern that is worn in the center of the differential ring gear tooth toward the heel. Tooth contact pattern shown on the drive side of the gear teeth. The low contact pattern indicates that the drive pinion is installed too deep into the carrier. The differential ring gear backlash is correct. A thicker drive pinion shim is needed.
11. A contact pattern that is worn at the top of the differential ring gear tooth toward the heel. Tooth contact pattern shown on the drive side of the gear teeth. The pinion gear depth is correct. Decrease the differential ring gear backlash.
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DIAGNOSIS AND TESTING (Continued) Tyre Wear Patterns and Frequency Calculations Tyre Wear Chart
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Noise, Vibration and Harshness
100-04-53
DIAGNOSIS AND TESTING (Continued) Wheel and tyre NVH concerns are directly related to vehicle speed and are not generally affected by acceleration, coasting or decelerating. Also, out-of-balance wheel and tyres can vibrate at more than one speed. A vibration that is affected by the engine rpm, or is eliminated by placing the transmission in NEUTRAL is not related to the tyre and wheel. As a general rule, tyre and wheel vibrations felt in the steering wheel are related to the front tyre and wheel assemblies. Vibrations felt in the seat or floor are related to the rear tyre and wheel assemblies. This can initially isolate a concern to the front or rear. Careful attention must be paid to the tyre and wheels. There are several symptoms that can be caused by damaged or worn tyre and wheels. Carry out a careful visual inspection of the tyres and wheel assemblies. Spin the tyres slowly and watch for signs of lateral or radial runout. Refer to the tyre wear chart to determine the tyre wear conditions and actions. For a vibration concern, use the vehicle speed to determine tyre/wheel frequency and rpm. Calculate tyre and wheel rpm and frequency by carrying out and following: Measure the diameter of the tyre. Record the speed at which the vibration occurs. Obtain the corresponding tyre and wheel rpm and frequency from the Tyre Speed and Frequency Chart. If the vehicle speed is not listed, divide the vehicle speed at which the vibration occurs by 16 (km/h (10 mph). Multiply that number by 16 km/h (10 mph) tyre rpm listed for that tyre diameter in the chart. Then divide that number by 60. For example: a 40 mph vibration with 835 mm (33 in) tyres. 40 ÷10 = 4. Multiply 4 by 105 = 420 rpm. Divide 420 rpm by 60 seconds = 7 Hz at 40mph. Tyre Speed and Frequency Chart Tyre Diameter Tyre RPM/Hz mm (inch) @ 16 km/h (10 mph) 483 (19) 182 508 (20) 173 533 (21) 165 560 (22) 158 585 (23) 151 610 (24) 145 635 (25) 139 660 (26) 134 685 (27) 129 710 (28) 124 735 (29) 119 760 (30) 115 G72679 en
Tyre RPM/Hz @ 80 km/h (50 mph) 910/15 865/14 825/14 790/13 755/13 725/12 695/12 670/11 645/11 620/10 595/10 575/10
Tyre RPM/Hz @ 97 km/h (60 mph) 1092/18 1038/17 990/16 948/16 906/15 870/14 834/14 804/13 774/13 744/12 714/12 690/11
Tyre RPM/Hz @ 113 km/h (70 mph) 1274/21 1211/20 1155/19 1106/18 1057/18 1015/17 973/16 938/16 903/15 868/14 833/14 805/13
01/2003 2003.0 BA Falcon
100-04-54
Noise, Vibration and Harshness
100-04-54
DIAGNOSIS AND TESTING (Continued) Tyre Diameter 785 (31) 810 (32) 835 (33) 864 (34)
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Tyre RPM/Hz 111 108 105 102
Tyre RPM/Hz 555/9 540/9 525/9 510/8
Tyre RPM/Hz 666/11 648/11 630/10 612/10
Tyre RPM/Hz 777/13 756/13 735/12 714/12
01/2003 2003.0 BA Falcon
100-04-55
Noise, Vibration and Harshness
100-04-55
GENERAL PROCEDURES
Brake Disc Machining
Using the match marks, mount the brake disc on the hub. 12. Install the caliper. 13. Install the tyre and wheel assembly. 14. Test the system for normal operation.
CAUTION: Do not install brake discs that are less than the minimum thickness specified. Do not machine a brake disc below the minimum thickness specification. Powertrain/Drivetrain Mount 1. Check wheel bearing end-play and correct as Neutralizing necessary. 1. Raise and support the vehicle. For additional 2. Remove the tyre and wheel. information, refer to Section 100-02. NOTE: Begin at the front of the vehicle unless the 2. Loosen, but do not remove, the vibration has been isolated to the rear. powertrain/drivetrain mount fasteners. 3. Remove the brake caliper. 3. Lower the vehicle. 4. Inspect the brake linings. Install new brake linings 4. Move the vehicle in forward and reverse 0.6-1.2 if below specification. For additional information, meters (2-4 ft). refer to the appropriate brake section. 5. Measure and record the brake disc thickness. Install a new brake disc if the thickness after machining will be at or below specification. The specification is stamped on the brake disc. Do not machine a new brake disc. 6. For vehicles with a two-piece hub and brake disc assembly: Match-mark before disassembly. Remove the brake disc. Using a die grinder with a mild abrasive (Scotch Brite® type), remove any rust or corrosion from the hub and brake disc mounting surfaces. Align the match-marks and reinstall the brake disc on the hub. 7. Using the special tool, machine the brake discs. Follow the manufacturer’s instructions. After machining, make sure the brake disc still meets the thickness specification. CAUTION: Do not use a bench lathe to machine brake discs. NOTE: The depth of cut must be between 0.10 and 0.20 mm (0.004 and 0.008 inch). Lighter cuts will cause heat and wear. Heavier cuts will cause poor brake disc surface finish. 8. Using a dial indicator, verify that the brake disc lateral runout is now within specification. 9. Remove the special tool hub adapter. 10. Remove any remaining metal chips from the machining operation. 11. For vehicles with a two-piece hub and brake disc assembly: Remove the brake disc from the hub. Remove any remaining metal chips from hub and brake disc mounting surfaces and from the ABS sensor. Apply a high temperature anti-seize lubricant to the mounting surfaces. G72682 en
5. 6. 7. 8.
CAUTION: Do not twist or strain the powertrain/drivetrain mounts. Raise and support the vehicle. Tighten the powertrain/drivetrain mount fasteners. Lower the vehicle. Test the system for normal operation.
Exhaust System Neutralizing WARNING: Exhaust gases contain carbon monoxide, which is harmful to health and potentially lethal. Repair exhaust system leaks immediately. Never operate the engine in an enclosed area. Failure to follow these instructions may result in personal injury. WARNING: Exhaust system components are hot. Failure to follow these instructions may result in personal injury. NOTE: Neutralize the exhaust system to relieve strain on mounts which can be sufficiently bound up to transmit vibration as if grounded. 1. Raise and support the vehicle. For additional information, refer to Section 100-02.
2. 3. 4. 5.
CAUTION: Make sure the system is warmed up to normal operating temperature, as thermal expansion can be the cause of a strain problem. Loosen all exhaust hanger attachments and reposition the hangers until they hang free and straight. Loosen all exhaust flange joints. Place a stand to support the muffler parallel to the vehicle frame with the muffler pipe bracket free of stress. Tighten the muffler connection.
01/2003 2003.0 BA Falcon
100-04-56
Noise, Vibration and Harshness
100-04-56
GENERAL PROCEDURES (Continued) 6. Tighten all the exhaust hanger clamps and 3. Grip each front tyre at the top and bottom and flanges (tighten the exhaust manifold flange joint move the wheel inward and outward while lifting last). the weight of the tyre off the front wheel bearing. Verify there is adequate clearance to prevent grounding at any point in the system. Make sure that the catalytic converter and heat shield do not contact the frame rails. After neutralization, the rubber in the exhaust hangers should show some flexibility when movement is applied to the exhaust system. With the exhaust system installed securely and cooled, the rear hanger should be angled forward. 7. Lower the vehicle. 8. Test the exhaust system for normal operation.
Wheel Bearing Check 1. Raise the vehicle until the front tyres are off the floor. Make sure the wheels are in a straight forward position. 2. Spin the tyre by hand to check the wheel bearings for roughness. NOTE: Make sure the wheel rotates freely and that the brake pads are retraced sufficiently to allow free movement of the tyre and wheel assembly.
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4. If the tyre and wheel (hub) is loose on the spindle, does not rotate freely, or has a rough feeling when spun, install a new wheel hub.
01/2003 2003.0 BA Falcon
204-00-1
Suspension System — General Information
204-00-1
SECTION : 204-00 Suspension System — General Information VEHICLE APPLICATION : 2003.0 BA Falcon CONTENTS
PAGE
DESCRIPTION AND OPERATION Suspension System — General Information ..........................................................................204-00-2 Front Wheel Alignment ........................................................................................................204-00-2 Rear Wheel Alignment .........................................................................................................204-00-4 DIAGNOSIS AND TESTING Suspension System — General Information ..........................................................................204-00-5 Inspection and Verification ...................................................................................................204-00-5 Symptom Chart ....................................................................................................................204-00-5 Shock Absorbers ..................................................................................................................204-00-8 GENERAL PROCEDURES Toe Adjustment ......................................................................................................................204-00-9 Front Wheel Alignment ..........................................................................................................204-00-9 Toe & Steering Wheel Spoke Adjustments ............................................................................204-00-9 Front Wheel Lock Angle Adjustment .....................................................................................204-00-9 Upper & Lower Ball Joint Inspection ......................................................................................204-00-9 XR Rear Camber Adjustment ................................................................................................204-00-9 RLCA (Rear Lower Control Arm) to Subframe Cambolt Adjustment .....................................204-00-9
01/2003 2003.0 BA Falcon
204-00-2
Suspension System — General Information
204-00-2
DESCRIPTION AND OPERATION
Suspension System — General Information Front Wheel Alignment Suggested method and sequence for checking steering wander or drift 1. Check and adjust tyre pressures to specification. Make sure the vehicle is loaded evenly so ride heights are relatively even side to side. 2. Check all wheel bearings, steering mechanisms and suspension joints are to specification. Adjust, repair or replace as required. 3. Check tyres for uneven wear patterns especially the inner edges compared to the outer edges. Rotate tyres front to rear if required. 4. Road test vehicle on a level road surface and note direction and extent of steering pull or drift. Ensure prevailing crosswinds are not a factor. 5. If pull of drift is confirmed check the wheel alignment and confirm that the vehicle is within specification.
where necessary at kerb height. NOTE: When checking ute and wagon front caster it is important that the rear ride height is correct. This can be achieved by ensuring the vehicle unladen. The following charts show wheel alignment data for the various models. Toe settings are provided in degrees.
Wheel Alignment Equipment/Maintenance It is extremely important the wheel alignment equipment used is periodically checked and recalibrated to ensure vehicle readings are both accurate and repeatable. Please consult your equipment supplier for advice as to how and when the periodic checking and recalibration should occur. Regular checking and calibration of wheel alignment equipment is essential with the current generation of wheel alignment machines. NOTE: See text for XR camber adjustment. NOTE: Ute and Wagon rear alignment can not be adjusted. NOTE: Camber and castor figures will vary depending on the vehicle ride height. The ride height will alter depending on the how heavily the vehicle is loaded, the way the load is distributed, the amount of fuel in the tank and accessories fitted eg: bulbar. The lower the vehicle the more negative the camber value becomes and the more positive the castor value becomes. NOTE: Toe in is shown as a + (positive) value while toe out is shown as a - (negative) value. It is preferable to measure vehicles in degrees. Data is for reference only. NOTE: With correct tyre pressures the ride height is measured vertically from the exact centre of the wheel to the underside of the guard lip (refer figure). Measure all four corners of the vehicle and locate the appropriate ride height in the left hand column in both table: 1 for front the suspension and table: 2 for the rear suspension. Then select the appropriate alignment values for each corner of the vehicle and confirm if vehicle is within specification. Adjust toe G22340 en
01/2003 2003.0 BA Falcon
204-00-3
Suspension System — General Information
204-00-3
DESCRIPTION AND OPERATION (Continued) Front Wheel Alignment Sedan / Wagon Ride Camber Height Min. ° Opt. ° Max. ° 350 360 370 380 390 400 410 420
-1.91 -1.66 -1.44 -1.23 -1.07 -0.92 -0.81 -0.72
-1.41 -1.16 -0.94 -0.73 -0.57 -0.42 -0.31 -0.22
-0.91 -0.66 -0.44 -0.23 -0.07 -0.08 -0.19 -0.28
XR Sedan Ride Camber Height Min. ° Opt. ° Max. ° 340 350 360 370 380 390 400 Ute Ride Height 370 380 390 400 410 420
-1.52 -1.22 -0.95 -0.71 -0.50 -0.33 -0.17
-1.02 -0.72 -0.45 -0.21 0.00 0.17 0.33
-0.52 -0.22 0.05 0.29 0.50 0.67 0.83
Camber Min. ° Opt. ° Max. ° -1.24 -1.05 -0.88 -0.73 -0.62 -0.54
-0.74 -0.55 -0.38 -0.23 -0.12 -0.04
-0.24 -0.05 -0.12 -0.27 -0.38 -0.46
Castor Max. Min. ° Opt. ° Max. ° Max. Variation ° Variation 0.7 7 7.50 8 0.7 0.7 6.9 7.40 7.9 0.7 0.7 6.8 7.30 7.8 0.7 0.7 6.69 7.19 7.69 0.7 0.7 6.59 7.09 7.59 0.7 0.7 6.48 6.99 7.48 0.7 0.7 6.38 6.88 7.38 0.7 0.7 6.27 6.77 7.27 0.7
Total Toe at kerb height Min. ° Opt. ° Max. °
Castor Max. Min. ° Opt. ° Max. ° Max. Variation ° Variation 0.7 7.32 7.82 8.32 0.7 0.7 7.21 7.71 8.21 0.7 0.7 7.10 7.60 8.10 0.7 0.7 6.99 7.49 7.99 0.7 0.7 6.88 7.38 7.88 0.7 0.7 6.77 7.27 7.77 0.7 0.7 6.65 7.15 7.65 0.7
Total Toe at kerb height Min. ° Opt. ° Max. °
Castor Max. Min. ° Opt. ° Max. ° Max. Variation ° Variation 0.7 6.81 7.31 7.81 0.7 0.7 6.7 7.20 7.7 0.7 0.7 6.59 7.09 7.59 0.7 0.7 6.48 7.99 7.48 0.7 0.7 6.38 7.88 7.38 0.7 0.7 6.27 6.77 7.27 0.7
Total Toe at kerb height Min. ° Opt. ° Max. °
XR Ute, XLS Ute with standard sports suspension Ride Camber Castor Height Min. ° Opt. ° Max. ° Max. Min. ° Opt. ° Max. ° Max. Variation ° Variation 340 -1.92 -1.42 -0.92 0.7 5.70 6.20 6.70 0.7 350 -1.63 -1.13 -0.63 0.7 5.56 6.06 6.56 0.7 360 -1.37 -0.87 -0.37 0.7 5.43 5.93 6.43 0.7 370 -1.13 -0.63 -0.13 0.7 5.30 5.80 6.30 0.7 380 -0.93 -0.43 0.07 0.7 5.18 5.68 6.18 0.7 390 -0.76 -0.26 0.24 0.7 5.06 5.56 6.06 0.7 400 -0.61 -0.11 0.39 0.7 4.93 5.43 5.93 0.7
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-0.02
0.06
-0.02
0.08
0.16
0.08
0.18
0.26
0.18
Total Toe at kerb height Min. ° Opt. ° Max. °
0.06
0.16
0.26
01/2003 2003.0 BA Falcon
204-00-4
Suspension System — General Information
204-00-4
DESCRIPTION AND OPERATION (Continued) Rear Wheel Alignment Sedan Ride Height
350 360 370 380 390 400 410 420
Min. °
Camber Opt. ° Max. °
-1.96 -1.76 -1.57 -1.38 -1.19 -1 -0.81 -0.61
-1.71 -1.51 -1.32 0.13 -0.94 -0.75 -0.56 -0.36
-1.46 -1.26 -1.07 -0.88 -0.69 -0.50 -0.31 -0.11
Max. Variation ° 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5
Total Toe at kerb height Min. ° Opt. ° Max. °
0.14
0.24
0.34
NOTE: Sedan camber settings cannot be adjusted, for reference only. XR Sedan Ride Height
340 350 360 370 380 390 400
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Min. °
Camber Opt. ° Max. °
-1.35 -1.14 -0.95 -0.75 -0.56 -0.37 -0.18
-1.10 -0.89 -0.70 -0.50 -0.31 -0.12 0.07
-0.85 -0.64 -0.45 -0.25 -0.06 0.13 0.32
Max. Variation ° 0.5 0.5 0.5 0.5 0.5 0.5 0.5
Total Toe at kerb height Min. ° Opt. ° Max. °
0.06
0.16
0.26
01/2003 2003.0 BA Falcon
204-00-5
Suspension System — General Information
204-00-5
DIAGNOSIS AND TESTING these symptoms are also common to suspension frame, and wheel and tyre troubles. For this reason, be sure that the cause of a concern is in the steering gear or linkage before adjusting, repairing, or replacing any of the steering parts.
Suspension System — General Information Inspection and Verification NOTE: Table 1 lists various steering gear and linkage trouble symptoms and possible causes. Several of
Symptom Chart Condition
Source
Action
Jerky Steering
Power Steering Fluid Level Low Leak Glazed, Loose or Broken Power Steering Pump Belt Air in Power Steering System Binding Front Suspension Ball Joints or Steering Linkage Loose, Worn, or Damaged Steering Linkage or Connections Loose Steering Gear Mountings Incorrect Steering Gear Adjustment Incorrect Brake Adjustment Incorrect Front Wheel Bearing Adjustment Wheel Out of Balance Obstruction Within Steering Gear
Remove/Repair as required
Loose Steering
Loose, Worn, or Damaged Steering Linkage or Connections Loose Steering Gear Mountings Incorrect Steering Gear Adjustment Incorrect Front Wheel Bearing Adjustment
Remove/Repair as required
Hard Steering and/ or Loss of Power Assist
Incorrect Tyre Pressure Tyre Sizes Not Uniform Power Steering Fluid Level Low Leak Glazed, Loose or Broken Power Steering Pump Belt Lack of Lubrication Air in Power Steering System Obstruction in Power Steering Lines Binding Front Suspension Ball Joints or Steering Linkage Insufficient Steering Pump Pressure Incorrect Steering Gear Adjustment Incorrect Front Wheel Alignment Excessive Wear of Steering Pump Internal Parts Steering Gear Valve Sleeve or Seals Worn Obstruction Within Steering Gear
Remove/Repair as required
Hard Turning When Stationary
Incorrect Tyre Pressure Tyre Sizes Not Uniform Power Steering Fluid Level Low Leak Glazed, Loose or Broken Power Steering Pump Belt Lack of Lubrication Obstruction in Power Steering Lines Binding Front Suspension Ball Joints or Steering Linkage Insufficient Steering Pump Pressure Incorrect Steering Gear Adjustment Steering Gear Valve Sleeve or Seals Worn Obstruction Within Steering Gear
Remove/Repair as required
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204-00-6
Suspension System — General Information
204-00-6
DIAGNOSIS AND TESTING (Continued) Condition
Source
Action
Steering and Suspension Noises
Power Steering Fluid Level Low Leak Sagging or Broken Spring Glazed, Loose or Broken Power Steering Pump Belt Broken Rear Spring Tie Bolts (Wagon) Lack of Lubrication Air in Power Steering System Obstruction in Power Steering Lines Loose or Weak Shock Absorber Loose or Worn Suspension Arm Bushings Binding Front Suspension Ball Joints or Steering Linkage Loose, Worn, or Damaged Steering Linkage or Connections Loose Steering Gear Mountings Incorrect Steering Gear Adjustment Incorrect Brake Adjustment Incorrect Front Wheel Bearing Adjustment Incorrect Front Wheel Alignment Bent Rear Axle Housing Excessive Wear of Steering Pump Internal Parts
Remove/Repair as required
Shimmy or Wheel Tramp
Incorrect Tyre Pressure Broken Rear Spring Tie Bolts (Wagon) Air in Power Steering System Loose or Weak Shock Absorber Loose or Worn Suspension Arm Bushings Loose, Worn, or Damaged Steering Linkage or Connections Loose Steering Gear Mountings Incorrect Steering Gear Adjustment Incorrect Front Wheel Bearing Adjustment Wheel Out of Balance Incorrect Front Wheel Alignment Out-of-Round Wheel
Remove/Repair as required
Pull to One Side
Incorrect Tyre Pressure Tyre Sizes Not Uniform Overloaded or Unevenly Loaded Vehicle Sagging or Broken Spring Rear Spring Tie Bolt Off Centre (Wagon/Ute) Broken Rear Spring Tie Bolts (Wagon) Rear Spring Front Hanger Mislocated (Wagon/Ute) Bent Spindle Arm Bent Spindle Loose or Worn Suspension Arm Bushings Incorrect Brake Adjustment Incorrect Front Wheel Bearing Adjustment Incorrect Front Wheel Alignment Frame or Underbody Out of Alignment Bent Rear Axle Housing Steering Gear Valve Sleeve or Seals Worn
Remove/Repair as required
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01/2003 2003.0 BA Falcon
204-00-7
Suspension System — General Information
204-00-7
DIAGNOSIS AND TESTING (Continued) Condition
Source
Action
Side- to- side Wander
Incorrect Tyre Pressure Tyre Sizes Not Uniform Overloaded or Unevenly Loaded Vehicle Sagging or Broken Spring Broken Rear Spring Tie Bolts (Wagon) Bent Spindle Arm Bent Spindle Loose or Weak Shock Absorber Loose or Worn Suspension Arm Bushings Loose, Worn, or Damaged Steering Linkage or Connections Loose Steering Gear Mountings Incorrect Steering Gear Adjustment Incorrect Front Wheel Bearing Adjustment Incorrect Front Wheel Alignment
Remove/Repair as required
Body Sway or Roll
Incorrect Tyre Pressure Sagging or Broken Spring Broken Rear Spring Tie Bolts (Wagon) Loose or Weak Shock Absorber Incorrect Steering Gear Adjustment
Remove/Repair as required
Tyre Squeel on Turns
Incorrect Tyre Pressure Tyre Sizes Not Uniform Bent Spindle Arm Bent Spindle Loose, Worn, or Damaged Steering Linkage or Connections Incorrect Front Wheel Alignment
Remove/Repair as required
Binding or Poor Recovery
Incorrect Tyre Pressure Lack of Lubrication Binding Front Suspension Ball Joints or Steering Linkage Insufficient Steering Pump Pressure Incorrect Steering Gear Adjustment Incorrect Brake Adjustment Incorrect Front Wheel Alignment Steering Gear Valve Sleeve or Seals Worn Obstruction Within Steering Gear
Remove/Repair as required
Abnormal or Irregular Tyre Wear
Incorrect Tyre Pressure Tyre Sizes Not Uniform Overloaded or Unevenly Loaded Vehicle Sagging or Broken Spring Rear Spring Tie Bolt Off Centre (Wagon/Ute) Broken Rear Spring Tie Bolts (Wagon) Rear Spring Front Hanger Mislocated (Wagon/Ute) Bent Spindle Arm Bent Spindle Loose or Weak Shock Absorber Loose or Worn Suspension Arm Bushings Loose, Worn, or Damaged Steering Linkage or Connections Incorrect Steering Gear Adjustment Incorrect Brake Adjustment Incorrect Front Wheel Bearing Adjustment Wheel Out of Balance Incorrect Front Wheel Alignment Out-of-Round Wheel Frame or Underbody Out of Alignment Bent Rear Axle Housing
Remove/Repair as required
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01/2003 2003.0 BA Falcon
204-00-8
Suspension System — General Information
204-00-8
DIAGNOSIS AND TESTING (Continued) Condition
Source
Action
Sag at One Wheel
Incorrect Tyre Pressure Tyre Sizes Not Uniform Overloaded or Unevenly Loaded Vehicle Sagging or Broken Spring Loose or Worn Suspension Arm Bushings
Remove/Repair as required
Hard or Rough Ride
Incorrect Tyre Pressure Overloaded or Unevenly Loaded Vehicle Sagging or Broken Spring Lack of Lubrication Loose or Weak Shock Absorber Loose or Worn Suspension Arm Bushings Binding Front Suspension Ball Joints or Steering Linkage Wheel Out of Balance Out-of-Round Wheel
Remove/Repair as required
Rear Suspension Misalignment (DogTracking)
Rear Spring Tie Bolt Off Centre (Wagon/Ute) Broken Rear Spring Tie Bolts (Wagon) Rear Spring Front Hanger Mislocated (Wagon/Ute) Loose or Worn Suspension Arm Bushings Frame or Underbody Out of Alignment Bent Rear Axle Housing
Remove/Repair as required
Shock Absorbers
Hand Test
1. With the shock absorber removed from the vehicle, hold the shock absorber such that it is in Grasp the vehicle bumper bar and bounce the a vertical position, as it would be installed in the corner of the vehicle up and down. If the shock vehicle. Fully compress and extend the shock absorbers are in serviceable condition the vehicle absorber unit three times to bleed the shock will settle to it’s original position within two absorber. Compress the unit and observe that the bounces after the bumper is released. piston rod extends under it’s own internal gas Check the shock absorber to be sure that it is pressure. There should be a smooth movement of securely and properly installed on the vehicle. the shock absorber rod over the complete stroke Check the shock absorber mounting bushes and as the shock extends. Any noticeable slowing of body insulators for damage and / or wear. the rod, loss of movement or drag, especially as Replace any defective body insulators and tighten the piston rod nears the top of its stroke, will attachments to the specified torque. If wear or indicate low internal gas pressure, loss of shock damage is visible on shock absorber mounting fluid or faulty internal valve operation. bushes, the entire shock absorber should be 2. Extend and compress the shock as fast as replaced. possible, using as much travel of the shock as Check the compression rubbers or bumpers fitted possible. The action of the shock should become on the shock rod for signs of damage. Replace if smooth and uniform throughout each stroke. It is necessary. normal for the shock to have higher resistance to extension than compression. Faint fluid "swishing" Inspect the shock absorber for evidence of fluid noises are also normal during extension and leakage. It is important to be sure that any fluid compression of the shock. observed is from the shock absorber and not from any other source. 3. If the action is smooth, but the shock absorbers are suspected of being weak, repeat Step 2 on a If the leakage is severe, replace the shock new shock absorber or on the mating shock absorber if leakage. (Some evidence of fluid absorber fitted to the opposite side of the vehicle. weepage on the shock body is not considered Compare the results of both tests. harmful to the shock provided that the on-vehicle and hand tests described below are acceptable).
On Vehicle Tests 1.
2.
3. 4.
5.
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01/2003 2003.0 BA Falcon
204-00-9
Suspension System — General Information
204-00-9
GENERAL PROCEDURES
Toe Adjustment
Front Wheel Lock Angle Adjustment
1. Toe is the inward point of both front wheels at the 1. When the inside wheel is turned 20°, the turning front. The checking and optimum resetting toe-in angle of the outside wheel should be specified in in specifications are specified in the Description the Description and Operation section. and Operation section. 2. If the turning angles are incorrect or uneven when 2. Check the toe with the steering wheel in the compared with the figures obtained on the other straight-ahead position. lock, first check the toe. If this is correct, examine the tie rods which should be approximately the 3. On vehicles with power steering, the steering same length. It they are appreciably different (i.e. wheel must be in the straight-ahead position when 3.0mm) the turning angles will be adversely the engine is switched off. affected. It should be noted that minor differences 4. If it is necessary to again move the steering wheel in tie rod length are acceptable and, in fact, on a power steering vehicle the engine must be sometimes necessary to compensate for restarted. production tolerances in the build up of the 5. Measure the angle of each front wheel from the suspension and steering assembly. straight-ahead position and add the angles 3. If the toe and the tie rod lengths are satisfactory together. examine the tie rods for distortion. The tie rod ball joints should also be checked for wear or Front Wheel Alignment looseness. 1. The Caster, Camber and King Pin Inclination Upper & Lower Ball Joint Inspection angles are set in production and are not adjustable. 1. Raise the vehicle. 2. The tie rods, part of the steering rack assembly, 2. Grasp the tyre at the top and bottom and try to are adjustable for length to permit the setting of move it in and out. Toe and wheel lock angles. 3. There should be no perceptible movement in 3. Do not attempt to carry out alignment checks either joint. If movement is detected in either joint, without first making a preliminary check of the that joint should be replaced. serviceability of the front end components.
Toe & Steering Wheel Spoke Adjustments
XR Rear Camber Adjustment
1. Measure ride height. Refer to wheel Alignment charts in this section for ride heights vs. camber. NOTE: Check the steering wheel spoke position when Select appropriate camber setting. the front wheels are in the straight-ahead position. If 2. Complete RLCA (Rear Lower Control Arm) to the spoke is not in its correct position, it can be subframe cam bolt adjustment (set Toe). corrected while toe is being adjusted. 3. With toe set and locked in position, adjust left 1. Clean and lubricate the exposed threads on the camber to specification using the cambolt. tie-rods. Loosen the clips on the outer ends of the 4. Adjust the right camber to specification using the rack bellows and ensure that the bellows are free cambolt. on the tie-rods. 5. Re-adjust left camber if necessary. Tighten both 2. Hold the tie-rod and loosen the lock nut on each nuts to the specified torque (126 ± 24 Nm). rod. 6. Take care during the above procedure to ensure NOTE: Both rods have right hand threads. the brake hose bracket is located correctly. 3. Adjust toe-in. If the steering wheel spokes are in RLCA (Rear Lower Control Arm) to their correct position, lengthen or shorten both rods equally to obtain correct toe. If the steering Subframe Cambolt Adjustment wheel spoke is not in its correct position, make 1. Loosen both bolts and adjust as required to reach the necessary rod adjustments to obtain correct spesified toe. toe and steering wheel spoke alignment. 2. Tighten both nuts to the specified torque 4. When the toe and steering wheel spoke alignment (105 ± 10 Nm). are both correct tighten the lock nut on each rod. 5. Position each tie-rod end ball joint at the centre of its articulation and tighten the clips on the rack bellows.
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01/2003 2003.0 BA Falcon
204-01-1
Front Suspension
204-01-1
SECTION : 204-01 Front Suspension VEHICLE APPLICATION : 2003.0 BA Falcon CONTENTS
PAGE
SPECIFICATIONS Specifications .........................................................................................................................204-01-2 DESCRIPTION AND OPERATION Front Suspension ...................................................................................................................204-01-3 Suspension ..........................................................................................................................204-01-3 DIAGNOSIS AND TESTING Front Suspension ...................................................................................................................204-01-4 REMOVAL AND INSTALLATION Lower Control Arm .................................................................................................................204-01-5 Lower Control Arm Ball Joint .................................................................................................204-01-5 Upper Control Arm .................................................................................................................204-01-6 Upper Control Arm Ball Joint .................................................................................................204-01-7 Stabilizer Bar ..........................................................................................................................204-01-8 Stabilizer Bar Centre Bushing (Front or Rear Bar) ...............................................................204-01-8 Stabilizer Bar Link Bushing ....................................................................................................204-01-9 Lower Arm Bushing ................................................................................................................204-01-9 Lower Arm - Large Bushing .................................................................................................204-01-11 Upper Arm Bushing ..............................................................................................................204-01-11 Front Wheel Spindle and Hub ..............................................................................................204-01-13 Spring and/or Shock Absorber Assembly ............................................................................204-01-15
01/2003 2003.0 BA Falcon
204-01-2
Front Suspension
204-01-2
SPECIFICATIONS Torque Specifications Description Upper Arm to Mounting Bracket Upper Arm Mounting Bracket to Body Lower Control Arm to Sub-frame Shock Absorber to Upper Attachment Shock Absorber to Lower Control Arm Spring Seat to Body Ball Joint to Spindle Stabilizer Bar Bracket Stabilizer Bar Link Nuts Wheel Bearing Nut Wheel Nut Brake Caliper to Spindle
G48690 en
Nm 50 35 115 35 80 35 90 35 55 300 125 115
01/2003 2003.0 BA Falcon
204-01-3
Front Suspension
204-01-3
DESCRIPTION AND OPERATION
Front Suspension Suspension The suspension is so designed that it allows an individual wheel to compensate for changes in the road’s surface level without considerably affecting the opposite wheel. Each wheel is independently connected to the frame and body by a spindle, ball joint assemblies, and upper and lower control arms. The control arms are specifically designed and positioned to allow the steering spindle to move in a prescribed three dimensional arc. The front wheels are held in proper relationship to each other by two tie rods that are connected to the steering rack and to the spindles. Coil chassis springs are mounted between the spring housings on the front end sheet metal and the spring seats that are integral with the shock absorber body. Ride control is provided by double, direct acting shock absorbers mounted inside the coil springs and attached to the lower control arms by bolts. The upper portion of each shock absorber extends through the dual path shear mount and is secured with two grommets, two grommet retainers, and a nut.
Item 1 2 3
Item Description 4 Bracket Assy 5 Insulator 6 Shock Absorber Frt 7 Arm & Shaft Assy Frt Susp Upr 8 Bolt Hex M14 9 Nut M14 10 Arm Assy Frt Susp Lwr 11 Nut M10 Flange 12 Spring Frt Susp Coil 13 Nut Side roll of the suspension is controlled by a spring steel stabilizer bar. It is mounted in rubber bushings held to the frame side rails by brackets. The ends of the stabilizer are connected to the lower control arms. Rubber grommets at these connections provide flexibility and ride features. The upper control arm is attached to the body through isolating rubber bushings connected to brackets that are bolted to the body. The upper ball joint is a press fit into the upper control arm, and the stud is fitted into the upper control end of the spindle forging. A nylok nut and bolt clamps the spindle to the ball joint. The lower ball joint is a press fit into the lower arm, and secures to the lower end of the spindle forging by a tapered stud and nylok nut. The inner ends of the lower control arms have pressed in bushings and are attached to the cross members by a single bolt through each bushing. The suspension mounting points are all rubber insulated to minimise the transmission of road noise and vibration to the vehicle body. Compliance in the lower arm bushes permits the wheel a small amount of fore and aft movement and so reduce the shock loading on the steering linkage when the wheel hits a sudden irregularity in the road surface.
Description Nut Washer Insulator
G48691 en
01/2003 2003.0 BA Falcon
204-01-4
Front Suspension
204-01-4
DIAGNOSIS AND TESTING
Front Suspension Refer to Section 204-00.
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01/2003 2003.0 BA Falcon
204-01-5
Front Suspension
204-01-5
REMOVAL AND INSTALLATION
Lower Control Arm Special Tools
7. Lower the vehicle and tighten the pivot bolts and shock absorber bolt with the vehicle at curb attitude.
E9332 Removal 1. Raise the vehicle and support it under the body rails. 2. Remove the wheel. 3. Loosen the ball joint nut. Using Tool No. E9332 free the taper. Remove the nut. 4. Disconnect the stabilizer bar link. 5. Loosen the hardware securing the front crossmember and lower the crossmember sufficiently to allow the front boss of the arm to be withdrawn. 6. Remove the shock absorber bolt. 7. Remove the control arm pivot bolts and remove the arm. Installation 1. Fit the lower arm to the crossmembers. 2. Install but do not tighten the pivot bolts. 3. Install the shock absorber bolt from the rear and install the washer and a new nut on the strut. Do not tighten either at this time. 4. Position the ball joint stud in the spindle. Tighten with new nylok nut. 5. Install the wheel. 6. Tighten the hardware securing the front crossmember.
Item 1 2 3
Description Arm Assy Frt Susp Lower Nut Lock Spindle Assy Frt Wheel
Lower Control Arm Ball Joint Special Tools 204-236
204-230
Removal NOTE: Eye protection must be worn during the following procedures. 1. Place small end of Installer/Remover tool 204-236-Item 3 over shaft of ball joint. 2. Place Receiver 204-236-Item 2 above lower control arm.
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01/2003 2003.0 BA Falcon
204-01-6
Front Suspension
204-01-6
REMOVAL AND INSTALLATION (Continued) 3. Using a hydraulic press, push ball joint out using 6 tonne removal force.
Item 1 2
Description Receiver 204-236-Item 2 204-236-Item 3
Installation 1. Carefully remove rubber boot & retaining ring prior to installation. 2. Place ball joint into position in casting. 3. Place large end of installer/remover 204-230-Item 8 over butt of ball joint. 4. Place receiver 204-230-Item 3 under lower control arm.
G48693 en
5. Press home using a hydraulic press using 6.5 tonne installing force.
Item 1 2 3
Description An appropriate plate to support hydraulic ram 204-230-Item 8 Receiver 204-230-Item 3
Upper Control Arm Removal 1. Raise the vehicle and support it under the body rails. 2. Remove the wheel. 3. Separate the upper ball joint from the upper arm. Tie the spindle to prevent it from failing away from the body and straining the brake hose. 4. Remove the four nuts securing the upper arm brackets to the suspension tower and remove the assembly from the vehicle. 5. Remove the two bolts and the bracket assemblies from the control arm. Installation 1. Position the bracket assemblies on the upper arm and loosely install new prevailing torque nuts. 2. Position the control arm on the suspension tower and install and tighten the attaching nuts. 01/2003 2003.0 BA Falcon
204-01-7
Front Suspension
204-01-7
REMOVAL AND INSTALLATION (Continued) 3. Attach the ball joint to the spindle, tighten the clamp joint. Remove the spindle tie. 4. Install the wheel and lower the vehicle. 5. With the vehicle at curb attitude tighten the spindle pivot bolts to specification.
Item 1 2 3 4
2. Using a hydraulic press with two tonne approx. force push out ball joint using tool 204-229-2, small diameter down.
Description Arm Assy Frt Susp Upper Receiver Bolt Spindle Assy Nut
Upper Control Arm Ball Joint Special Tools 204-229
Removal NOTE: Eye protection must be worn during the following procedures. 1. Place receiver 204-229-Item 1 large diameter facing up, under upper arm casting.
G48695 en
Item 1 2 3 4
Description 204-229-Item 2 Ball Joint 204-229-Item 1 Receiver Upper Control Arm
Installation 1. Remove rubber boot from the new ball joint, ensuring not to damage the boot or retainer ring clip. 2. Position ball joint over control arm. 3. Place receiver 204-229-Item 1, small end up, under upper arm casting. 4. Using a hydraulic press push ball joint home with tool 204-229-Item 2 large end facing down.
01/2003 2003.0 BA Falcon
204-01-8
Front Suspension
204-01-8
REMOVAL AND INSTALLATION (Continued) 5. Reinstall protective rubber boot and retainer ring clip.
Item 1 2 3 4
3. Fit the bolt and nut securing the shock absorber to the lower arm. 4. Fit the upper ball joint stud to the spindle and fit the clamp bolt and nut. 5. Fit the insulators and brackets supporting the stabilizer bar to the siderails ensuring that the bar is cenrally located. 6. Attach the ends of the bar links, ensuring that the insulators are correctly positioned. 7. Fit the wheel and lower the vehicle.
Description 204-229-Item 2 Upper Control Arm 204-229-Item 1 Receiver Ball Joint with Boot Removed
Stabilizer Bar Removal 1. Raise the vehicle supporting the body by the side-rails. 2. Disconnect the stabilizer bar from each link. Remove the retaining brackets. 3. Remove the wheel and disconnect the upper ball joint stud from the spindle. 4. Remove the shock absorber lower bolt. 5. Move the shock absorber to allow the end of the stabilizer bar to be brought rearwards past it. 6. Remove the stabilizer bar. Installation 1. Place one end of the bar into position. 2. Move the other side shock absorber to allow that end of the bar to be brought into position in front of the shock absorber. G48695 en
Stabilizer Bar Centre Bushing (Front or Rear Bar) Removal NOTE: Damage to suspension and/or steering components may occur if care is not exercised when positioning hoist adaptors or jacks when lifting the vehicle. Do not allow contact with the steering linkage. 1. Raise the vehicle on a hoist positioning the suspension in the curb load position. 2. Remove the hardware and brackets attaching the centre section of the stabilizer bar. 3. Remove the insulators from the bar. Installation 1. Position the insulators on the front bar. Position the insulator on the rear bar.
01/2003 2003.0 BA Falcon
204-01-9
Front Suspension
204-01-9
REMOVAL AND INSTALLATION (Continued) 2. Ensure that the links on each end of the bar are located at approximately the same angle relative to the centre line of the vehicle and install the attaching brackets. 3. Lower the vehicle.
Stabilizer Bar Link Bushing Removal 1. Raise the vehicle on a hoist positioning the suspension in the curb load position. 2. Remove the nut, washers, spacer, insulators and link bolt attaching the ends of the stabilizer bar.
Scenario 1-Replacement of small bush only 1. Clamp lower control arm in vice using soft jaws with both bushes at top. 2. Apply a graphite grease to forcing screw thread before usage. 3. Screw the holding nut fully onto the forcing screw 204- 230-Item 5.
Item 1 2 3 4 5
Description Locating collar 204-230-Item 8 204-230-Item 9 Forcing screw 204-230-Item 5 Holding Nut 204-230-Item 10 Orient anvil so stamping is to top (this positions eccentric hole)
Installation 1. Install the bolt, washers, insulators, spacer and nut as illustrated. Ensure that the insulators are correctly located in the respective mounting holes. 4. Slide large bush anvil 204-230-Item 10 onto the 2. Lower the vehicle. threaded end of forcing screw. 5. Orient large bush anvil so part no stamping is on Lower Arm Bushing top. Special Tools 6. Position assembly over the inside end of large bush. 204-230 7. Place locating collar 204-230-Item 8 over assembly. 8. Place small hole in small bush tool 204-230-Item 9 over forcing screw spigot. 9. Slide locating collar over small bush tool 204-230-Item 9 to prevent assembly slipping during use. Removal 10. Screw out holding nut to remove slack. NOTE: Three scenarios exist for the replacement of 11. With suitable spanners, clamp holding nut and lower control arm bushes. They are: turn forcing screw using its hexagonal section scenario 1 - replacement of the small bush only, until small bush is removed. scenario 2 - replacement of the large bush only, NOTE: Beware, the unit will collapse as the bush is removed. scenario 3 - replacement of both bushes. Refer to the applicable scenario numbers.
Removal Scenario 2-Replacement of large bush only
Scenario 1 - Replacement of small bush only NOTE: If both bushes are to be removed then remove 1. Apply a graphite grease to Forcing Screw thread small bush first. before usage.
G48699 en
01/2003 2003.0 BA Falcon
204-01-10
Front Suspension
204-01-10
REMOVAL AND INSTALLATION (Continued) 2. Screw the Holding Nut fully on to the Forcing Screw (204-230-Item 5).
Scenario 3-Replacement of both large and small bushes 1. First follow procedure to remove small bush. 2. Slide Small Bush Anvil (204-230-Item 3) on the threaded end of Forcing Screw (204-230-Item 5).
3. Slide Small Bush Anvil (204-230-Item 3) on the threaded end of Forcing Screw. 4. Orient eccentric hole in Small Bush Anvil so part stamping ‘UP’ is on Top. 5. Position assembly over the inside end of Small Bush. 6. Place Locating Collar (204-230-Item 1) over assembly. 7. Place small hole in Large Bush Tool (204-230-Item 2) over Forcing Screw spigot.
Item 1 2 3 4 5
Description Locating collar 204-230-Item 1 204-230-Item 2 Forcing screw 204-230-Item 5 Holding Nut 204-230-Item 3 Orient anvil so stamping is to top (this positions eccentric hole)
3. Place narrow end of Small Bush Anvil Locator (204-230-Item 4) in to empty small bush socket. 4. Orient Small Bush Anvil so stamping ‘UP’ is on Top. 5. Position assembly over the exposed end of Small Bush Anvil Locator. 6. Place Locating Collar (204-230-Item 1) over assembly. 7. Place small hole in Large Bush Tool (204-230-Item 2) over Forcing Screw spigot.
Item 1 2 3 4 5
Description Locating collar 204-230-Item 1 204-230-Item 2 Forcing screw 204-230-Item 5 Holding Nut 204-230-Item 3 Orient anvil so stamping is to top (this positions eccentric hole)
8. Slide Locating Collar over Large Bush Tool to prevent assembly slipping during use. 9. With suitable spanners, clamp Holding Nut and turn Forcing Screw using its hexagonal section 8. Slide Locating Collar over Large Bush Tool to until large bush is removed. prevent assembly slipping during use. Removal 9. With suitable spanners, clamp Holding Nut and NOTE: If both bushes are to be removed then remove turn Forcing Screw using its hexagonal section small bush first. until large bush is removed. G48699 en
01/2003 2003.0 BA Falcon
204-01-11
Front Suspension
204-01-11
REMOVAL AND INSTALLATION (Continued)
Lower Arm - Large Bushing
3. Place the shaft of the installer 204-230-Item 8 into the bush.
Special Tools 204-230
Installation Large bush 1. Position large bush in arm orientating keyway along central access of arm. NOTE: Large bush keyway must be positioned ± 5° from centreline of control arm.
Item 1 2 3
Description Installer 202-230-Item 8 Small Bush Receiver 204-230-Item 3
4. Using a hydraulic press and suitable “V” blocks place a steel plate over the installer and press the bush home (2.5-3 tonne req’d). CAUTION: Always wear safety glasses and try to protect your body by placing yourself at the side of the press frame during operation or use a transparent ballistic nylon protective blanket 1230PB.
Upper Arm Bushing Item 1 2 3
Description Installer 204-230-Item 1 Large Bush Receiver 204-230-Item 10
2. Place the open side of the installer 204-230-Item 2 onto the bush. 3. Place receiver 204-230-Item 10 under the arm, cup upwards. 4. Using a hydraulic press on the installer press the bush home (2.5-3 tonne req’d). Installation Small bush 1. Position small bush in arm. 2. Place the receiver 204-230-Item 3 cup upward onto the shaft of the installer 204-230-Item 8.
G48701 en
Special Tools 204-228
Removal NOTE: For introduced at AV Falcon are different bushes in front of arm to rear of arm. Front bushes are visually different & are voided around the circumference. NOTE: Eye protection must be worn during the following procedures.
01/2003 2003.0 BA Falcon
204-01-12
Front Suspension
204-01-12
REMOVAL AND INSTALLATION (Continued) 1. Support receiver tool 204-228-Item 1 under bush.
Item 1 2
Description Upper control arm Receiver 204-228-Item 1
2. Press receiver tool 204-228-Item 1 onto bush until it supports on casting.
3. Insert mandrel 204-228-Item 2 into bush sleeve. Insert aligning bush 204-228-Item 3 into bottom of receiver. Proceed to push bush out until it releases itself from the upper arm casting.
Item 1 2
Description Mandrel 204-228-Item 2 Aligning bush 204-228-Item 3
Installation NOTE: Insert voided bush into forward housing in arm. Insert non-voided bush into rear housing in arm. 1. Place receiver tool 204-228-Item 1 under upper control arm. 2. Insert aligning bush 204-228-Item 3 into receiver. 3. Insert reducing bush tool 204-228-Item 4 on top of upper control arm. 4. Insert suspension bush onto mandrel 204-228-Item 2 and insert into reducing bush. 5. Lubricate bush in soapy water. Item 1 2
Description Upper control arm Receiver 204-228-Item 1
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01/2003 2003.0 BA Falcon
204-01-13
Front Suspension
204-01-13
REMOVAL AND INSTALLATION (Continued) 6. Insert bush until bush is correctly inserted into Item upper control arm. 4 NOTE: Correct insertion can be viewed by cutouts 5 in receiver. Bush should be central to the control arm.
Description Aligning bush 204-228-Item 3 Reducing bush 204-228-Item 4
Front Wheel Spindle and Hub
Item 1 2 3
Description Mandrel 204-228-Item 2 Upper control arm Receiver 204-228-Item 1
G48702 en
Removal 1. Raise the vehicle and support it under the body rails. 2. Remove the wheel. 3. Remove the brake caliper from the spindle and suspend it so that there is no strain on the brake hose. 4. Remove the hub and disc from the spindle. 5. Loosen the tie rod end nut and using a taper breaker free the stud taper. Remove the nut and detach the tie rod end from the spindle. 6. Loosen the nuts on the spindle ball joint studs and free the tapers using a taper breaker. 7. Remove the bolt and nut securing the upper ball joint stud and move the stud out of the spindle. 8. Remove the nut from the lower ball joint stud and remove the spindle from the vehicle. Installation 1. Locate the lower ball joint stud into the spindle and attach the nut. 2. Locate the upper ball joint stud into the spindle and fit the clamp bolt and nut. 3. Torque the nuts to specification. 4. Install the tie rod end in the spindle. Torque the nut. 5. Install the hub and disc on the spindle. Torque nut to specification. 6. Install the brake caliper. 7. Install the wheel and lower the vehicle.
01/2003 2003.0 BA Falcon
204-01-14
Front Suspension
204-01-14
REMOVAL AND INSTALLATION (Continued)
Item 1 2 3 4 5 6 7 8 9 10 11
Description Nut M14x2 Bolt and Retainer Arm Assembly Front Susp. Lower Nut Lock Spindle Assembly Nut 3/8-24 UNF Stabilizer Bar Link Nut Front Stabilizer Bar Bolt M8x26 Stab. Bar Mounting Bracket
G48702 en
Item 1 2 3 4
Description Hub & Bearing Assy Frt Brake Nut & Washer Assy Seal Frt Wheel Hub Spindle Assy Frt Wheel
01/2003 2003.0 BA Falcon
204-01-15
Front Suspension
204-01-15
REMOVAL AND INSTALLATION (Continued)
Spring and/or Shock Absorber Assembly Removal 1. Remove the coolant bottle or the air cleaner box depending upon which side is to be removed.
Item 1 2 3 4
Description Shock Absorber Ftr Bolt Hex Hd M14 Nut M14 Arm Assy Frt Susp Lwr
2. Remove the two of the three nuts securing the shock absorber/sprlng assembly to the suspension tower and loosen the third nut. 3. Raise the vehicle - supporting it under the body rails. 4. Remove the wheel and separate the upper ball joint stud from the spindle. 5. Remove the shock absorber lower mounting bolt. 6. Remove the third nut supporting the shock absorber/spring assembly to the suspension tower, gently ease down the lower arm and remove the assembly, taking care to ensure that the shock absorber lower brackets do not damage the dust boot of the lower ball joint. Also take care not to damage the ABS wire (where fitted). 7. Install the shock absorber/spring assembly onto the spring compressor and compress the spring to relieve the tension from the shock absorber piston rod.
Installation 1. Ensure that the bumpstop, washer and dirtshield fitted are correctly fitted onto the shock absorber; compress the spring in the spring compressor and assemble the shock absorber into it. 2. Set the stop of the shock absorber spring seat, against the spring lower end, fit the upper spring seat insulator and rotate it’s stop against the upper end of the spring. Fit the spring cap with any of the three studs at the specified angle relative to the centre line of the shock absorber assembly to lower control arm mounting bolt (lower spring seat stop end). 3. Assemble the dual path shear mount and nut onto the shock absorber piston rod. 4. Partly release the spring compressor and torque the nut to specification whilst preventing the spring cap from rotating by use of a soft lever (eg: piece of wood) against two of the three studs. 5. Fully release the spring compressor. 6. Install the shock absorber/spring assembly into the vehicle. The lower spring tail is to be to the front on LHS and to the rear on RHS. Take care not to damage boot of the lower ball joint, or the ABS wire (where fitted) and loosly fit one of the nuts supporting the assembly to suspension tower. 7. Fit the shock absorber lower mounting bolt and loosely fit the nut. NOTE: Bolt thread must point towards the front of the vehicle. 8. Fit the upper ball joint stud to the spindle; fit the clamp bolt and nut. torque the nut. 9. Fit the two remaining nuts securing the upper spring seat cap to the tower. 10. Fit the wheel. 11. With the vehicle weight on it’s wheels, torque the shock absorber lower mounting hardware and the three nuts on the suspension tower, to specification.
WARNING: Do not attempt to separate the spring from the shock absorber until the spring is restrained by the use of a spring compressor. 8. Remove the nut, dual path shear mount and spring seat insulator from the shock absorber piston rod and withdraw the shock absorber. 9. Release the tension from the spring if the spring is to be changed.
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01/2003 2003.0 BA Falcon
204-01-16
Front Suspension
204-01-16
REMOVAL AND INSTALLATION (Continued)
Item 1 2 3 4 5 6 7 8
Description Nut Washer Insulator Bracket Assy Insulator Spring Frt Susp Coil Shock Absorber Assy Frt Nut
Item 1 2 3
G48703 en
Description 2A Crossmember 2B Crossmember Nut Nyloc M12
01/2003 2003.0 BA Falcon
204-02a-1
Rear Suspension — IRS
204-02a-1
SECTION : 204-02a Rear Suspension — IRS VEHICLE APPLICATION : 2003.0 BA Falcon CONTENTS
PAGE
SPECIFICATIONS Specifications .......................................................................................................................204-02a-2 DESCRIPTION AND OPERATION Rear Suspension — IRS ......................................................................................................204-02a-3 Components .......................................................................................................................204-02a-3 DIAGNOSIS AND TESTING Inspection and Verification ...................................................................................................204-02a-6 Stabiliser Bar ......................................................................................................................204-02a-6 Diagnosis ...........................................................................................................................204-02a-6 GENERAL PROCEDURES FPV Cam bolt adjustment ....................................................................................................204-02a-7 RLCA to subframe cam adjustment .....................................................................................204-02a-7 REMOVAL AND INSTALLATION Upper Control Arm Assembly (UCA) ...................................................................................204-02a-8 Front Lower Control Arm Assembly (FLCA) ........................................................................204-02a-9 Rear Lower Control Arm Assembly (RLCA) ......................................................................204-02a-10 Knuckle ..............................................................................................................................204-02a-13 Rear Lower Control Arm (RLCA) park brake cable bracket ..............................................204-02a-15 Abutment bracket ...............................................................................................................204-02a-15 Control Blade .....................................................................................................................204-02a-16 Shock Absorber .................................................................................................................204-02a-17 Spring and Upper Spring Insulator ....................................................................................204-02a-18 Stabiliser bar ......................................................................................................................204-02a-20 Upper Stabiliser Bar Insulator ............................................................................................204-02a-21 Jounce Bumper ..................................................................................................................204-02a-22 Body Brace ........................................................................................................................204-02a-22 IRS Module ........................................................................................................................204-02a-23
01/2003 2003.0 BA Falcon
204-02a-2
Rear Suspension — IRS
204-02a-2
SPECIFICATIONS Stabiliser Bar Specifications Description Specification Stabiliser bar diameter: 18 ± 0.2mm Stabiliser bar diameter: 19 ± 0.2mm Stabiliser bar/droplink M10 X 1.25 flanged head attachment nut: nut / Zinc plated Stabiliser bar/droplink M10 X 1.25 flanged head attachment bolt: bolt / Zinc plated Torque Specifications Description Nut - M12 - RLCA to Subframe Bolt - M12 - Diff Blade to Diff Bolt - M16 - Front Diff Bush (subframe) to Diff Nut - M14 - RLCA to Knuckle Nut - M14 - FLCA to Subframe Nut - M14 - UCA to Subframe Nut - M12 - FLCA to Knuckle Nut - M12 - UCA to Knuckle Bolt - M14 - Diff Rear Cover to Subframe Bolt - M14 - Diff Rear Cover to Subframe with Mass Damper Nut - M24 - Wheel End Pacnut Bolt - M12 - Caliper to Knuckle Screw - M8 - Stabiliser Bar Bracket to Subframe Nut - M10 - Stabiliser Bar Droplink to RLCA Nut - M10 - Stabiliser Bar Lower Attachment Screw - M8 - Abutment Bracket to Knuckle Screw - M6 - ABS Sensor to Knuckle Nut - M10 - Body Brace to Subframe Screw - M12 - Control Blade to Knuckle Bolt - M14 - Shock Absorber to Knuckle Shock Absorber to Upper Mount (upper bolt) Nut - M12 - Subframe to Body (rear spring area) Nut - M12 - Subframe to Body (front area of subframe) Nut - M12 - Control Blade to Body Bolt - M10 - Body Brace to Body Bolt - M10- Vee Brace to Subframe (rear diff bush mount frame) * Torque at ride height.
G765430 en
Nm 105 ± 15 88 ± 17 140 ± 28 140 ± 28 * 140 ± 28 * 140 ± 28 * 126 ± 24 126 ± 24 200 ± 40 200 ± 40 325 ± 25 103 ± 16 25 ± 5 25 ± 5 52.5 ± 2.5 25 ± 5 10.4 ± 2 50 ± 9.5 88 ± 17 121 ± 18 70 108 ± 17 108 ± 17 100 50 ± 9.5 108 ± 17
01/2003 2003.0 BA Falcon
204-02a-3
Rear Suspension — IRS
204-02a-3
DESCRIPTION AND OPERATION
Rear Suspension — IRS
The Independent Rear Suspension (IRS) design is based on three control arms attached to the subframe and knuckle. The Rear Lower Control Arms (RLCA) seat the base of the spring and also allow for adjusting wheel alignment. Torque is transmitted to the wheels via a centrally located differential and two independent halfshafts. The design allows for servicing on either side of the module. Alternatively, the entire module may be removed from the vehicle.
press-fitted rubber bush in the lower control arm. At the other end the droplink also has a press fitted rubber bush for the attachment to the stabiliser bar. The stabiliser bar and droplink can be replaced individually or altogether as an assembly if necessary.
Components Wheel Knuckle Assembly carries the wheel hub. carries the brake caliper assembly. carries the parkbrake assembly. carries the ABS sensor. carries the shock absorber. is supported by three arms and a knuckle support blade each side.
Stabiliser Bar Assembly The stabiliser bar assembly consists of the stabiliser bar and two droplinks. The assembly is attached to the subframe with two brackets with rubber d-blocks. The droplink serves as a linkage between the lower control arm and the stabiliser bar. The droplink has a spigot at one end, which is bolted inside the G765431 en
Item 1 2 3 4
Description Droplink Stabiliser Bar Attachment Bolt Attachment Nut
01/2003 2003.0 BA Falcon
204-02a-4
Rear Suspension — IRS
204-02a-4
DESCRIPTION AND OPERATION (Continued) Upper Control Arm Assembly (UCA)
Front Lower Control Arm Assembly (FLCA)
Assembly consists of a forged arm with a rubber bush Assembly consists of a stamped arm with rubber on the subframe end and a cross axis ball joint bushes on the subframe end and a CABJ on the (CABJ) on the Wheel Assembly end. Wheel Assembly end.
Item 1 2 3 4 5 6 7
Description Bushing Nut-UCA to Subframe UCA without Bushing Bolt-UCA to Knuckle Nut-UCA to Knuckle Cross Axis Ball Joint (CABJ) Bolt-UCA to Subframe
Item 1 2 3 4 5 6 7
Description Nut FLCA to Subframe FLCA without Bushing Bolt-FLCA to Knuckle Cross Axis Ball Joint (CABJ) Nut-FLCA to Knuckle Bolt-FLCA to Subframe Bushing - Upper Inner
Rear Lower Control Arm Assembly (RLCA) Assembly consists of a stamped arm with rubber bushes on the subframe end and a CABJ on the wheel assembly end. A cam bolt fixes the RLCA to the subframe.
G765431 en
01/2003 2003.0 BA Falcon
204-02a-5
Rear Suspension — IRS
204-02a-5
DESCRIPTION AND OPERATION (Continued)
Item 1 2 3 4 5 6 7 8 9
Description Cam Washer Nut RLCA to Subframe Bolt RLCA to Knuckle Cross Axis Ball Joint (CABJ) Nut RLCA to Knuckle Rear Lower Control Arm RLCA Bolt RLCA to Subframe Cam Washer Bush - Lower Inner
Control Blade Assembly Assembly consists of a stamped blade with a rubber bush on the end connecting to the body and is retained by 3 bolts at the knuckle end.
G765431 en
01/2003 2003.0 BA Falcon
204-02a-6
Rear Suspension — IRS
204-02a-6
DIAGNOSIS AND TESTING
Inspection and Verification
4. Inspect rubber bush for damage.
Stabiliser Bar 1. Inspect the stabiliser bar for signs of corrosion, deep scoring or cracks, which can dramatically reduce the fatigue life of the stabiliser bar. Replace if necessary. 2. Check the stabiliser bar for permanent deformation. This can be checked by laying the stabiliser bar on a flat bench as shown in figure below. Measure the height of the eyes from the bench and they should be within 4mm from each other. Do not attempt to heat the stabiliser bar and bend the eyes into position, as doing so will affect the fatigue properties of the material. Replace if necessary. NOTE: The droplink and its rubber bush must be replaced as a unit.
3. Inspection of press fit.
G765432 en
Diagnosis 1. Inspect the droplink for signs of corrosion or deep scoring which can dramatically reduce the life of the product. Replace if necessary. 2. Check the integrity of the press-fit for the rubber bushes in the droplinks. Measure the distances shown in the figure below. If the measurements are outside the tolerances shown the press-fit has probably worked itself loose under excessive loads. If the facilities are available, the integrity of the press-fit can also be checked by applying a 3kN (300kg) load to the bush. The bush should be capable of taking the load without slipping. Do not attempt to refit the rubber bushes into the droplinks. Replace if necessary. 3. Inspect the rubber bush for any signs of tearing or the failure of the bond from the steel sleeves in the region shown in the figure above. Replace if necessary.
01/2003 2003.0 BA Falcon
204-02a-7
Rear Suspension — IRS
204-02a-7
GENERAL PROCEDURES
FPV Cam bolt adjustment Refer to section Section 204-00.
RLCA to subframe cam adjustment Refer to section Section 204-00.
G765434 en
01/2003 2003.0 BA Falcon
204-02a-8
Rear Suspension — IRS
204-02a-8
REMOVAL AND INSTALLATION
Upper Control Arm Assembly (UCA)
Item 1 2 3 4 5 6 7
Description Bushing Nut-UCA to Subframe UCA without Bushing Bolt-UCA to Knuckle Nut-UCA to Knuckle Cross Axis Ball Joint (CABJ) Bolt-UCA to Subframe
Removal 1. Hoist vehicle and remove rear wheels. Refer to Section 100-02. 2. Remove IRS module. Refer to IRS Module in this section. 3. Set the suspension to ride height. Refer to Section 204-00. 4. Loosen and remove UCA-knuckle nut. 5. Remove UCA-knuckle bolt.
G765435 en
6. Loosen and remove UCA-subframe nut. 7. Remove UCA-subframe bolt. 8. Slide UCA free. Installation 1. Locate UCA in subframe as shown. 2. Attach UCA-subframe bolt and loosely attach UCA Subframe nut. NOTE: Bolt head faces the front of the module. 3. Set the suspension to the correct ride height. Refer to Section 204-00. 4. Locate UCA into knuckle attachment point with UCA-knuckle bolt and loosely attach UCA-Knuckle nut. NOTE: Bolt head faces the front of the module. 5. Torque UCA-knuckle bolt and UCA-knuckle nut to 126 ± 24 Nm.
01/2003 2003.0 BA Falcon
204-02a-9
Rear Suspension — IRS
204-02a-9
REMOVAL AND INSTALLATION (Continued) 6. Torque UCA-subframe bolt and UCA-Subframe nut to 140 ± 28 Nm.
2. Set suspension to design height with springs installed. Refer to Section 204-00. Support wheel ends under the knuckle positions and under RLCAs as indicated. 3. Remove nut on FLCA bolt to knuckle. 4. Remove nut on FLCA bolt to subframe.
7. Install the IRS module back into the vehicle. Refer to IRS Module in this section.
Front Lower Control Arm Assembly (FLCA)
Item 1 2 3 4 5 6 7
Description Nut FLCA to Subframe FLCA without Bushing Bolt-FLCA to Knuckle Cross Axis Ball Joint (CABJ) Nut-FLCA to Knuckle Bolt-FLCA to Subframe Bushing - Upper Inner
Removal 1. Hoist vehicle and remove rear wheels. Refer to Section 100-02.
5. Remove both FLCA-knuckle and FLCA-subframe bolts. 6. Slide FLCA free.
Installation 1. Locate FLCA to subframe. NOTE: The FLCA should be oriented so that the CABJ fits to the knuckle, that the face with the "REAR" label faces the rear of the module and that the upper and lower flanges face the rear of the module. 2. Fit nut to bolt loosely. NOTE: Ensure bolt head faces the rear of the module. This is the only bolt head that faces the rear of the vehicle. 3. Set suspension to ride height. See Section 204-00.
G765436 en
01/2003 2003.0 BA Falcon
204-02a-10
Rear Suspension — IRS
204-02a-10
REMOVAL AND INSTALLATION (Continued) 4. Locate FLCA to knuckle and fit nut to bolt loosely. Removal NOTE: Ensure bolt head faces the front of the 1. Hoist vehicle so that the wheels are fully module. supported. 2. Set suspension to ride height. See Section 204-00. 3. Remove rear wheels. 4. Disconnect Control Blade from Wheel End Assembly.
5. Torque FLCA-knuckle bolt to 126 ± 24 Nm. 6. Torque FLCA-subframe bolt to 140 ± 28 Nm. 7. Attach wheels and lower vehicle. CAUTION: Care should be taken when removing transmission jack from under RLCA due to the high compressive force in the spring.
5. Remove Knuckle-RLCA bolt.
Rear Lower Control Arm Assembly (RLCA)
6. Disconnect Stabiliser Bar links by removing nut/washer.
Item 1 2 3 4 5 6 7 8 9
Description Cam Washer Nut RLCA to Subframe Bolt RLCA to Knuckle Cross Axis Bolt Joint (CABJ) Nut RLCA to Knuckle Rear Lower Control Arm RLCA Bolt RLCA to Subframe Cam Washer Bush - Lower Inner
G765436 en
01/2003 2003.0 BA Falcon
204-02a-11
Rear Suspension — IRS
204-02a-11
REMOVAL AND INSTALLATION (Continued) 7. Loosen bolts connecting Stabiliser Bar brackets to 11. Lower jack slowly and rotate RLCA downwards. Subframe.
8. Rotate stabiliser bar away from RLCA, and towards Control Blade. 9. Unclip park brake cable from RLCA park brake cable bracket.
12. Remove spring and Spring Insulators when spring becomes fully extended. CAUTION: Springs have high spring rate and extreme care should be taken when releasing jack. NOTE: Wheel-ends must be supported at the knuckle in the two indicated positions so that halfshafts are not over-articulated. 13. Remove RLCA Cam bolt assembly.
10. Loosen RLCA Cam bolt assembly at subframe attachment.
14. Slide RLCA downward from vehicle.
G76555 en
01/2003 2003.0 BA Falcon
204-02a-12
Rear Suspension — IRS
204-02a-12
REMOVAL AND INSTALLATION (Continued) Installation 1. Ensure that park brake cable and stabiliser bar links are positioned away from the RLCA position within module. 2. Locate RLCA and locate RLCA cam bolt assembly through RLCA bush and subframe.
3. Position upper spring insulator and spring into position on subframe. Position lower spring insulator onto RLCA. 4. While holding spring and insulators in position, rotate RLCA upward into position.
5. Insert jack underneath RLCAs. Extend jack so that spring is compressed and return the halfshafts to a horizontal position.
G76555 en
6. Locate and loosely fit RLCA-knuckle bolt. Ensure bolt head faces the front of the module, and that the nut is fully closed over the bolt shank.
7. Attach Control Blade to knuckle using new Control Blade-knuckle bolts. NOTE: Replace Control Blade-Knuckle bolts as they are a 1 use only item.
8. Torque RLCA-knuckle bolt to 140±28Nm. 9. Torque Control Blade-Knuckle bolts to 88±17Nm. 10. Adjust RLCA Cam bolt as necessary (see below) and torque to 105 ± 15 Nm. 11. Clip park brake cable into RLCA cable bracket.
01/2003 2003.0 BA Falcon
204-02a-13
Rear Suspension — IRS
204-02a-13
REMOVAL AND INSTALLATION (Continued) 12. Rotate stabiliser bar and insert stabiliser bar links into RLCA. Complete stabiliser bar assembly as detailed later in this section.
13. Attach wheels and lowere vehicle.
6. Lower transmission jack from ride height so that springs are fully extended. Support wheel-ends at the knuckle in the two indicated positions so that halfshafts are not over-articulated.
Knuckle Removal 1. Secure wheel/hub to prevent halfshaft rotation loosen axle pac nuts from halfshafts. NOTE: Pac nuts are substantially torqued. 2. Hoist vehicle with wheels fully supported. Refer to Section 100-02. 3. Set vehicle to ride height (Refer to Section 204-00) and remove rear wheels. 4. Unbolt ABS sensor. 5. Disconnect Control Blade and remove from Knuckle.
7. Release park brake. Disconnect park brake cable from knuckle mount.
Item 1 2
G76540 en
Description Hand Brake Cable Retaining Spring Clip
01/2003 2003.0 BA Falcon
204-02a-14
Rear Suspension — IRS
204-02a-14
REMOVAL AND INSTALLATION (Continued) 8. Detach abutment brackets from knuckle. Refer later in this section.
9. Detach caliper and rotor. Refer to Section 206-00. 10. Disconnect shock absorbers from knuckle. 11. Loosen and remove UCA-knuckle nut, FLCA-knuckle nut, and RLCA-knuckle nut. 1. FPV Vehicles Loosen nut from UCA to knuckle and remove Cam bolt and washer. FLCA-knuckle and RLCA-knuckle connections are as for the standard IRS module. 12. Remove axle pac nut, UCA-knuckle bolt, FLCA-knuckle bolt and RLCA-knuckle bolt.
However, halfshafts and control arms must be adequately supported so that they remain horizontal.
Installation 1. Set the suspension to ride height. Refer to Section 204-00. 2. Position knuckle assembly over halfshaft (with halfshaft supported horizontally). Replace axle pac nut and torque to 50Nm. 3. Locate FLCA to knuckle using FLCA-knuckle bolt and nut. 4. a) Locate UCA to knuckle using UCA-knuckle bolt and nut. b) Insert Cam bolt into Cam slot on FPV knuckle. 5. Locate RLCA to knuckle using RLCA-knuckle bolt and nut. NOTE: This may require the adjustment of the spring height, via the jack attached to the RLCA, in order to position the RLCA groove over the knuckle. 6. Torque RLCA-knuckle nut to 140 ± 28 Nm. 7. Torque FLCA-knuckle bolt to 126 ± 24 Nm. 8. Torque UCA-knuckle bolt to 126 ± 24 Nm. NOTE: Torquing of bolts should be done with the vehicle at ride height.
Item 1 2 3 4 5
Description Upper Control Arm Nut and Bolt Axle Pac Nut Rear Lower Control Arm Nut and Bolt Lower Shock Absorber Bolt Front Lower Control Arm Nut and Bolt
13. Remove knuckle from halfshaft in a horizontal direction. NOTE: Knuckles must be removed in a direction parallel to the halfshafts to avoid damage to the teeth on the halfshaft and knuckle splines.
9. 10. 11. 12. 13.
1. FPV Vehicles Adjust Camber on UCA-knuckle as required connection prior to the torque of the Cam bolt. For more information, see Section 204-00. Secure wheel/hub to prevent halfshaft rotation when torquing axle nut. Torque axle nuts to 325 ± 25 Nm. Fit ABS sensor. See Section 206-09. Fit abutment brackets. Attach park brake cable to Banksia lever on knuckle.
NOTE: After removal of knuckle(s), the suspension may be extended from ride height, to allow springs to extend to uncompressed height. G76540 en
01/2003 2003.0 BA Falcon
204-02a-15
Rear Suspension — IRS
204-02a-15
REMOVAL AND INSTALLATION (Continued) 14. Fit Control Blade to knuckle.
15. Replace wheels. Release jack supporting the suspension and slowly lower vehicle weight onto the wheels.
Rear Lower Control Arm (RLCA) park brake cable bracket
3. Remove park brake cable bracket by squeezing the wire ends together using wide-grip pliers or equivalent.
Installation 1. Attach park brake cable bracket to RLCA by squeezing ends together and inserting into two holes on the RLCA.
Removal 1. Hoist vehicle (Refer to section 100-02) to obtain access to IRS module. 2. Unhook park brake cable from RLCA cable bracket.
2. Clip park brake cable onto RLCA bracket.
3. Ensure that park brake cable is fitted correctly to all attachment points as given in park brake cable procedure.
Abutment bracket Removal 1. Release park brake. G76542 en
01/2003 2003.0 BA Falcon
204-02a-16
Rear Suspension — IRS
204-02a-16
REMOVAL AND INSTALLATION (Continued) 2. Hoist vehicle and remove rear wheels. See Installation Section 100-02. 1. Locate abutment brackets with two abutment 3. Disconnect abutment bracket v-clip. bracket-knuckle bolts per side. 4. Disconnect park brake cable from attachment point on knuckle and feed cable through abutment bracket.
Item 1 2
Description Hand Brake Cable Retaining Spring Clip
2. Torque bolts to 25 ± 5 Nm. 3. Locate park brake cable through abutment bracket and attach to Banksia lever on inside of knuckle assembly.
5. Loosen abutment bracket-knuckle bolts - 2 per side. 6. Remove bolts and release abutment brackets.
Item 1 2
Description Hand Brake Cable Retaining Spring Clip
4. Attach park brake cable to abutment bracket using v-clips. 5. Ensure park brake cable routing and adjust park brake cable as required. See Section 206-05.
Control Blade Removal 1. Hoist vehicle so that the wheels are fully supported. See Section 100-02. 2. Set vehicle to design height. For more information, see Section 204-00. 3. Remove rear wheels.
G76542 en
01/2003 2003.0 BA Falcon
204-02a-17
Rear Suspension — IRS
204-02a-17
REMOVAL AND INSTALLATION (Continued) 4. a) Detach ABS cable from attachment point beneath the rear seat. b) Remove both ferntree clips from the control blade. c) Feed the ABS cable through the hole in the control blade.
Installation 1. Set vehicle to ride height. See Section 204-00. 2. Locate knuckle support arm to knuckle with 3 bolts each side. NOTE: The flanges of the knuckle support arms face inwards on the vehicle. 3. Fit knuckle support arm-chassis mounting bolts. NOTE: The transmission jack used to set design height may require adjustment to correctly align the knuckle support arm with the chassis mounting points.
5. Disconnect Control Blade from chassis mounts. 6. Hoist vehicle and remove rear wheels. Allow spring to extend to uncompressed length and support wheel ends at this length. 7. Disconnect control blade from chassis mounting points.
8. Disconnect Control Blade from knuckle by loosening and removing knuckle support arm-knuckle bolts - 3 per side.
9. Remove knuckle support arm. G76544 en
4. Torque knuckle support arm-knuckle bolts to between 85-100Nm and torque knuckle support arm-chassis mounting bolts. 5. Feed ABS cable through hole in knuckle support arm. Attach ferntree clip to ABS cable and clip to knuckle support arm. Connect ABS cable to attachment point at front of knuckle support arm. Refer to Section 206-09.
Shock Absorber Removal 1. Disconnect brake hose from support bracket. 2. With the vehicle on the ground, remove the upper shock absorber bolt by gaining access through the wheel arch gap directly above the rear tyre. 3. Hoist vehicle slowly. Refer to Section 100-02. Shock absorber will drop with the lower control arm. Watch for spring dislodgment. 4. Remove lower shock absorber attachment bolt. 5. Maneuver the shock absorber from the vehicle. WARNING: Never attempt to remove the shock absorber from the fully installed position by removing the upper or lower bolts when the vehicle is raised on a hoist. This may cause the wheel to drop suddenly resulting injury. Installation 1. Install the shock absorber to the vehicle and loosely install the lower mounting bolt. 2. Begin to lower the vehicle from hoist, stopping the hoist and guiding the upper shock absorber into the upper bracket where necessary. Do not guide the shock absorber whilst the hoist is in operation. Ensure rear spring is not dislodged. Lower the hoist until the shock absorber upper mount is aligned with the bracket hole. 3. Install the upper shock absorber bolt. Lower the vehicle completely (if not already) and tighten both the upper and lower bolts to the specified torque. 4. Reconnect the brake hose to bracket. NOTE: Shock absorber hand tests are detailed in section Section 204-00. 01/2003 2003.0 BA Falcon
204-02a-18
Rear Suspension — IRS
204-02a-18
REMOVAL AND INSTALLATION (Continued)
Spring and Upper Spring Insulator
5. Remove links from RLCA and rotate stabiliser bar towards the front of the vehicle.
Removal 1. Hoist vehicle, remove rear wheels and set suspension to ride height. For further information, see Section 204-00. 2. Disconnect park brake cable from knuckle.
Item 1 2
Description Hand Brake Cable Retaining Spring Clip
3. Unclip cable from RLCA cable clips.
6. Loosen RLCA-knuckle nuts and remove RLCA-knuckle bolts.
4. Loosen and remove stabiliser bar link nuts and washers.
7. Loosen RLCA-subframe nut.
G76544 en
01/2003 2003.0 BA Falcon
204-02a-19
Rear Suspension — IRS
204-02a-19
REMOVAL AND INSTALLATION (Continued) 8. By slowly extending the transmission jack, lower the RLCA to extend the spring.
3. Connect RLCA to knuckle by loosely fitting bolt and nut. NOTE: Ensure bolt head faces front of vehicle.
9. Remove spring and insulators as necessary. Installation 4. Torque RLCA to knuckle to 140Nm. 1. With vehicle hoisted and RLCA-subframe 5. Rotate stabiliser bar links through RLCAs and connection loose, insert spring insulators and attach nut and washer. Torque nut to 15-20Nm. spring. NOTE: The flat end of spring faces the subframe and the curved end of the spring faces the RLCA. 2. Insert transmission jack underneath RLCAs. Extend jack to slowly compress spring and return suspension to design height.
6. Adjust RLCA-subframe cam bolt as required. See Section 204-00.
7. Attach wheels to knuckles. Lower jack under RLCAs while returning the vehicle weight to its own wheels. CAUTION: Ensure that the vehicle is well supported on its own wheels before completely removing the jack. G76544 en
01/2003 2003.0 BA Falcon
204-02a-20
Rear Suspension — IRS
204-02a-20
REMOVAL AND INSTALLATION (Continued)
Stabiliser bar
Item 1 2 3 4 5 6 7 8 9
Description Stabiliser Bar Link Insulator Drop Link Stabiliser Bar Lower Bolt Stabiliser Bar Stabiliser Bar Insulator Stabiliser Bar Mounting Bracket M8 Screw - Stabiliser Bar Bracket to Subframe M10 - Stabiliser Bar Lower Attachment Stabiliser Bar Bush
Removal 1. Hoist vehicle and remove rear wheels. NOTE: Support knuckles to ensure halfshafts are not over-articulated.
5. Undo stabiliser bar link-RLCA nuts and disconnect stab bar.
6. Unclip stabiliser bar bushes from the stabiliser bar. 7. Undo bolt/nut from stabiliser bar link to stabiliser bar. 8. Remove link. Installation 1. Locate stabiliser bar link to stabiliser bar. Stabiliser bar links should be positioned on the outside of the stabiliser bar. 2. Connect bolt/nut from stabiliser bar link to stabiliser bar loosely. 3. Locate stabiliser bar bushes to stabiliser bar. 4. Locate stabiliser bar links through insulators on RLCAs. Affix stabiliser bar to RLCAs by loosely fitting stabiliser bar link-RLCA nut/washer.
2. Loosen stabiliser bar link-RLCA nuts. 3. Loosen stabiliser bar bracket bolts and remove from the subframe. 4. Remove stabiliser bar bush brackets.
G76544 en
01/2003 2003.0 BA Falcon
204-02a-21
Rear Suspension — IRS
204-02a-21
REMOVAL AND INSTALLATION (Continued) 5. Locate stabiliser bar bush brackets to stabiliser bar bushes. Locate the stabiliser bar brackets to the subframe using bracket-subframe bolts.
6. Torque stabiliser bar bush brackets to subframe to between 20Nm and 30Nm. 7. Torque stabiliser bar link to RLCA to between 20Nm and 30Nm. 8. Torque stabiliser bar link bolt to stabiliser bar. NOTE: Module should be supported on its own wheels with halfshafts horizontal before torquing stabiliser bar links.
3. Loosen bolts connecting stabiliser bar brackets to subframe.
4. Rotate stabiliser bar and links away from RLCA towards knuckle support arms. 5. Reach into rear of module over the top of RLCA. Remove stabiliser bar insulator.
Upper Stabiliser Bar Insulator Removal 1. Hoist vehicle and set to ride height. For more information, see Section 204-00. 2. Disconnect stabiliser bar links by removing nut/washer connecting link to RLCA. Installation 1. Locate and fit upper stabiliser bar insulator by compressing the insulator with a screwdriver and using a twisting motion. NOTE: Two grooved steps of the stabiliser bar insulator should be inserted into the RLCA. 2. Rotate stabiliser bar and insert stabiliser bar links into RLCA. Complete stabiliser bar assembly as detailed in stabiliser bar installation procedure.
G76547 en
01/2003 2003.0 BA Falcon
204-02a-22
Rear Suspension — IRS
204-02a-22
REMOVAL AND INSTALLATION (Continued)
Jounce Bumper
2. Torque subframe-body brace nut to 50 ± 9.5 Nm. 3. Torque chassis-body brace bolt to 50 ± 9.5 Nm.
Removal 1. Hoist vehicle so that access is available to the suspension module. NOTE: The vehicle should be supported on its wheels so that the halfshafts remain horizontal (i.e. design height). Unclip jounce bumper from upper subframe. Installation 1. With vehicle hoisted, locate jounce bumper and plug on subframe above RLCA.
Body Brace
Removal 1. Loosen subframe-body brace bolt. 2. Loosen chassis-body brace connection. 3. Remove subframe-body brace and chassis-body brace bolts. Disconnect body brace. Installation 1. Locate body brace to subframe and chassis using respective bolts. Body brace should be fixed so that standard hole is fitted to the module subframe and the slotted hole is fitted to vehicle chassis. NOTE: Body brace should be oriented with flanged ends higher than the middle section of the body brace. G76547 en
01/2003 2003.0 BA Falcon
204-02a-23
Rear Suspension — IRS
204-02a-23
REMOVAL AND INSTALLATION (Continued) Special Tool(s)
IRS Module
IRS alignment pins 204-478
Special Tool(s) IRS module remover and installer cradle 502-006
General
Removal 1. Using a 2 post hoist (note position).
3. Replace 1 wheel nut to retain rear rotors. 4. Remove rear seat bottom cushion.
2. Remove rear wheels. G76549 en
01/2003 2003.0 BA Falcon
204-02a-24
Rear Suspension — IRS
204-02a-24
REMOVAL AND INSTALLATION (Continued) 5. Unplug both ABS connector and push out 11. Remove loctite from bolts. grommet and connect through the floor sheet metal. 6. Remove both brake calipers and secure up out off the way. Beware not to kink brake hose.
7. Raise vehicle on hoist. 8. Remove the rear intermediate exhaust mounting rubber from the LH side of vehicle.
9. Mark rear drive shaft CV and diff flange. If the vehicle is fitted with drive shaft balance weight, number them and their corresponding location before removing them.
Item 1 2 3
Description Constant Velocity Joint Differential Flange Bolt
12. Disconnect the rear hand brake cables.
13. Disconnect the differential breather hose.
10. Unbolt and drive shaft from diff flange.
G76549 en
01/2003 2003.0 BA Falcon
204-02a-25
Rear Suspension — IRS
204-02a-25
REMOVAL AND INSTALLATION (Continued) 14. Remove IRS braces (note orientation).
18. Remove the 2 nuts forward of the springs on the subframe.
15. Remove the 4 nuts retaining the front bush off the 19. Loosen (crack) the 2 nuts reward of the springs Trailing Arms to the body. on the subframe.
16. Remove the bolt at the rear of the differential.
20. Loosen (crack) both lower shock absorber bolts. 21. Fit the IRS module removal and installation cradle 502-006.
17. Remove the 2 bolts on the front off the IRS module (in front of the springs). Item 1 2 3
Description Front Location Bosses Front Tabs Rear Pins
1. Locate the 2 front bosses of the SST 502-006 into the IRS subframe G76549 en
01/2003 2003.0 BA Falcon
204-02a-26
Rear Suspension — IRS
204-02a-26
REMOVAL AND INSTALLATION (Continued) 2. Tighten the rear pins 3. Engage the 2 front tabs and tighten with a spanner
25. Move the trolley jack under the IRS module SST and take up the weight of the IRS. Do not lift the vehicle off of the hoist.
26. Remove the remaining 2 nuts (rearward of the springs) on the subframe.
22. Lower the vehicle until the knuckle is approx 1 foot above the ground. 23. Using a trolley jack take up the load of the spring/shocker and remove the shocker lower bolt lower jack slowly. NOTE: It is important that the knuckle be supported by the jack to avoid having the spring & half shaft fall-out.
27. Lower the IRS using the trolley jack. The front bush off the trailing arms may need some help coming away from the studs using a breaker bar. 28. Raise the vehicle on the hoist. Installation 1. Unbolt and remove the IRS sensors.
24. Repeat step 23 for the other side.
G76549 en
01/2003 2003.0 BA Falcon
204-02a-27
Rear Suspension — IRS
204-02a-27
REMOVAL AND INSTALLATION (Continued) 2. Remove the Control Blades.
8. Place the larger of the two location pins SST 204-478 in the left hand alignment hole and tighten the rearward nut.
3. Move the IRS into the approximate position under the vehicle. The IRS should just be clear of the 9. Place the smaller of the two location pins SST ground. Don’t have the Jack fully raised. 204-478 in the right hand alignment hole and 4. Lower the vehicle until the chassis stud for tighten the rearward nut. attaching the IRS are approx 1" off of the IRS module. 5. Raise the IRS Module locating the 4 studs (Don’t lift the vehicle off of the hoist). 6. Install the 4 nut each side of the rear springs.
10. Place the larger of the two location pins in the left hand alignment hole and tighten the forward nut.
7. Raise the vehicle.
G76549 en
01/2003 2003.0 BA Falcon
204-02a-28
Rear Suspension — IRS
204-02a-28
REMOVAL AND INSTALLATION (Continued) 11. Place the smaller of the two location pins in the right hand alignment hole and tighten the forward nut.
15. Replace the Y braces. Apply thread-locker (ie. loctite) to both nuts and bolts. Note the orientation.
12. Torque all 4 nuts. 13. Install and torque the 2 bolts in the front of the IRS module.
16. Put the hand brake cable back. Refer to Section 206-05.
14. Install and torque the bolt in the rear of the differential to the chassis.
G76549 en
17. Reconnect the tail shaft. Apply thread-locker (ie. loctite) to all bolts. Make sure that if weights were present on disassembly that they are return to there original position.
01/2003 2003.0 BA Falcon
204-02a-29
Rear Suspension — IRS
204-02a-29
REMOVAL AND INSTALLATION (Continued) 18. Reconnect the differential breather tube.
19. Install the nuts that fix the Trailing Arms to the Body/Chassis and torque the nuts to specification.
22. Using a jack raise the knuckle to align the top bolt hole of the knuckle and the Control Blade. You may need to pull the knuckle forward.
23. Now replace the middle and then the lower bolt. Some manipulation of the knuckle height may be require to align the bolt hole. 24. Torque all 3 Trailing Arm bolts. 25. Refit the shock absorber into position and torque the bolts. Use a jack to hold the knuckle into place.
20. Replace the exhaust mounting rubber.
26. Bolt the ABS sensor back into position.
21. Lower the vehicle to approx 300mm off the ground.
G76549 en
01/2003 2003.0 BA Falcon
204-02a-30
Rear Suspension — IRS
204-02a-30
REMOVAL AND INSTALLATION (Continued) 27. Push the ABS connector plug back through the sheet metal and engage the grommet correctly.
28. Reinstall the rear brake caliper. Refer to Section 206-04. 29. Repeat steps 22 to 28 for the other side. 30. Refit the wheels. 31. Connect the ABS plugs.
32. Refit the rear seat base.
G76549 en
01/2003 2003.0 BA Falcon
204-02b-1
Rear Suspension — Beam Axle
204-02b-1
SECTION : 204-02b Rear Suspension — Beam Axle VEHICLE APPLICATION : 2003.0 BA Falcon CONTENTS
PAGE
SPECIFICATIONS Specifications .......................................................................................................................204-02b-2 DESCRIPTION AND OPERATION Rear Suspension — Beam Axle ..........................................................................................204-02b-3 Ute & Wagon Rear Suspension .........................................................................................204-02b-3 Shock Absorbers ................................................................................................................204-02b-4 DIAGNOSIS AND TESTING Rear Suspension .................................................................................................................204-02b-5 GENERAL PROCEDURES Ride Height Procedure .........................................................................................................204-02b-6 Wheel Balancing ..................................................................................................................204-02b-6 Hoisting Instructions .............................................................................................................204-02b-6 REMOVAL AND INSTALLATION Shock Absorber — Ute/Wagon ............................................................................................204-02b-7 Leaf Spring — Ute/Wagon ...................................................................................................204-02b-7 Leaf Spring Front Eye Bushing — Ute ................................................................................204-02b-7 Leaf Spring Front Eye Bushing — Wagon ...........................................................................204-02b-7
01/2003 2003.0 BA Falcon
204-02b-2
Rear Suspension — Beam Axle
204-02b-2
SPECIFICATIONS Torque Specifications Description Rear Hanger Bracket to Body Spring Shackle to Rear hanger and Spring Rear Shock Absorber to Upper Mounting Bracket Rear Shock Absorber Upper Mounting Bracket to Body Rear Shock Absorber to Rear Spring Plate Rear Spring to Rear Axle U-bolt, Nut Wheel Nut Rear Spring to Rear Spring Front Hanger
G478919 en
Nm 50 120 70 35 40 60 125 105
01/2003 2003.0 BA Falcon
204-02b-3
Rear Suspension — Beam Axle
204-02b-3
DESCRIPTION AND OPERATION spring is suspended from the underbody side rail by a hanger at the front and shackle at the rear. The upper end of each shock absorber is mounted to a bracket Ute & Wagon Rear Suspension in the underbody. The lower end is mounted to the 3/4 tonne & 1/2 tonne (Sports suspension) spring clip plate. Ute and Wagon The springs and shock absorbers control the up and Two spring pads integral with the axle housing rest on down movement of the rear axle and wheels as a spring plate and rubber insulator. These are located required by changes in the road surface. They also on two leaf-type springs. The axle housing is fastened cushion road shocks. to the springs by U-bolts, spring plates and nuts. Each
Rear Suspension — Beam Axle
Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14
Description Nut (Wagon only) Nut Bump stop Bolt U bolt Nut Bushing Bushing Rear spring bracket hanger Nut Shackle Bolt Bolt Bolt
G478920 en
Item 15 16 17 18 19 20 21 22 23 24 25 26 27
Description Shock absorber Shock absorber bracket Plate assy. RR Spring Nut Nut Insulator Nut Leaf spring Bolt Hex HD Washer ½ 13x6 Insulator Retaining bracket Bolt (Wagon only) Pinion nose bump stop (Wagon only)
01/2003 2003.0 BA Falcon
204-02b-4
Rear Suspension — Beam Axle
204-02b-4
DESCRIPTION AND OPERATION (Continued)
1 Tonne Ute The rear suspension layout differs from, 3/4 tonne & 1/2 tonne (Sports suspension) ute only by the deletion of the rubber insulator between the spring pads and the spring plate.
Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
Description Nut Bump stop Bolt U bolt Nut Bushing Bushing Rear spring bracket hanger Nut Shackle Bolt Bolt Bolt Shock absorber Shock absorber bracket Plate assy. RR Spring Nut
G478920 en
Item 18 19 20 21 22 23 24 25
Description Bolt Bolt Bush Leaf Spring eye Leaf spring bushing Nut Bush Nut
Shock Absorbers All vehicles are equipped with hydraulic gas pressurised shock absorbers of the direct-acting type and are non-adjustable and non-refillable, and cannot be repaired. WARNING: Under no circumstances should the shock absorbers be pierced or heated. Before replacing a shock absorber, check the action of the shock absorbers. 01/2003 2003.0 BA Falcon
204-02b-5
Rear Suspension — Beam Axle
204-02b-5
DIAGNOSIS AND TESTING
Rear Suspension Refer to, Section 204-00.
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01/2003 2003.0 BA Falcon
204-02b-6
Rear Suspension — Beam Axle
204-02b-6
GENERAL PROCEDURES
Ride Height Procedure Loading Reqirements 1. 2. 3. 4. 5.
Full tank of fuel. Cooling system filled. Crankcase oil at full. Spare wheel and tyre stowed in design position. Front seat one notch forward from rearmost position. Measuring Procedure 1. Position vehicle on level surface as loaded above. 2. Bounce the front and rear of the vehicle up and down approximately 50 mm in each direction. 3. With the parking brake disengaged, push the vehicle rear end at the centre of the rear bumper evenly down, approximately 25 mm, and release slowly. 4. With appropriate instruments measure from the fender opening eyebrow to the wheel centreline on both sides and record these measurements. 5. Raise the vehicle rear end at the centre of the rear bumper evenly, approximately 25 mm, and release slowly. 6. Repeat item 4. 7. Average the above measurements for each side and record as rear ride heights left and right. NOTE: Ride height specifications for coil springs are base on springs that have settled in operation. When are fitted a further 6 mm for coil springs and 15 mm for leaf springs may be added to the maximum allowable height. Ride height is also dependent on the options fitted to a base vehicle and the quantity of fuel carried.
Wheel Balancing NOTE: Refer to the instructions provided with the Wheel Balancer.
Hoisting Instructions NOTE: Damage to suspension and/or steering components may occur if care is not exercised when positioning hoist adaptors or jacks when lifting the vehicle. Do not allow contact with the steering linkage.
G478922 en
01/2003 2003.0 BA Falcon
204-02b-7
Rear Suspension — Beam Axle
204-02b-7
REMOVAL AND INSTALLATION 2. Position the upper insulator pad and the bracket to the spring. Lift the rear end of the spring, locate the insulator bracket to the rear axle and install Removal the bushings and the shackle plate and pin 1. Raise the vehicle on a hoist supporting it under assemblies. Install the nuts finger tight. the body side-rails. Position a jack under the axle 3. Position the lower insulator pad to the spring and to ensure that the axle breather hose and the the upper insulator bracket. brake hose are not stretched. 4. Install the U-bolts, spring plate and the attaching 2. Remove the nut securing the shock absorber nuts. lower mounting to the U-bolt plate and disconnect this lower mounting. 5. Place stands beneath the rear axle and lower the vehicle to the curb load position. 3. Remove the bolt from the shock absorber upper mounting, and rotate the shock absorber and 6. Install the lower shock absorber mounting. remove. 7. Tighten the front hanger and the rear shackle lock Installation nuts. 1. With the vehicle raised and supported under the 8. Where the RH spring has been removed attach body rails, fit the shock absorber and upper the exhaust system. mounting bolt. 9. Remove the stand and lower the vehicle. 2. Fit the shock absorber lower mounting stud to the Leaf Spring Front Eye Bushing — Ute U-bolt plate. 3. Lower the vehicle to the ground and torque the Removal hardware to specification. 1. Remove the spring as previously described. Leaf Spring — Ute/Wagon 2. Using suitable adaptors press the old bush from the spring eye. Removal 3. Press the new bush into the spring eye. 1. Raise the vehicle on an underbody support hoist. 4. Install the spring as previously described. 2. Place a stand beneath the rear axle and lower the hoist sufficient to remove the weight of the rear axle from the shock absorber. Disconnect the lower end of the shock absorber from the spring plate, and push the shock absorber clear of the work area. 3. Raise the hoist and support the rear axle on the stand. 4. Remove the nuts from the U-bolts: then, remove the plate and insulator (where fitted). 5. Remove the nut from the front hanger bolt. 6. Remove the nuts, the rear shackle plate and pin assemblies and the shackle bushings. Lower the rear end of the spring. 7. Remove the upper insulator and spring plate from Installation the spring. 1. Install by reverse procedure. 8. When removing the RH side spring detach the 2 NOTE: Torque nuts to specification with the rear exhaust system supports and lower the suspension in curb load position. muffler to enable the front hanger bolt to be 2. Where necessary attach exhaust system. removed. 9. Remove the front hanger bolt and remove the rear 3. Lower vehicle. spring. Leaf Spring Front Eye Bushing — Installation Wagon 1. Position the spring front eye in the front hanger and (from the inboard side) insert the bolt through Removal the hanger and the bushing. Install the lock nut on 1. Remove the spring as previously described. the bolt and tighten finger tight. 2. Using suitable adaptors press the old bush from the spring eye.
Shock Absorber — Ute/Wagon
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01/2003 2003.0 BA Falcon
204-02b-8
Rear Suspension — Beam Axle
204-02b-8
REMOVAL AND INSTALLATION (Continued) 3. Press the new bush into the spring eye. NOTE: The bush must be installed with the void toward the front of the spring and flange at the inboard side of the spring. 4. Install the spring as previously described.
Installation 1. Install by reverse procedure. NOTE: Torque nuts to specification with the suspension in curb load position. 2. Where necessary attach exhaust system. 3. Lower vehicle.
G478928 en
01/2003 2003.0 BA Falcon
204-04-1
Wheels and Tyres
204-04-1
SECTION : 204-04 Wheels and Tyres VEHICLE APPLICATION : 2003.0 BA Falcon CONTENTS
PAGE
SPECIFICATIONS Specifications .........................................................................................................................204-04-2 DESCRIPTION AND OPERATION Wheels and Tyres ..................................................................................................................204-04-3 Wheels .................................................................................................................................204-04-3 Tyres ....................................................................................................................................204-04-3 Safety Precautions ..............................................................................................................204-04-3 DIAGNOSIS AND TESTING Wheels and Tyres .................................................................................................................204-04-4 Inspection and Verification ...................................................................................................204-04-4 Symptom Chart ....................................................................................................................204-04-5 Component Tests .................................................................................................................204-04-6 GENERAL PROCEDURES Straightening Wheels, Rims or Components .........................................................................204-04-8 Wheel and Tyre Assembly Balancing ...................................................................................204-04-8 REMOVAL AND INSTALLATION Wheel ....................................................................................................................................204-04-9 Tyre ........................................................................................................................................204-04-9
01/2003 2003.0 BA Falcon
204-04-2
Wheels and Tyres
204-04-2
SPECIFICATIONS Torque Specifications Description Wheel Nuts
G43320 en
Nm 135
01/2003 2003.0 BA Falcon
204-04-3
Wheels and Tyres
204-04-3
DESCRIPTION AND OPERATION
Wheels and Tyres Wheels The road wheels are of the double safety rim type. They may be steel or aluminium according to the model variant. It is essential that correct wheel nuts are used at all times.
Correct tyre pressure and driving techniques have an important influence on tyre life. Heavy cornering, excessively rapid acceleration and unnecessary sharp braking, increase tyre wear. To equalize tyre wear, the tyres should be rotated at recommended intervals.
WARNING: Never run the engine with one wheel off the ground, for example, when changing a tyre. The wheel(s) resting on the ground could Steel wheels are fitted with wheel covers that must be cause the vehicle to move. Failure to follow these removed to access the wheel nuts. instructions may result in personal injury. The wheel nuts are conventional conical nuts. WARNING: The tyre and wheel must always Aluminium Wheels be correctly matched. It is very important to The aluminium wheels are protected against corrosion determine the size of each component before any by a special coating. Care must be taken when either assembly operations commence. Failure to adhere replacing a tyre or fitting wheel balance weights not to to these instructions can result in an explosive separation and cause serious bodily injury or chip or score this protective coating. death.
Steel Wheels
Tyres
Radial tyres are fitted as standard equipment to all models. For tyre data refer to the decal attached to the lock face of the right hand front door.
Tyre Care It is essential that the recommended inflation pressures are always maintained. Radial ply tyres may appear underinflated at the correct recommended pressures.This is normal and they should never be inflated beyond the recommended pressures.
Tyre Pressures The tyre pressures quoted are cold pressures. In this context, the tyre temperature is considered ‘hot’ after extended motoring at speed. Under certain extreme conditions of operation, a tyre may require up to one hour at rest before it can be considered ‘cold’.
Tyre Wear If irregular wear is noticed, check the wheel bearings and front suspension ball joints for excess play and also check the front suspension geometry.
WARNING: Aftermarket aerosol tyre sealants are extremely flammable. Always question the customer to make sure these products have not been used. Failure to follow these instructions may result in personal injury. WARNING: Aftermarket wheel assemblies may not be compatible with the vehicle. Use of incompatible wheel assemblies can result in equipment failure and possible injury. Use only approved wheel assemblies. Failure to follow these instructions may result in personal injury. WARNING: Use only wheels and wheel nuts that have been designed for the vehicle. Aftermarket wheels or wheel nuts may not fit or function correctly. Failure to follow these instructions may result in personal injury. WARNING: Always wear safety goggles or a face shield when performing any work with the tyre and wheel assemblies. Failure to follow these instructions may result in personal injury.
CAUTION: Reduce the air pressure as much as possible by pushing the valve core plunger in prior to removing the valve core. Avoid working in WARNING: Do not mix different types of tyres a position in which the face or body is directly on the same vehicle such as radial, bias, or over a tyre in which there is pressure. bias-belted tyres except in emergencies When carrying out any inspection or repair (temporary spare usage), because vehicle handling may be seriously affected and may result procedures on wheels and tyres, follow the preceding safety precautions. in loss of control. Failure to follow these instructions may result in personal injury. Factory-installed tyres and wheels are designed to operate satisfactorily with loads up to and including full-rated load capacity when inflated to recommended inflation pressures.
Safety Precautions
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01/2003 2003.0 BA Falcon
204-04-4
Wheels and Tyres
204-04-4
DIAGNOSIS AND TESTING
Wheels and Tyres Inspection and Verification WARNING: Do not balance the wheels and tyres while they are still mounted on the vehicle. Possible tyre disintegration or differential failure can result, causing serious injury and extensive component damage. Use off-vehicle wheel and tyre balancer only. Failure to follow these instructions may result in personal injury. Be sure to follow the warnings when carrying out inspection and verification.
Road Test Verify the customer concern by carrying out a road test on a smooth road. If any vibrations are apparent, refer to Section 100-04. To maximize tyre performance, inspect for signs of incorrect inflation and uneven wear, which can indicate a need for balancing, rotation, or a suspension alignment. Correct tyre pressure and driving techniques have an important influence on tyre life. Heavy cornering, excessively rapid acceleration and unnecessary sharp braking increase tyre wear. Replacement tyres should follow the recommended: tyre sizes speed rating load range tyre construction type Use of any other tyre size or type may seriously affect: ride handling speedometer/odometer calibration vehicle ground clearance tyre clearance between the body and chassis wheel bearing life brake cooling Wheels need to be replaced when: bent dented cracked heavily corroded leaking they have elongated wheel hub bolt holes they have excessive lateral or radial runout Wheel and tyre assemblies are attached by five wheel nuts
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It is mandatory to use only the tyre sizes recommended on the tyre chart attached to the vehicle. Larger or smaller tyres can damage the vehicle, affect driveability, and require changing the speedometer calibration. Make sure wheel size and offsets match those recommended for the tyre in use. 1. Inspect for signs of uneven wear that can indicate a need for balancing, rotation, suspension alignment, or damaged steering components. 2. Check tyres for: cuts stone bruises abrasions blisters embedded objects 3. Tread wear indicators are moulded into the bottom of the tread grooves. Install a new tyre when the indicator bar becomes visible.
Match Mounting Tyres Match mounting is a technique used to reduce radial runout. Excessive runout is a source of vibration, shimmy and poor handling concerns. Use the following steps to reduce radial runout: 1. Mark the wheel at the same point as the mark previously made when measuring the tyre runout. 2. Dismount the tyre and remount it 180 degrees on the wheel so the original mark on the tyre is opposite the mark on the wheel. 3. Inflate the tyre to specification. 4. Measure the radial runout with Radial Runout Gauge at the center of the tread face. If the radial runout is reduced to acceptable guidelines, the tyre can be used. If the radial runout remains excessive, check the wheel runout.
Tyre Drift Diagnosis Drift is the deviation of the vehicle from a straight path on a level road with no pressure on the steering wheel. Drift can be caused by: incorrect wheel alignment dragging brakes incorrect/uneven tyre pressure defective tyres If defective tyres are suspected in a drift condition, use the following steps to determine the defective tyre: 1. Rotate the two front tyres. For additional information, refer to Wheel and Tyre in this section. 2. Road test the vehicle. If the vehicle drifts to the opposite direction, one of the front tyres is at fault.
01/2003 2003.0 BA Falcon
204-04-5
Wheels and Tyres
204-04-5
DIAGNOSIS AND TESTING (Continued) 3. Rotate the two front tyres back to their original position. 4. Rotate one of the front tyres with its corresponding rear tyre on the same side of the vehicle.
5. Road test the vehicle. If the drift is corrected, install a new rear tyre. If the drift remains, install a new front tyre on the opposite side of the vehicle.
Symptom Chart Condition Tyres show excess wear on edge of tread
Source
Action
Underinflated tyres.
ADJUST the tyre pressure.
Vehicle overloaded.
RETURN vehicle —NOTIFY the customer of overload condition.
Incorrect wheel alignment.
SET the alignment to specification. REFER to Section 204-00.
High-speed cornering.
RETURN vehicle — NOTIFY the customer of cause of condition.
Incorrect tyre rotation
ADVISE the customer of intervals. condition. ROTATE tyres.
Tyres show excess wear in center of tread
Overinflated tyres.
ADJUST the tyre pressure.
Other excessive/uneven tyre wear problems
Improper tyre pressure.
ADJUST the tyre pressure.
Worn or damaged suspension components.
REFER to Section 204-00.
Incorrect tyre/wheel usage.
INSTALL the correct tyre and wheel combination.
Damaged, loose, or leaking shock absorbers or struts.
TIGHTEN or INSTALL new shock absorbers as necessary.
Incorrect wheel alignment.
SET to specification. REFER to Section 204-00.
Wheel and tyre assembly out of balance.
BALANCE the wheel and tyre assembly.
Excessive lateral or radial runout of wheel or tyre.
REFER to Component Tests in this section.
Tyres need rotating.
ADVISE the customer of the condition. ROTATE the tyres.
Incorrect application or mismatched parts, including lug bolts and wheel nuts.
FOLLOW the manufacturer’s specifications.
Corroded, worn or damaged parts.
CLEAN or INSTALL new parts as necessary.
Worn or damaged wheel bearings.
REFER to Section 204-00.
Loose or damaged suspension components.
REFER to Section 204-00.
Bent or damaged wheel.
INSTALL a new wheel as necessary.
Wheel and tyre assembly out of balance.
BALANCE the wheel and tyre assembly.
Damaged tyre.
INSTALL a new tyre as necessary.
Loose wheel nuts.
TIGHTEN to specification. Refer to Wheel and Tyre in this section.
Wheel mounting is difficult
Wobble or shimmy
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01/2003 2003.0 BA Falcon
204-04-6
Wheels and Tyres
204-04-6
DIAGNOSIS AND TESTING (Continued) Condition Vehicle vibrations
Source
Action
Driveline.
REFER to Section 100-04.
High-speed shake
Wheel hub face/pilot/bolt circle runout. Wheel and tyre assembly out of balance. Damaged or worn wheel bearings. Damaged or worn suspension/steering linkage. Driveline. Brake discs/imbalance.
REFER to Section 100-04.
Damaged wheel nuts
Loose wheel assembly.
INSTALL new wheel nuts. Refer to Wheel and Tyre in this section.
Overtightened wheel nuts.
REMOVE the wheel nuts. INSPECT for damage. INSTALL new components as necessary. Refer to Wheel and Tyre in this section.
Corrosion or galling.
If the corrosion is slight, BRUSH away the corrosion with a wire brush. If the corrosion is excessive, INSTALL new wheel studs and wheel nuts. REFER to Section 204-01 (front) or Section 204-02 (rear). If the condition persists, LUBRICATE the first three threads of each wheel stud with a graphite-based lubricant
Wheel and tyre assembly out of balance.
Frozen wheel nuts
CAUTION: Do not allow the lubricant to get on the cone seats of the stud holes or on the cone angles of the wheel nuts. Overloading.
REDUCE the load weight.
Component Tests
Tyre Runout
Tyre and Wheel Runout
Measure radial and lateral runout at the positions shown in the illustration. Runout should not exceed specifications.
Before checking runout, and to avoid false readings caused by temporary flat spots in the tyres, check runout only after the vehicle has been driven far enough to warm the tyres. Excessive radial and lateral runout of a wheel and tyre assembly can cause roughness, vibration, wheel tramp, tyre wear, and steering wheel tremor. The extent of the runout is measured with a radial runout gauge. All measurements are made on the vehicle with the tyres inflated to recommended inflation pressures.
Wheel Runout Measure radial and lateral wheel runout at the positions shown on the illustration. Runout should not exceed specifications. Note that the tyre has been removed.
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01/2003 2003.0 BA Falcon
204-04-7
Wheels and Tyres
204-04-7
DIAGNOSIS AND TESTING (Continued)
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01/2003 2003.0 BA Falcon
204-04-8
Wheels and Tyres
204-04-8
GENERAL PROCEDURES
Straightening Wheels, Rims or Components NOTE: Do not heat wheels in an attempt to soften them for straightening to repair damage. The special alloy used in these wheels is heat-treated. Uncontrolled heating from welding affects the properties of the material. Do not weld the wheels for any reason.
Wheel and Tyre Assembly Balancing 1. Wheel and tyre assemblies should be dynamically balanced. The wheel centre should be mounted and located on a 70.45 to 70.50 mm diameter spigot and clamped against the mounting plate via the wheel stud holes, (i.e. as on a vehicle). 2. When balancing wheels note that the weights are different on alloy and steel wheels. 3. Clip-on weights are to be used where the wheel has a lip on the flange to accept a clip-on weight, otherwise stick-on weights are to be used. For stick on weights, the thickness of the lead weight plus the adhesive should not exceed 4.5mm. NOTE: It is important that only the correct balance weights are used.
Item 1 2
Description Steel wheel weights Aluminium wheel weights
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01/2003 2003.0 BA Falcon
204-04-9
Wheels and Tyres
204-04-9
REMOVAL AND INSTALLATION
Wheel Removal 1. Remove the wheel cover by inserting the small end of a wheel nut removal tool inside the outer edge of the cover and progressively prying off the cover (steel wheels only). 2. Loosen the wheel nuts one turn. 3. Raise the vehicle until the tyre clears the floor. 4. Remove the wheel nuts and the centre cap (where fitted). Installation 1. Clean all dirt from the hub. 2. Position the wheel on the hub. Install the wheel centre cap (where fitted) on the wheel bolts. 3. Install the wheel nuts and tighten them alternately in order to draw the wheel evenly against the hub. 4. Lower the vehicle to the floor, and tighten the nuts. 5. Position the wheel cover recess for the valve, symmetrically around the valve and using a rubber mallet gently knock the cover onto the wheel, hitting on the outer edge. (Steel wheels only.)
Tyre Removal NOTE: When fitting a new tubeless tyre, a new snap-in valve should also be fitted. The valve is made to last the life of the tyre, but beyond that time fatigue of the valve body rubber is likely to impair the air-seal at the rim hole. NOTE: The tyre can be demounted or mounted on a machine. A machine should always be used on aluminium alloy wheels. NOTE: Be sure that outer side of the wheel is positioned upward. It is acceptable to use tyre irons on steel wheels using the following procedure.
3. Stand the wheel and tyre upright with the tyre inner bead in the drop centre well at the bottom of the wheel. Insert the tyre iron between the bead and the edge of the wheel rim, and pry the wheel out of the tyre. Installation 1. If a used tyre is being installed remove all dirt from the tyre. If a tyre is being mounted to the original wheel, check the tyre bead seat on the rim for imperfections and rectify same before installing the tyre. If a new tyre or wheel is being installed coat a new valve with lubricant and position the valve to the wheel. Use a valve replacing tool to seat the valve in the rim. 2. Apply lubricant to the sealing surface on both tyre beads and wheel. With the outer side of the wheel up, install the beads one at a time over the wheel rim, by using a rubber mallet or a tyre mounting machine. 3. Remove the valve core and give the tyre a few quick bursts of air to seal the beads. 4. If the beads do not seal, hold the beads against the rim by positioning a tyre mounting band over the tyre. If a mounting band is not available, tie a tourniquet of heavy cord around the circumference of the tyre. Tighten the cord with a tyre iron. Centre the tyre on the wheel with a rubber mallet. Repeat item 3. Remove the mounting band. 5. Install the valve core then inflate the tyre to 275 kPa pressure to seat the beads against the rim flanges. 6. Check to see that the bead positioning rings (rings on the side walls near the rim) are evenly visible just above the rim flanges all the way around the tyre. If the rings are not even, deflate the tyre completely and inflate it again. 7. When the rings are properly positioned, deflate the tyre to the recommended pressure. 8. Dynamically balance the wheel and tyre assembly.
1. Remove the valve cap and core, and deflate the tyre completely. 2. With the bead loosening tool, break loose the tyre beads from the wheel. 3. Remove the wheel weights (if fitted). 1. With the outer side of the wheel upward, insert two tyre irons about 200 mm apart between the tyre outer bead and the wheel rim. Use only tyre irons with rounded edges or irons designed for demounting tubeless tyres. 2. Lever the tyre bead over the wheel rim with one iron and hold it in this position. Pry the rest of the bead over the rim with the other iron. Take small "bites" with the iron around NOTE: Ensure correct rotational direction when fitting the tyre in order to avoid damaging the a directional tyre to a rim. sealing surface of the tyre bead. G43326 en
01/2003 2003.0 BA Falcon
205-00-1
Driveline System — General Information
205-00-1
SECTION : 205-00 Driveline System — General Information VEHICLE APPLICATION : 2003.0 BA Falcon CONTENTS
PAGE
SPECIFICATIONS Specifications .........................................................................................................................205-00-2 DESCRIPTION AND OPERATION Driveline System ....................................................................................................................205-00-3 General Specifications .........................................................................................................205-00-3 Run in ...................................................................................................................................205-00-5 Towing ..................................................................................................................................205-00-5 Oil Changes ........................................................................................................................205-00-5 DIAGNOSIS AND TESTING Driveline System ....................................................................................................................205-00-5 In Vehicle Diagnostics ..........................................................................................................205-00-5 Symptom Chart ....................................................................................................................205-00-5 Bearing Noise .......................................................................................................................205-00-7 Gear Tooth Contact Pattern Check .....................................................................................205-00-7 Shim and Backlash Changes ...............................................................................................205-00-8 Driveline Vibration ................................................................................................................205-00-9 Limited Slip Differentials (M78 & M86) ...............................................................................205-00-9 Inspection after Removal & Dismantling ............................................................................205-00-10
01/2003 2003.0 BA Falcon
205-00-2
Driveline System — General Information
205-00-2
SPECIFICATIONS Torque Specifications Refer to, Specifications and Special Tools of Section 205-02 for all Torque Specifications.
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01/2003 2003.0 BA Falcon
205-00-3
Driveline System — General Information
205-00-3
DESCRIPTION AND OPERATION
Driveline System General Specifications M78 & M86 IRS (Sedan) M78 IRS
Conventional M86 differentials are not fitted with a metal tag. For LSD units, a metal tag marked “SPIN RESISTANT DIFF. USE APPROVED LUBRICANT ONLY” is attached under the filler plug on the rear cover.
M78 & M86 Beam Axle (Wagon & Ute) M78 Beam axle
M86 IRS M86 Beam axle
A label identifying the drive unit assembly part number, serial number, final drive ratio and model is fixed to the carrier casting. Two different model final drive units are used in sedan vehicles: 1. M78 final drive units are fitted with 3.23 or 3.45 7.75" (197mm) diameter gear sets, with or without LSDs. All M78 final drive units should be filled with synthetic oil as per Section 205-02 Specifications. Conventional M78 differentials are fitted with a metal tag marked “HIGH PERFORMANCE. USE APPROVED LUBRICANT ONLY” that is attached under the filler plug on the rear cover. For Limited Slip Differentials (LSD) units, the metal tag is marked “LSD - HIGH PERFORMANCE. USE APPROVED LUBRICANT ONLY”. 2. M86 final drive units are fitted with 3.23 or 3.46 8.6" (220mm) diameter gear sets, with or without LSDs. M86 final drive units are fitted to all sedan vehicles powered by a V8 or turbo I6 engine. All M86 final drive units should be filled with mineral oil as per Section 205-02 Specifications. G77666 en
A label identifying the beam axle assembly part number, serial number, and final drive ratio is fixed to the axle tube adjacent to the carrier. Two different model beam axles are used on wagon and utility vehicles: 1. M78 beam axles are fitted with 3.23 or 3.45 7.75" (197mm) diameter gear sets, with or without ABS and with or without LSDs. All M78 beam axles should be filled with synthetic oil as per Part 4-5 Specifications. Conventional M78 differentials are fitted with a metal tag marked “HIGH PERFORMANCE. USE APPROVED LUBRICANT ONLY” that is attached under the filler plug on the rear cover. For LSD units, the metal tag is marked “LSD - HIGH PERFORMANCE. USE APPROVED LUBRICANT ONLY”. 2. M86 beam axles are fitted with 3.23 or 3.46 8.6" (220mm) diameter gear sets, with or without ABS and with or without LSDs. M86 axles are fitted to 1 tonne rated utilities, and all vehicles powered by 01/2003 2003.0 BA Falcon
205-00-4
Driveline System — General Information
205-00-4
DESCRIPTION AND OPERATION (Continued) a V8 or turbo I6 engine. All M86 beam axles should be filled with mineral oil as per Part 4-5 Specifications. Conventional M86 differentials are not fitted with a metal tag. For LSD units, a metal tag marked “SPIN RESISTANT DIFF. USE APPROVED LUBRICANT ONLY” is attached under the filler plug on the rear cover. NOTE: Upgrading the lubricating oil to synthetic type is recommended for vehicles fitted with a M86 final drive unit where the vehicle will be regularly used for towing. Refer to, Specifications of Section 205-02 for the recommended synthetic lubricant.
over-running of the cones; such a condition or sound does not indicate failure of the unit.
These axle types are a hypoid type of unitised carrier construction. The two pinion differential case and the drive pinion are mounted in opposed taper roller bearings in the carrier. Differential bearing preload adjustment is provided by the screw adjusters. Pinion bearing preload is regulated by a collapsible spacer and adjusted using the pinion nut. Torque is transferred from the propshaft to the final drive assembly via the constant velocity type companion flange that is splined to the hypoid pinion. The torque is then transferred from the pinion through the ring gear, differential case, differential pinion cross shaft, differential pinions and side gears to the constant velocity joint halfshafts for conventional differentials. Halfshaft end play is pre-set and is not adjustable. Oil seals are located between the haflshafts and the screw adjusters. M78 Limited Slip Differentials (LSDs), the differential case houses two cone type clutches behind the side gears. These cones are splined to the halfshafts, their tapered faces bearing on the differential case. Thrust springs pre-load the gears and cones, forcing the tapered face of the cones into contact with the differential case. The partial locking action due to the spring load on the cones is automatically increased by the inherent separating forces between the side gears and pinion. This locking action directs a portion of the driving force to the wheel with the least traction. M86 LSDs transfer torque in a similar manner as M78 LSDs, except that a multiplate oil bath type design is utilised where alternate plates are splined to the differential case and side gear. Compressive preloading of the plates provides frictional resistance to rotation, providing torque transfer to the rear wheel with the least traction. With a conventional differential, when the rear wheels are under extreme unbalance tractive conditions, such as one wheel on dry road and the other in mud or ice, wheel spin will occur if over acceleration is attempted. However, with the limited slip differential, when the tendency for wheel spin occurs, the friction generated between the cones and the differential case (M78) or between the friction plates (M86) transfers a portion of the driving torque to the non-spinning wheel. NOTE: (For M78 LSDs) In the event of continued spinning a whirring sound is produced due to
Towing
G77666 en
Run in It is recommended that the vehicle is driven conservatively for the first 1500kms from new, and that towing is avoided during this period. This allows the final drive to bed in correctly and helps assure satisfactory final drive component life. During the run-in period, the vehicle should be driven at normal road speeds (within the posted limits) as final drive loading not vehicle speed is of primary importance. Ensure that the vehicle is fitted with a Ford approved tow pack, and that the towing limits for the particular vehicle as designated by Ford and relevant State regulatory bodies are adhered to. The final drive must be filled to the correct level with the correct type of oil to ensure satisfactory performance while towing. Overheating can occur where low oil level or the wrong type of lubricant is used.
Oil Changes If the vehicle is going to be used for towing on a regular basis, or occasional heavy towing, an oil change after run-in is recommended. Note that this is not part of regular scheduled vehicle maintaince.
01/2003 2003.0 BA Falcon
205-00-5
Driveline System — General Information
205-00-5
DIAGNOSIS AND TESTING
Driveline System In Vehicle Diagnostics For other than obvious mechanical failures, careful tests should be made to locate final drive troubles since noises from engine, transmission and wheels may all be attributed to the final drive. A suggested test routine is as follows:- Ensure that the axle lubricant is correct and at the correct level. Drive at low speed until thoroughly familiar with vehicle noises by which time the rear axle assembly should have warmed up. Accelerate gradually from the lowest
practical speed in top gear to 110 kilometres per hour (or maximum legal speed), noting any noises and the speeds at which they occur. Release the accelerator and without using the brakes allow the vehicle to lose speed, again noting noise and speed. Next, allow the vehicle to coast to rest from 110 kph with the transmission in neutral position. Any noises common to earlier tests may be eliminated, as the final drive is not under load in these conditions. Engine noise is gauged by gradually accelerating the engine with the vehicle at rest. Noises not eliminated at this stage are most probably final drive gear noise.
Symptom Chart Symptom Chart Condition Rear Wheel Noise (Beam Axles)
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Source Worn brake rotor. Wheel bolts loose. Brinnelled or scored bearings. Insufficient lubrication. Bent axle shaft or wheel. Dragging brakes. Axle shaft retainer plate loose. Tyre defective. Damaged or worn C.V. joints (IRS).
Action Replace/Repair as required
01/2003 2003.0 BA Falcon
205-00-6
Driveline System — General Information
205-00-6
DIAGNOSIS AND TESTING (Continued) Condition Final Drive Noise
Source Bearing noise is usually fairly constant throughout the entire speed range and of a pitch that increases in proportion to vehicle speed. NOTE: Final drive noises fall into two categories: Gear Noise and Bearing Noise.
Action Replace/Repair as required
Gear noise is of a periodic nature being produced at various speeds on drive, float, coast and cruise conditions. If the pinion and ring gear have been set up with too little backlash a continuous whine may be produced. NOTE: Gear noise is most commonly caused by: Incorrect mesh of gear teeth (i.e. incorrect pinion head positioning shim or backlash setting shims). Scored gear teeth - usually the result of incorrect lubricant type or level. End play in bearings. Bruised or chipped teeth. Excessive runout of pinion head or ring gear backface. Ring gear creeping on differential housing resulting from ring gear bolts loosening - noise from this source usually appears as a sharp metallic sound when shifting from reverse to first gear. NOTE: Bearing Noise is usually caused by worn bearings and can be the result of: Contaminants in the lubricant. Incorrect preload setting. Bearings incorrectly mounted - e.g. dirt trapped behind abutment faces during assembly. Rear Axle Shaft Breakage (Beam Axle)
Abnormal clutch operation. Bent axle tubes/half shafts. Excessive vehicle loads.
Replace/Repair as required
Overheating of Final Drive Assembly
Lubricant level incorrect. Incorrect lubricant type. Incorrect run-in procedure.
Replace/Repair as required
Loss of Lubricant
Lubricant level too high. Breather malfunction. Damaged or worn oil seals. Rear cover bolts / filler plug loose. Rear cover flange distorted. Rear cover gasket/sealant damaged or incorrectly applied. Split cover or tubes (beam axles). Incorrect type of lubricant - can cause foaming. Loose drain plug, or sealant not replaced on drain plug at refitting.
Replace/Repair as required
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01/2003 2003.0 BA Falcon
205-00-7
Driveline System — General Information
205-00-7
DIAGNOSIS AND TESTING (Continued) Condition Excessive Backlash
Source Worn axle shaft or halfshaft splines. Loose wheel nuts. Loose universal or constant velocity propshaft joint flange mountings. Excessive backlash in either the differential or hypoid gears. Bearings worn or incorrectly adjusted. Worn or loose constant velocity halfshaft joints (IRS).
Bearing Noise Defective bearings can produce a whine that varies in proportion to vehicle speed. This will help distinguish between bearing and/or gear noise. 1. Pinion bearing noise can be identified as a constant grinding noise. Pinion bearings are rotating at a higher speed than differential side bearings or axle shaft bearings. The noise is most noticeable during light acceleration between 30 to 40 km/h. 2. Wheel bearing noise may be confused with rear axle noise. To differentiate between wheel bearings and rear axle, drive the vehicle on a smooth road at a medium low speed. With traffic permitting, turn the vehicle sharply right and left. If noise is caused by wheel bearings, the noise will increase on the defective bearings because of side loading. 3. Side bearings will produce a constant grinding noise of a slower nature than pinion bearing, (side bearing noise cannot be determined by the wheel bearing test), but will be of a similar frequency as axle shaft bearings.
Gear Tooth Contact Pattern Check Paint the gear teeth with suitable gear marking compound. Wrap a cloth around the drive shaft to act as a brake. Rotate the ring gear back and forth (use a box wrench on the drive gear attaching bolts for a lever) until a clear tooth contact pattern is obtained (approximately 4 ring gear rotations in both directions). After diagnosing the tooth pattern, make the appropriate adjustments as explained in the following pages. Drive and coast patterns indicating changes required to obtain the correct operating position of the gears is illustrated in the “ideal tooth contact pattern on ring gear” diagram. The movement of tooth contact patterns with changes in gear location can be summarised as follows: 1. Decreasing backlash moves the drive gear closer to the pinion: Drive pattern (convex side of gear) moves slightly lower and toward the toe. Coast pattern (concave side of gear) moves lower and toward the toe.
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Action Replace/Repair as required
2. Increasing backlash moves the drive gear away from the pinion: Drive pattern moves slightly higher and toward the heel. Coast pattern moves higher and toward the heel. 3. Thicker pinion shim with the backlash constant moves the pinion closer to the driver gear. Drive pattern moves deeper on the tooth (flank contact) and slightly toward the toe. Coast pattern moves deeper on the tooth toward the heel. 4. Thinner pinion shim with the backlash constant moves the pinion further from the drive gear: Drive pattern moves toward the top of the tooth (face contact) and toward the heel. Coast pattern moves toward the top of the tooth and slightly toward the toe. If the patterns are not correct, make the changes as indicated. When the pattern is correct, remove the marking compound from the gear teeth. Regardless of all previous measurements and other factors, the tooth contact pattern must be correct for successful rear axle operation. The Ideal Tooth Pattern The ideal tooth pattern is not a rigid standard but merely a general rule. In general, desirable tooth patterns should have the following characteristics: The drive pattern should be fairly well centred on the tooth. The coast pattern should be centred on the tooth but may be slightly toward the toe. Some clearance between the pattern and the top of the tooth is desirable. There should be no hard lines where the pressure is high. The individual gear set need not conform exactly to the ideal pattern in order to be acceptable. Characteristic differences between individual gear sets will result in patterns that are acceptable yet different from those illustrated.
01/2003 2003.0 BA Falcon
205-00-8
Driveline System — General Information
205-00-8
DIAGNOSIS AND TESTING (Continued) Ideal Tooth Contact Pattern on Ring Gear
Acceptable Pattern Faulty gear set. The drive pattern shown was rolled on a hunting-type Shim and Backlash Changes gear set. Since each pinion tooth came into contact with each ring gear tooth, the pattern is a result of the The patterns shown are typical of gear sets that have combined tooth contacts. Therefore, the pattern is either an incorrect backlash or an incorrect shim uniform from tooth to tooth. adjustment. Since each gear set rolls a characteristic pattern, the patterns shown should be considered as Acceptable Gear Tooth Contact Pattern typical only and should be used as a guide rather than a rigid standard. The drive pattern is rolled on the convex side of the tooth, and the coast pattern is rolled on the concave side.
Unacceptable Pattern An erratic tooth pattern on a hunting gear set indicates gear set runout and is caused by one of the following conditions: Foreign matter between differential hemisphere gear locating base and back face of crown wheel.
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01/2003 2003.0 BA Falcon
205-00-9
Driveline System — General Information
205-00-9
DIAGNOSIS AND TESTING (Continued) Typical Gear Tooth Contact Patterns Indicating Shim or Backlash Change
2. Chock the front wheels. 3. Raise the rear of the vehicle, remove one rear For information regarding driveline, Refer to Section wheel and attach the Special Tool No. E6662. 205-01. 4. Lower the rear of the vehicle to simulate normal Limited Slip Differentials (M78 & M86) ride height (ie. For IRS, lower arms should be horizontal to the ground). Cone Chatter 5. Place the transmission in neutral and release the When encountering complaints of limited slip cone park brake. chatter, the vehicle should be warmed up for 10 6. Ensure that there is no brake drag affecting wheel minutes and then driven in tight circles (slightly less rotation. than full steering lock), five times clockwise and five times anti-clockwise at approximately 10 km/h to allow 7. Attach a torque meter to the special tool, and rotate the axle. lubricant to work in between the cone friction surfaces. The torque required to rotate the axle shaft for a used M78 L.S.D. unit should be between 50 and 130 Nm. If the chatter persists, drain the lubricant, refill the axle Reading should be steady within 10 Nm. with the specified lubricant and repeat the aforesaid The torque required to rotate the axle shaft for a used procedure. It may be necessary to drive the vehicle M86 L.S.D. unit should be between 50 and 130 Nm. 10-20 km before re-evaluating to allow the new lubricant to take affect. Should chatter still be evident, Reading should be steady within 10 Nm. dismantling of the differential for further inspection and repair will be necessary. A whirring sound due to over-running of the cones is no indication of LSD unit failure.
Driveline Vibration
In Vehicle Limited Slip Differential Torque Testing To test the Limited Slip Differential (LSD) for correct operation proceed as follows: 1. Drive vehicle 10 km to warm up axle oil. G77667 en
01/2003 2003.0 BA Falcon
205-00-10
Driveline System — General Information
205-00-10
DIAGNOSIS AND TESTING (Continued) Drive Pinion Flange Check the flange mating face for damage and wear. The end of the flange contacting the bearing cone and the seal surface must be free from surface imperfections like burrs and scoring. Carrier Casting Make sure that the differential bearing bores are smooth and the differential bearing preload spacer abutment faces are not damaged.
If the torque required to continuously rotate the wheel is outside the specification check the differential for improper assembly and/or rework.
Inspection after Removal & Dismantling Thoroughly clean all parts. Always use new solvent when cleaning bearings. Oil the bearings immediately after cleaning to prevent rusting. Inspect the parts for any major defects. Clean the inside of the case, particularly the oil ports, before rebuilding and installing. Inspect individual parts as outlined below. Hypoid and Differential Gears The pattern taken during dismantling should help in judging if the gears can be re-used. Worn gears cannot be rebuilt to correct a noisy condition. Gear scoring is the result of excessive shock loading or the use of an incorrect lubricant. Scored gears must be replaced. Examine the teeth and thrust surface of the differential gears. NOTE: Check the fit of the side gear hubs in the case on M78 conventional differentials. Wear on the hub of the side gear can cause a “chuckling” noise known as “chuckle” when the vehicle is driven at low speeds. Wear on splines, thrust surfaces, or thrust washers can contribute to excessive driveline backlash. Bearings Check bearing cups for rings, scores, galling or erratic wear patterns. Pinion bearing cups must be solidly seated. Check by attempting to insert a 0.05 mm feeler between the cups and the bottom of their bores. The cone and roller assemblies on the differential case and the rear cone and roller on the pinion should be checked before being removed from the differential case or pinion. When these cones and rollers have been removed the cones and rollers and their respective bearing cups should be discarded. When revolved in the cups, bearing rollers must turn without roughness. Examine the roller ends for wear. Stepwear on the roller ends indicates the bearing preload was incorrect or the rollers were slightly misaligned.
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Differential Case Carefully examine the case bearing hubs for damage. The bearing assemblies will fail if they do not seat against the shoulder on the hubs correctly. Limited Slip Differential (LSD) For M78 LSDs, thoroughly clean and dry all parts and check the following: The cone seats in the case should be smooth and free from excessive scoring. Slight grooves or scratches are permissible and normal. The land surfaces of the cones will duplicate the case surface condition. Excessive wear or damaged cone surfaces will necessitate renewal of the cone and casing. Inspect thrust springs for damage. Replace where necessary. Check the thrust blocks for excessive wear. Replace where necessary. For M86 LSDs, thoroughly clean and dry all parts and check the following: The LSD plates and disc must be in good condition. If any one member of either stack shows evidence of excessive wear or scoring, the complete stack is to be replaced on both sides of the assembly. Side and pinion gears should be checked for extreme wear and possible cracks. The external teeth of the side gear, which retain the concentric groove discs, should also be checked for wear or cracks. If replacement of one gear is required due to wear, etc., then both side gears, pinion mate gears, and washers are to be replaced. If excessive wear is evident on the cross pin, it should be replaced. If wear is evident on any one of the clutch retainer clips, all four clips must be replaced. If scoring, wear or metal pick-up is evident on the machined surfaces of the differential case, then replacement of the case is necessary.
01/2003 2003.0 BA Falcon
205-01-1
Driveshaft
205-01-1
SECTION : 205-01 Driveshaft VEHICLE APPLICATION : 2003.0 BA Falcon CONTENTS
PAGE
SPECIFICATIONS Specifications .........................................................................................................................205-01-2 DESCRIPTION AND OPERATION Driveshaft ...............................................................................................................................205-01-3 Universal Joints ......................................................................................................................205-01-3 DIAGNOSIS AND TESTING Driveshaft ...............................................................................................................................205-01-4 Inspection and Verification ...................................................................................................205-01-4 Symptom Chart ....................................................................................................................205-01-5 GENERAL PROCEDURES Take — Off Shudder ..............................................................................................................205-01-6 REMOVAL AND INSTALLATION Driveshaft Assembly ..............................................................................................................205-01-7 DISASSEMBLY AND ASSEMBLY Flex Joint Replacement .........................................................................................................205-01-8 Universal Joint Replacement .................................................................................................205-01-8 Centre Bearing Replacement .................................................................................................205-01-9 CV Joint Replacement .........................................................................................................205-01-10
01/2003 2003.0 BA Falcon
205-01-2
Driveshaft
205-01-2
SPECIFICATIONS Two Piece General Specifications Description Specification Constant velocity joint Supplied in CV Kit grease Constant velocity joint 262 Loctite loctite for bolts Two Piece Torque Specifications Description Centre bearing bolts (x2) Constant velocity joint bolts (x6) Flexible coupling nuts / bolts (x6) End yoke lock nut (x1)
Nm 36 (±7) 72 (±13) 77 157 (±20)
Single Piece Torque Specifications Description Single piece U/J comp
Nm 82.5 (±7.5)
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01/2003 2003.0 BA Falcon
205-01-3
Driveshaft
205-01-3
DESCRIPTION AND OPERATION
Driveshaft The driveshaft is the means of transferring power from the engine to the differential in the rear axle and then to the rear wheels. The two piece Drive shaft in corporates a flex coupling (with slip flange) centre bearing, a universal joint and a constant velocity joint with the ability to plunge. The single piece Drive shaft incorporates two Universal joint mounted at each end. The plunging CV (two piece) (& to some degree, the slip splines) allows lateral movement of the driveshaft components & assembly as the diff moves up & down. CAUTION: All driveshafts are balanced. If the vehicle is to be undercoated, cover the driveshaft to prevent application of the undercoating material.
Universal Joints The single center joint is: a lubed-for-life design that requires no periodic lubrication. equipped with nylon thrust washers, located at the base of each bearing cup, which control end play, position the needle bearings and improve grease movement.
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01/2003 2003.0 BA Falcon
205-01-4
Driveshaft
205-01-4
DIAGNOSIS AND TESTING
Driveshaft Inspection and Verification Driveline Vibrations Characteristics of driveline vibrations: high frequency. worse on acceleration or rapid deceleration. usually described as a ‘droning’ noise. often more noticeable from the rear seat of the vehicle. Driveline vibrations can originate from wear of bearings or damage to the driveshaft. Damage and wear may produce vibrations due to the fact that the components will be rotating on a centre other than the centre of balance.
Driveshaft Inspection Driveshaft Runout The driveshaft runout is measured at the centre of the shaft and at 130 mm from the weld at each end. NOTE: Be careful not to offset shaft at centre bearing. Maximum Runout Specification Driveshaft in vehicle . . . . . . Not Recommended Driveshaft mounted on centres . . . . 0.42 (Ends) 0.35 (Middle) mm Driveshaft Balance The driveshaft balance specification is 9 gm. cm at 3200 rpm. The light side is marked with yellow paint on the rear yoke.
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01/2003 2003.0 BA Falcon
205-01-5
Driveshaft
205-01-5
DIAGNOSIS AND TESTING (Continued) Symptom Chart Symptom Chart Condition
Source
Action
Driveline vibration
Axle flange and driveshaft yellow paint marks not aligned. Undercoating or other foreign material on shaft. Universal joint strap/flange bolts loose. Universal joints worn, or lack of lubricant. Universal joint locating clip faces of pinion flange damaged. Broken rear spring centre bolt. Broken rear spring. Rear springs not matched (sagged to one side). Driveshaft damaged (bent) or out of balance (missing balance weights). Bearing cups improperly seated in pinion flange. Pinion flange run out. W orn or dry PCV. Eng/Trans/Diff mounts worn. Flex coupling/coupling bolts worn. Flex coupling bolts loose. Centre bearing bracket bolts loose.
Remove/Repair as required.
T/OFF Shudder
Coupling Bolts misallignment in Z.
See General Procedures "Take-Off Shudder"
U-Joint Noise
Universal joint strap/flange bolts loose. W orn U-joints.
Remove/Repair as required.
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01/2003 2003.0 BA Falcon
205-01-6
Driveshaft
205-01-6
GENERAL PROCEDURES
Take — Off Shudder NOTE: Take off shudder is characterised by a driveline vibration (felt in the driver / passenger seats), which peaks and abates between 15 - 25kph under heavy throttle applications. It is due to the misalignment of the centre bearing bracket in the ’Z’ (vertically) direction. 1. To eliminate take off shudder, follow the steps outlined below: Check engine/transmission/diff mounts for condition and correct location. If OK then proceed to next step. With vehicle on hoist, remove existing shims (if any) and re-torque bolts up to the floor brkt mounting surface. Using an Inclinometer, take the front and rear shaft angles. NOTE: Use the same inclinometer in the same orientation for each shaft, failing to do this will result in inaccurate measurements.
UJ Side view Angle (in degrees) (front shaft angle - rear shaft angle) -1.9° -1.8° -1.7° -1.6° (Optimal U/J angle) -1.5° -1.4° -1.3° -1.2° -1.1° -1.0° -0.9°
Actual shim required (mm) 5 4 4 3 3 2 2 1 1 0 0
Determine the resultant angle by subtracting the front shaft angle from the rear shaft angle (ie front shaft angle - rear shaft angle). Use look-up table below to determine shim size required. Loosen CB bolts, and assemble correct determined shims, re-torque bolts to 36Nm (±7Nm). Using an Inclinometer, take the front and rear shaft angles. NOTE: Use the same inclinometer in the same orientation for each shaft, failing to do this will result in inaccurate measurements. Check if front and rear resultant angle is at the optimal figure (-1.6°). Take vehicle for short run on safe roads and do two WOT runs to 25kph to verify fix. UJ Side view Angle (in degrees) (front shaft angle - rear shaft angle) -3.0 -2.9 -2.8 -2.7 -2.6° -2.5° -2.4° -2.3° -2.2° -2.1° -2.0° G96424 en
Actual shim required (mm) 10 10 9 9 8 8 7 7 6 6 5 01/2003 2003.0 BA Falcon
205-01-7
Driveshaft
205-01-7
REMOVAL AND INSTALLATION Installation 1. If the seal installed on the end of the transmission NOTE: If assembling or disassembling any part of the extension housing is damaged in any way, install driveshaft asy then either a driveshaft or system a new seal. re-balance is recommended. 2. Lubricate the slip spline with transmission lubricant. Install the slip spline on the transmission NOTE: Before disassembly mark location (and output shaft. weight) of clip on balance weights (if fitted). 3. Match the alignment marks and locate the CV Re-assemble in original position. joint, bolts and balance weights to the companion NOTE: Before disassembly check if Centre Bearing flange and CV bolts. Torque 72Nm (+/- 13Nm). shims are present and retain for re-assembly. 4. Locate the center bearing bracket on the body. Torque to 36Nm (+/- 7Nm). NOTE: The driveshaft rear CV and the pinion flange of the axle have yellow paint alignment marks that are assembled as close together as possible. If these are not visible, mark the CV and the flange so that they may be installed in their original positions.
Driveshaft Assembly
Removal
Item 1 2 3 4 5 6 7 8 9
Description Flex Driveshaft Centre bearing assembly Universal joint Driveshaft CV assembly Differential assembly Bolt transmission assembly
1. Locate Jack or transmission stand at centre bearing to support before removal. 2. Disconnect the rear CV joint from the pinion flange. 3. Disconnect the Centre-Bearing closing bracket from the body. Pull the driveshaft toward the rear of the vehicle until the front Flex Coupling slip spline clears the transmission extension housing and the seal. NOTE: To prevent oil loss and ingress of foreign material plug the extension housing with a mainshaft dust cover or slip flange. G96425 en
01/2003 2003.0 BA Falcon
205-01-8
Driveshaft
205-01-8
DISASSEMBLY AND ASSEMBLY
Flex Joint Replacement
Universal Joint Replacement
Disassembly and Assembly
NOTE: Procedure can be used for single piece slip yoke/tube yoke removal as well. NOTE: To maintain driveline balance, mark the slip flange in relation to the Driveshaft so that they may be External Clip Type U-Joint installed in their original positions. NOTE: The arrows molded into the flex coupling must always be pointing to the slip or tube flange arms. Otherwise premature failure of the component will occur.
Item 1 2 3 4 5 6 7
Description Driveshaft Slip yolk assembly Snap ring Bearing Driveshaft U-joint assembly Nut
1. Remove the retaining bolts from the flex joint to shaft and flex joint to slip flange. 2. Replace flexible coupling, ensuring arrows (moulded in flex rubber) are pointing to the slip or tube flange arms and locate spigot to shaft. Reinstall new nuts and bolts (from service kit) and Disassembly Torque to 77 Nm. NOTE: If there is any damage to alignment bush NOTE: To maintain drive line balance, mark the relation of the slip yoke and the pinion flange on the on slip flange then replace slip flange. axle, with the shaft so that they may be installed in their original positions. 1. Remove the clips that retain the bearings in the yoke. Apply penetrating oil to the bearing cups to assist removal if required. 2. Using a “G” clamp and suitable adaptors, or similar equipment, press on one of the bearing cups so as to drive the opposite bearing from the yoke. NOTE: All hardware must be correctly installed and torqued to specification.
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01/2003 2003.0 BA Falcon
205-01-9
Driveshaft
205-01-9
DISASSEMBLY AND ASSEMBLY (Continued) 3. Remove the bearing from the spider, rotate the shaft 180° and remove the second bearing. Detach the yoke from the shaft.
Centre Bearing Replacement NOTE: To maintain driveline balance, mark the relation of the Universal joint end yoke to front and rear shafts so that they may be installed in their original position. NOTE: Do not use impact/rattle gun on centre bearing bolts as you will run the risk of stripping the thread in the nut located inside the body. NOTE: It is important to keep and replace original CB shims. Disassembly and Assembly
4. Repeat this procedure to remove the bearings from the yoke and rear of the shaft. Assembly 1. Position the spider in the yoke. Lift the spider to one side of the yoke and locate a bearing cup on the spider. While holding the spider in the bearing press the bearing into the yoke until the clip can be installed on the bearing. Install the clip. 2. Rotate the yoke 180° and install the other bearing while holding the spider into the bearing to prevent the needle rollers from being dislodged. Item Description The bearing cups are fitted with plastic pads that impart a preload on the ends of the spider. These 1 Shims pads must be compressed by use of a “G” clamp 2 Centre bearing bracket assembly or vice. Tap the yoke to seat the clip previously 3 Bolt fitted and install the remaining clip. 1. Remove Universal joint as directed. 3. Repeat this procedure to install the remaining bearings in the shaft. 2. Remove locking nut retaining end yoke flange to drive shaft, press off end yoke from front shaft. 3. Press Centre Bearing from shaft and Replace. 4. Press fit end yoke and new lock nut and torque to 157Nm (+/- 20Nm). NOTE: Careful not to apply force to other race of bearing.
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01/2003 2003.0 BA Falcon
205-01-10
Driveshaft
205-01-10
DISASSEMBLY AND ASSEMBLY (Continued)
CV Joint Replacement NOTE: To maintain balance mark all bolts and weights in reference to the companion flange. Disassembly
Item 1 2 3
Description CV Companion flange Bolt
Item 1 2 3 4 5 6 7 8 9
Description Stub Shaft Boot Clamp Boot Asy Grease Steel Gasket CV Joint Asy Cork Gasket Circlip Grease Cover
4. Using bearing puller (tool number ?) press CV joint from shaft. 5. Remove boot from shaft. Assembly 1. Inspect boot for damage and/or holes. 2. Take care whilst sliding boot onto stub shaft. A small amount of CV joint grease may be used as a lubricant. 3. Place metal sealing gasket inside boot can, keep bolt holes aligned. 4. Press CV onto stub shaft using unique tool (tool number ?), push on CV joint inner race. Ensure double grooves on CV joint body are toward the boot can. 5. Seat retainer circlip. 6. Pack joint with 60g of lubricant (supplied with CV kit) throughout cage and races. 7. Seat CV boot can onto CV joint body, ensuring bolt, and metal sealing gasket hole alignment, and relieve any twist in the boot. 8. Remove backing and place self-adhesive cork gasket (supplied with CV kit) into stepped recess on CV joint face, aligning bolt holes. Placing bolts through CV Joint as a guide to gasket alignment. Gasket alignment is critical to sealing integrity. 9. Seat rear can onto CV again ensuring bolt holes are aligned. 10. Clamp boot in location as shown in figure. 11. Bolts to be torqued to 72Nm (+/- 13Nm). Opposite bolts to be torqued until all reach spec.
1. Follow steps to remove drive shaft. 2. Remove end cap from CV joint, grease can and remove retaining clip. 3. Using a hammer and soft punch remove the boot can forwards from the CV joint. G96429 en
01/2003 2003.0 BA Falcon
205-02A-1
Rear Drive Axle / Differential — Beam Axle
205-02A-1
SECTION : 205-02A Rear Drive Axle / Differential — Beam Axle VEHICLE APPLICATION : 2003.0 BA Falcon CONTENTS
PAGE
SPECIFICATIONS Specifications .......................................................................................................................205-02A-2 DESCRIPTION AND OPERATION 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 DIAGNOSIS AND TESTING Rear Drive Axle / Differential — Beam Axle ......................................................................205-02A-12 GENERAL PROCEDURES In Vehicle Inspection .........................................................................................................205-02A-14 Beam Axle Oil Change .....................................................................................................205-02A-14 Flange Runout Check ........................................................................................................205-02A-15 In Vehicle Torque Check ...................................................................................................205-02A-15 Limited Slip Differential — M78 & M86 Check .................................................................205-02A-15 Limited Slip Differential Torque Check ..............................................................................205-02A-16 Limited Slip Differential — M86 Inspection for Wear .........................................................205-02A-16 Limited Slip Differential — M78 .........................................................................................205-02A-17 IN-VEHICLE REPAIRS Pinion Oil Seal Replacement .............................................................................................205-02A-18 REMOVAL AND INSTALLATION Axle Shaft Assembly ..........................................................................................................205-02A-19 M86 Limited Slip Differential ..............................................................................................205-02A-20 Axle Housing and Differential Assembly ...........................................................................205-02A-21 DISASSEMBLY AND ASSEMBLY Rear Axle Wheel Bearing and Seal Replacement .............................................................205-02A-24 Differential and Drive Pinion ..............................................................................................205-02A-26 Differential Bearing Preload Spacer Selection ..................................................................205-02A-27 Drive Pinion Position — Shim Selection ............................................................................205-02A-28 Drive Pinion and Bearings .................................................................................................205-02A-29 Differential Installation and Backlash Check .....................................................................205-02A-30 Differential Case — Conventional Type M78 and M86 .....................................................205-02A-30 Limited Slip Differential — M78 .........................................................................................205-02A-31 Limited Slip Differential — M86 .........................................................................................205-02A-32
01/2003 2003.0 BA Falcon
205-02A-2
Rear Drive Axle / Differential — Beam Axle
205-02A-2
SPECIFICATIONS General Specifications Description Specification Rear Axle Lubrication (Level with bottom of filler plug hole with vehicle at curb height.) Model 78 CONVENTIONAL Grade SAE 90 Hypoid Ford Specification ESW-M2C108-A Capacity 1.70 litre LIMITED SLIP Grade SAE 90 EP Ford Specification ESW-FM2C-1006-B Capacity 1.60 litre + 100ml Sturaco 7098 Additive Model 86 CONVENTIONAL Grade Mobilube SHC ID Ford Specification ESZ-FM2C190-A Capacity 1.9 litre LIMITED SLIP Grade Mobilube SHC ID Ford Specification ESZ-FM2C190-A Capacity 1.86 litre + 40ml Duraphos Mobil M3022 BEARING PRELOADS New Bearings Nm Differential — Measured without axle 0.6-1.9 shafts or pinion Pinion — With oil seal 1.5-2.1 — Without oil seal 1.5-1.9 Used Bearings Differential — Measured without axle 0.4-1.1 shafts or pinion Pinion — With oil seal 0.7-1.2 — Without oil seal 0.7-1.0 ADJUSTMENTS Pinion bearing preload Collapsible spacer adjustment. Differential bearing preload Selective spacer adjustment. Pinion depth of mesh Selective shim adjustment.
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Description Backlash between ring gear and pinion. Backlash variation between teeth. Maximum ring gear run out (assembled) Limited slip differential torque Model 78 New: (cone clutch type) Used: Model 86 New: (plate clutch type) Used:
Specification 0.13 to 0.18 mm 0.05 mm max. 0.13 mm
80-140 Nm 50-130 Nm 100-300 Nm 50-150 Nm
Torque Specifications Description Nm Ring gear bolts (L.H. Thread) 140 Bearing cap bolts 55 Differential case bolts (L.S.D.) 40 Rear cover bolts 30 Axle bearing retainer plate bolts 45 Spring ’U’ bolt nuts (Wagon) 60 * Track arms to body 75 * Track arms to pivot link 75 * Pivot link to axle housing cover 15 * Suspension arms to axle housing 75 * Suspension arms to body 75 * Shock absorber to spring plate 75 Caliper to bracket pin nuts 20 Splash shield screws 10 Shock absorber to spring plate nut 45 Stabiliser bar clamp bolt 20 Universal joint bolts 10 Vent - Rear axle housing 15 Pinion flange nut — Filler Plug 30 Drain Plug 30 * Items marked thus are to be tightened with the vehicle in the curb load position.
01/2003 2003.0 BA Falcon
205-02A-3
Rear Drive Axle / Differential — Beam Axle
205-02A-3
DESCRIPTION AND OPERATION
Rear Drive Axle / Differential — Beam Axle
Limited Slip Differential
This axle is a hypoid type of unitised carrier construction. The two pinion differential case and the Beam Axle Final Drive Identification drive pinion are mounted in opposed tapered roller bearings in the carrier. Differential bearing preload A label identifying the beam axle assembly part number, serial number, and final drive ratio is fixed to adjustment is provided by varying shim thicknesses behind the bearing cups. Pinion bearing preload is the axle tube adjacent to the rear cover. regulated by a collapsible spacer and adjusted using Two different model beam axles are used on wagon the pinion nut. and utility vehicles: Torque is transferred from the propshaft to the final 1. M78 beam axles are fitted with 3.23 or 3.45 7.75" drive assembly via the companion flange that is (197mm) diameter gear sets, with or without ABS splined to the hypoid pinion. Torque is then and with or without LSD’s. All M78 beam axles transferred from the pinion through the ring gear, whould be filled with lubricant as per the differential case, differential pinion cross shaft, Specifications. M78 LSD differentials are fitted differential pinions and side gears to the axle shafts. with a metal tag marked "SPIN RESISTANT DIFF. For M78 Limited Slip Differentials (LSDs), the USE APPROVED LUBRICANT ONLY". differential case houses two cone type clutches 2. M86 beam axles are fitted with 3.23 or 3.46 8.6" behind the side gears. These cones are splined to the (220mm) diameter gear sets, with or without ABS axle shafts, their tapered faces bearing on the and with or without LSD’s. M86 axles are fitted to differential case. Thrust springs pre-load the gears all vehicles powered by a V8 or turbo I6 engine. and cones, forcing the tapered face of the cones into All M86 beam axles should be filled with lubricant contact with the differential case. The partial locking as per the Specifications. Conventional M86 action, due to the spring load on the cones is differentials are fitted with a metal tag marked automatically increased by the inherent separating "HIGH PERFORMANCE. USE APPROVED forces between the side gears and pinion. This LUBRICANT ONLY". For LSD units, a metal tag locking action directs a portion of the driving force to marked "LSD - HIGH PERFORMANCE. USE the wheel with the greatest traction. APPROVED LUBRICANT & FRICTION MODIFIER" is attached under the filler plug on the M86 LSDs transfer torque in a similar manner as M78 LSDs, except that a multiplate oil bath type design is rear cover. utilised where alternate plates are splined to the NOTE: Upgrading the lubricating oil to synthetic type differential case and side gear. Preloading of the is recommended for vehicles fitted with a M86 beam plates provides frictional resistance to rotation, axle where the vehicle will be regularly used for providing torque transfer to the rear wheel with the towing. Refer to Specifications section for the greatest traction. recommended synthetic lubricant. The axle shafts are mounted using tapered roller bearings and held by retainer plates at the outer ends Conventional Differential of the axle housing. Axle shaft end play is pre-set and This axle is a hypoid type of unitised carrier is not adjustable. Oil seals are located between the construction. The two pinion differential case and the retainer plates and the bearing. drive pinion are mounted in opposed tapered roller With the conventional differential, when the rear bearings in the carrier. Differential bearing preload wheels are subject to highly unbalanced tractive adjustment is provided by varying shim thicknesses conditions such as one wheel on dry road and the behind the bearing cups. Pinion bearing preload is other in mud or ice, wheel spin will occur if over regulated by a collapsible spacer and adjusted using acceleration is attempted. However, with the limited the pinion nut. slip differential, when the tendency for wheel spin Torque is transferred from the propshaft to the final occurs, the friction generated between the cones and drive assembly via the companion flange that is the differential case (M78) or between the friction splined to the hypoid pinion. The torque is then plates (M86) transfers a portion of the driving torque transferred from the pinion through the ring gear, to the non-spinning wheel. differential case, differential pinion cross shaft, NOTE: (For M78 LSDs) In the event of continued differential pinions and side gears to the axle shafts spinning a whirring sound is produced due to for conventional differentials. over-running of the cones; such a condition or sound The axle shafts are mounted using tapered roller does not indicate failure of the unit. bearings and held by retainer plates at the outer ends of the axle housing. Axle shaft end play is pre-set and is not adjustable. Oil seals are located between the retainer plates and the bearing.
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01/2003 2003.0 BA Falcon
205-02A-4
Rear Drive Axle / Differential — Beam Axle
205-02A-4
DESCRIPTION AND OPERATION (Continued) Differential Assembly and Pinion Bearings This bearing is a single row, pre-set tapered roller bearing capable of accepting thrust loads and radial loads in any combination. The tapered roller bearing consists of four basic parts: the cup or outer race, the cone or inner race, the tapered rollers which roll freely between the cup and cone, and the cage which serves as a retainer to maintain the proper spacing between the tapered rollers grouped around the cone.
Wheel Bearings This bearing is a single row, pre-set tapered roller bearing capable of accepting thrust loads in either direction and radial loads in any combination. The tapered roller bearing consists of five basic parts: the cup or outer race, the cup rib ring, the cone or inner race, the tapered rollers which roll freely between the cup and cone, and the cage which serves as a retainer to maintain the proper spacing between the tapered rollers grouped around the cone. When the bearing is manufactured, the cup and rib ring are bonded together with an adhesive to facilitate bearing handling and installation. Since the cup and rib ring are clamped together in the axle housing, there is no need for a permanent bond. When the bearing is serviced the cup will usually be separated from the rib ring.
Item 1 2 3 4 5
Description Cup Cup rib ring Rollers Cone Cage
G98771 en
01/2003 2003.0 BA Falcon
205-02A-5
Rear Drive Axle / Differential — Beam Axle
205-02A-5
DESCRIPTION AND OPERATION (Continued) M86 Beam Rear Axle Assembly
G98771 en
01/2003 2003.0 BA Falcon
205-02A-6
Rear Drive Axle / Differential — Beam Axle
205-02A-6
DESCRIPTION AND OPERATION (Continued) Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
Description Axle & brake retaining bolt (8 off) Park brake assembly Inner bearing retainer Axle shaft oil seal Axle shaft wheel bearing Outer bearing retainer ABS tone wheel Wheel Stud (5 off each side) Axle shaft Differential bearing cap bolts (4 off) Differential bearing caps (2 off) Carrier and tube assembly Filler plug & gasket Drain Plug Lubricant tag Rear cover Differential position shim Differential bearing (cup and cone) Ring gear bolt (8 off) Differential case Rear pinion bearing (cup & cone) Pinion position shim Collapsible preload control spacer Front pinion bearing (cup & cone) Pinion oil seal Companion flange assembly Pinion nut Hypoid gearset (Ring gear & pinion) Load level bracket Park brake cable clips (2 off) Rear cover bolts
G98771 en
01/2003 2003.0 BA Falcon
205-02A-7
Rear Drive Axle / Differential — Beam Axle
205-02A-7
DESCRIPTION AND OPERATION (Continued) M78 Beam Rear Axle Assembly
G98771 en
01/2003 2003.0 BA Falcon
205-02A-8
Rear Drive Axle / Differential — Beam Axle
205-02A-8
DESCRIPTION AND OPERATION (Continued) Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
Description Axle & brake retaining bolt (8 off) Park brake assembly Inner bearing retainer Axle shaft oil seal Axle shaft wheel bearing Outer bearing retainer ABS tone wheel Wheel Stud (5 off each side) Axle shaft Differential bearing cap bolts (4 off) Differential bearing caps (2 off) Carrier and tube assembly Filler plug & gasket Drain Plug Lubricant tag Rear cover Differential position shim Differential bearing (cup and cone) Ring gear bolt (8 off) Differential case Rear pinion bearing (cup & cone) Pinion position shim Collapsible preload control spacer Front pinion bearing (cup & cone) Pinion oil seal Companion flange assembly Pinion nut Hypoid gearset (Ring gear & pinion) Load level bracket Park brake cable clips (2 off) Rear cover bolts
G98771 en
M86 Conventional Differential Assembly
Item 1 2 3 4 5 6 7
Description Case Differential pinion thrust washer Differential Pinion Side gear thrust washer Side gears Differential shaft Lock pin
01/2003 2003.0 BA Falcon
205-02A-9
Rear Drive Axle / Differential — Beam Axle
205-02A-9
DESCRIPTION AND OPERATION (Continued) M78 Conventional Differential Assembly
Item 1 2 3 4 5 6 7
Description Case Differential pinion thrust washer Differential Pinion Side gear thrust washer Side gears Differential shaft Lock pin
G98771 en
01/2003 2003.0 BA Falcon
205-02A-10
Rear Drive Axle / Differential — Beam Axle
205-02A-10
DESCRIPTION AND OPERATION (Continued) M86 Limited Slip Differential Assembly
Item 1 2 3 4 5 6 7 8 9
Description Case Side Gear Pinion mate spherical washers Retainer Clip Clutch Disc Clutch Plate Differential Shaft Differential Pinion Roll pin
G98771 en
01/2003 2003.0 BA Falcon
205-02A-11
Rear Drive Axle / Differential — Beam Axle
205-02A-11
DESCRIPTION AND OPERATION (Continued) M78 Limited Slip Differential Assembly
Item 1 2 3 4 5 6 7 8 9
Description Case Cone Spring washer Differential Pinion thrust washer Differential Pinion Gears Lock pin Side Gear thrust washer Side Gears Differential Shaft
G98771 en
01/2003 2003.0 BA Falcon
205-02A-12
Rear Drive Axle / Differential — Beam Axle
205-02A-12
DIAGNOSIS AND TESTING
Rear Drive Axle / Differential — Beam Axle Refer to Section 205-00.
Special Tool(s) Knife edge puller 205-410 (1123)
Special Tool(s) Differential Housing Spreader E9255 Installer drive pinion rear bearing 205-411 (E3C10AER) Adaptors differential Housing Spreader E9040 Jaw remover differential side bearing 205-410 (E1673H15) Kit drive pinion setting gauge 205-406 (E9300A) Installer differential side bearing spline axle 205-412 (E3C25) Press bolster 205-408 (E1673MT) Installer differential side bearing 28 spline axle 205-412 (E9277) Push - Puller, includes 6 ¼" (158mm) legs 205-408 (927) Base plate remove replace axle bearing 888-300 (E1721) Stepped plug-remover differential side brg. 666-777 (E1673C16) Remove installer axle bearing and bearing retainer (Alternate) Jaw remover drive pinion rear bearing 205-408-01(E1673A15)
G98772 en
01/2003 2003.0 BA Falcon
205-02A-13
Rear Drive Axle / Differential — Beam Axle
205-02A-13
DIAGNOSIS AND TESTING (Continued) Special Tool(s)
Special Tool(s) Installer drive pinion oil seal 205-414 (E9055)
IRS wheel bearing and hub remover installer 205-446
Kit - installer drive pinion bearing cups 666-500 (E9271)
IRS differential plugs 205-294
LSD torque check tool 888-200 (7372) 666-000 (E6662B)
Constant velocity boot clamp remover 205-343
Half shaft removal tool 205-465
LSD spline alignment 205-415 (E9293)
Remover drive pinion bearing cup 205-415 (E9293)
Remover pinion/flange (E9258B) Companion flange holder 777-111 (EN1205B)
G98772 en
01/2003 2003.0 BA Falcon
205-02A-14
Rear Drive Axle / Differential — Beam Axle
205-02A-14
GENERAL PROCEDURES 9. If no obvious defect is noted, check the gear tooth contact. Paint the gear teeth with suitable gear NOTE: The differential case assembly and the drive marking compound, such as a Henkel 39SY201 pinion should be inspected before they are removed Yellow Gear Marking Compound or similar. from the housing. These inspections can help to find Too dry a mixture cannot be pressed out from the cause of the trouble and to determine the between the teeth. Wrap a cloth around the corrections needed. companion flange to act as a brake. Rotate the ring gear back and forth (use a box wrench on the Removal drive gear attaching bolts for a lever) until a clear 1. Raise the vehicle on a hoist. tooth contact pattern is obtained (approximately three full revolutions in both directions). 2. Check for any external oil leaks. Note location and NOTE: A mixture that is too wet will run and replace oil seals, gaskets or breather hoses as smear. required to fix the leak(s). 3. Drain the lubricant by carefully removing the lower 10. Certain types of gear tooth contact patterns on cover bolt which is the drain plug. the drive gear indicate incorrect adjustment. Noise Clean the area immediately around the rear cover caused by incorrect adjustment can often be of all loose dirt and contaminates. corrected by re-adjusting the gears. Typical NOTE: When replacing the drain plug, clean the patterns and the necessary corrections are thread of old thread sealant (Loctite Dri-Loc 202 explained in Section 308-03. or similar) and reapply to ensure that the plug 11. Gear tooth runout can sometimes be detected by seals correctly. an erratic pattern on the teeth. However, a dial indicator should be used to measure the runout of 4. Remove the rear cover. Scrape the rear cover the back face of the ring gear, as shown. This gasket off the carrier cover mounting surface, runout should not exceed 0.13 mm. making sure that no dirt is allowed to enter the carrier housing. Ring Gear Runout Check (Typical) 5. Wipe the lubricant from the internal working parts, and visually inspect the parts for wear or damage. 6. Rotate the gears to see if there is any roughness that would indicate defective bearings or chipped gears. Check the gear teeth for scoring or signs of abnormal wear. 7. Check the differential case and the drive pinion for end play. 8. Set up dial indicator and check points around drive gear. Backlash should be 0.10 to 0.18 mm at tightest point.
In Vehicle Inspection
Ring Gear Backlash Check (Typical)
Beam Axle Oil Change 1. Raise the vehicle so that it remains completely level. 2. Remove the bottom rear cover flanged bolt from the beam axle to drain oil. NOTE: It is preferable to drain the oil while it is warm so that any wear debris can drain out more easily. 3. Apply thread sealant compound (eg. Loctite Dri-Loc 211 or 202) to the cover bolt, refit and tighten to 23-31 Nm. 4. Remove the lubrication tag, gasket and filler plug located on the rear cover. 5. Fill the beam axle with the appropriate lubricant (Refer to Specifications section). 6. Check the condition of the filler plug gasket to ensure proper oil sealing function of filler plug. G98773 en
01/2003 2003.0 BA Falcon
205-02A-15
Rear Drive Axle / Differential — Beam Axle
205-02A-15
GENERAL PROCEDURES (Continued) 7. Replace lubrication tag, gasket and filler plug and tighten to 23-31 Nm.
Flange Runout Check
Limited Slip Differential — M78 & M86 Check
CAUTION: Never place the transmission in gear with the engine running when only one wheel of a limited slip differential equipped vehicle is raised. The vehicle might drive itself off the jack and cause demage or injury. 1. The LSD construction permits differential action when required for turning comers and transmits equal torque to both wheels when driving straight ahead. However, when one wheel tries to spin due to leaving the ground, a patch of ice, etc., the clutch packs automatically provide more torque to the wheel which is not trying to spin. In Vehicle Torque Check 2. The LSD differential resists wheel spin on bumpy 1. To test the Limited Slip Differential (LSD) for roads and provides more pulling power when one correct operation proceed as follows: wheel tries to slip. In many cases of differences in Drive vehicle 10 km to warm up axle oil. traction, pulling power will be automatically provided until both wheels start to slip. Chock the front wheels. 3. In diagnosis of vehicle operators’ complaints, it is Raise the rear of the vehicle, remove one rear important to recognise two things: wheel and attach the Special Tool No. E6662B. 1. If, with unequal traction, both wheels slip, the LSD has done all it can possibly do. Lower the rear of the vehicle to simulate normal ride height. 2. In extreme cases of differences in traction, the wheel with the least traction may spin after Place the transmission in neutral and release the LSD has transferred as much torque as the park brake. possible to the non-slipping wheel. Ensure that there is no brake drag affecting 4. If noises or roughness, such as chatter, are wheel rotation. present during cornering, the probable cause is Attach a torque meter to the special tool, and incorrect or contaminated lubricant (Refer rotate the axle. Specification section for recommended axle 2. The torque required to rotate the axle shaft for a lubricants and additive). Before any differential is used LSD unit is detailed in the Specifications removed and disassembled for chatter section. complaints, the correctness of lubricant can and should be determined. 5. To confirm the problem, warm up the axle for ten (10) kms under normal driving conditions and then make a minimum of ten (10) figure 8 turns. If the unit chatters then replace the axle lubricant with new lubricant. If after changing the lubricant and repeating the above figure 8 procedure, the chatter continues, a complete lubricant drain, flush and refill is required. 6. The following procedure is recommended to ensure flushing the system of old lubricant. 1. Warm the axle lubricant for ten (10) kms under normal driving conditions. 2. Drain lubricant while warm. 3. If the torque required to continuously rotate the 3. Refill axle with specified Limited Slip wheel is outside the specification check the Differential lubricant and/or additive. differential for improper assembly and/or rework. 4. Drive the vehicle for approximately ten (10) kms, making at least ten (10) figure 8 turns to flush the old lubricant out of the differential. 1. Raise the vehicle on a hoist with the wheels unsupported. Disconnect the drive shaft from the drive pinion flange after marking the drive shaft and pinion flange to ensure correct radial positioning on re-assembly. (Refer Section 205-01.) 2. Using a dial indicator mounted in the carrier housing, check the mounting face runout and the radial runout of the drive pinion flange. Refer to Specifications section for applicable runout limits.
G98776 en
01/2003 2003.0 BA Falcon
205-02A-16
Rear Drive Axle / Differential — Beam Axle
205-02A-16
GENERAL PROCEDURES (Continued) 5. Repeat Steps 2, 3, and 4. 6. It is possible that slight chatter, requiring additional vehicle operation may remain after Step 5. If chatter still persists after one hundred (100) kms of vehicle operation, or remains severe after Step 5 above, disassembly and repair will be necessary. Follow procedures for disassembly and assembly as illustrated in the manual.
2. Side gears and pinion mate gears — The gear teeth of these parts should be checked for extreme wear and possible cracks. The external teeth of the side gear, which retain the concentric groove discs, should also be checked for wear or cracks. 3. If replacement of one gear is required due to wear, etc., then both side gears, pinion mate gears, and washers are to be replaced. Pin - If excessive wear is evident, the cross Limited Slip Differential Torque Check 4. Cross pin should be replaced. 1. Clamp Special Tool or an axle shaft in a vice with 5. Clutch Retainer Clips — If wear is evident on any approximately 75mm of the splined end extending one of the retainer clips, all four clips must be above the vice jaws. replaced. 2. Place the differential unit on its end with the 6. Differential Case — If scoring, wear or metal flange section above the cap section. Place over pick-up is evident on the machined surfaces, then the extended tool/ axle shaft spline. replacement of the case is necessary. 3. Install the remaining part of Special Tool or an axle shaft, into the flange section of the case. 4. Using Special Tool E6662 check that the torque required to continuously rotate the side gears is as per the values listed in the Specifications.
Item 1 2 Item 1 2 3 4
Description Concentric groove disc Radial groove plate
Description Tool E6662-LSO Torque check Axle shaft bearing Differential assembly Axle shaft
NOTE: LSD units that operate smoothly but with excessively low torque should be checked as per the Inspection for Wear sections.
Limited Slip Differential — M86 Inspection for Wear 1. Plates and discs — If any one member of either stack shows evidence of excessive wear or scoring, the complete stack is to be replaced on both sides.
G98776 en
01/2003 2003.0 BA Falcon
205-02A-17
Rear Drive Axle / Differential — Beam Axle
205-02A-17
GENERAL PROCEDURES (Continued)
Item 1 2 3 4
Description Plate Disc Dished spacer Side gear
Limited Slip Differential — M78 LSD units that operate smoothly but with excessively low torque should be checked as follows. With the limited slip differential unit fully dismantled examine the parts for wear and general condition. If the cone surfaces have a mirror like finish, then the following rework procedure should be followed. If the cone surfaces are scored then components should be replaced and the normal set up procedure followed as in the repair manual. 1. Mark the cones to ensure they are reassembled to the original differential cases. 2. Using P800 grade wet and dry abrasive paper, rub the tapered surfaces in the differential direction by hand, in order to remove the glazed coating from the surfaces. Give the surfaces a final rub using oil on the wet and dry to produce a fine finish. The abrasive paper must be rubbed around the surfaces in a uniform manner to avoid creating hollows in the cone surfaces. 3. Thoroughly clean debris from all components. 4. Use new spring washers. 5. Prior to reassembly coat all surfaces with an approved LSD lubricant. 6. Reassemble. 7. Check friction torque of unit as in the Torque Check procedure.
G98781 en
01/2003 2003.0 BA Falcon
205-02A-18
Rear Drive Axle / Differential — Beam Axle
205-02A-18
IN-VEHICLE REPAIR 7. Continue to tighten the nut until the marks previously made on the pinion flange and the nut are in alignment to re-establish the pinion bearing NOTE: Refer to Special Tools in this section. preload. Removal 8. Install the driveshaft with the marking on the drive 1. Raise the vehicle on a hoist. Disconnect the drive shaft and the pinion flange in alignment. (Refer to shaft from the drive pinion flange after marking Section 205-11.) the drive shaft and pinion flange to ensure correct 9. Check axle lubricant level and top up if necessary radial positioning on re-assembly. (Refer to with specified lubricant. Section 205-01.) 10. Remove the vehicle from the hoist. 2. Mark the pinion flange and the pinion nut to establish bearing preload on re-assembly. 3. Hold the pinion flange using tool EN1205B and remove the self locking nut. As Loctite is used on the pinion nut, the torque required to release the nut will be greater than 200Nm. 4. Place a drain pan beneath the pinion housing. 5. Mark the ends of the pinion shaft and a pinion flange spline for correct re-alignment during installation. 6. Clean the pinion bearing housing around the oil seal to remove loose dirt and oil so that it does not fall into the front of the carrier housing during the removal or replacement procedure. 7. Remove the pinion flange using tool number Item Description E9258B. Under no circumstances should a hammer be used. 1 Oil seal installation Tool E9055 8. Remove the pinion oil seal by carefully prying it 2 Drive pinion oil seal out with a suitable tool. Installation NOTE: All hardware must be correctly installed and torqued to specification.
Pinion Oil Seal Replacement
1. Check the mating splines on the pinion shaft and pinion flange for burrs and if necessary clean up with fine crocus cloth. Wipe the flange and shaft clean. Remove any Loctite thread locking compound from the pinion nut of flange thread. 2. Clean the oil seal seat. The lubricant return passage in the axle housing must be clear. 3. Lubricate the seal lips and the outside diameter with oil and install the seal, using the correct special tool. Seal location is from flush to 0.25 mm below the machined carrier face. 4. Align the pinion flange spline mark with the pinion shaft spline mark and start the flange onto the pinion splines by hand. A smear of lubricant on the pinion splines will assist in installation. 5. Install the pinion nut onto the pinion thread (without Loctite) and wind the nut down to pull the flange onto the pinion spline until no axial end play can be detected by hand in the pinion assembly. Remove the pinion nut. 6. Apply Loctite 262 Liquid Threadlocker to the pinion thread and reinstall the nut, tightening to 100Nm.
G98782 en
01/2003 2003.0 BA Falcon
205-02A-19
Rear Drive Axle / Differential — Beam Axle
205-02A-19
REMOVAL AND INSTALLATION
Axle Shaft Assembly Removal 1. Raise the vehicle and remove the road wheel. (Refer to Section 100-02.) 2. Disconnect the park brake cable from the park brake and remove from axle. (Refer to Section 206-05.) Remove the caliper. Remove ABS sensor (if ABS fitted). Remove the disc from the axle flange. NOTE: If ABS is fitted, take care not to damage tone wheel. 3. Working through the access hole in the axle flange using an allen key to remove the four bearing retainer plate bolts. 4. Withdraw the axle shaft and bearing assembly. NOTE: The bearing cup typically may be loose in the axle housing or may fall out on axle disassembly. Friction surfaces of brake parts must be kept contamination free.
Item 1 2 3 4 5 6
Description Score - M6 Shield Bolt - M12 Caliper Rotor Asle Assy.
Item 1 2 3 4 5 6 7
Description Seal Bearing assembly Bearing retaining collar Axle housing Brake anchor bracket Bearing retaining plate Tone wheel (ABS)
Installation NOTE: All hardware must be correctly installed and torqued to specification. NOTE: Friction surfaces of brake parts must be kept contamination free. 1. If the bearing cup was previously removed install the bearing cup in the axle housing. NOTE: A new bearing should always be used if the axle oil seal, retaining collar, retaining plate or tone wheel have been replaced. Ensure that the cup back face is seated against the back shoulder in the housing. The bearing must be lubricated with axle lubricant before installation. Also, apply a film of MIC75B Grease to the outside diameter of the seal prior to installation. Refer to Rear Axle Bearing And Seal Replacement section for how to service the axle assembly once removed from the tube housing.
G98783 en
01/2003 2003.0 BA Falcon
205-02A-20
Rear Drive Axle / Differential — Beam Axle
205-02A-20
REMOVAL AND INSTALLATION (Continued) 2. Start the splined end of the shaft into the 3. Remove cover plate screws, cover plate. Clean differential and start the bearing cone assembly sealant from cover faces. and seal into the housing. 3. Line up the retaining plate to the retaining plate bolts and push the axle into the housing as far as possible. 4. Start the bolts onto the tube flange holes and tighten to finger tight only. Then tighten the bolts to 20 Nm in a diagonal sequence. The bolts should be tightened in such a manner to assure that the seal and bearing cone assembly are drawn evenly against the cup in the housing. Refer to Specifications section for tightening torque required on retaining plate bolts. 5. Install the disc on the axle flange. Install the brake caliper. Route the park brake cable and connect to park 4. Remove differential bearing caps. Note letters brake. (Refer to Section 206-05.) stamped on the bearing caps and the cover face Replace ABS sensor (if fitted). of the housing. Letters are to correspond in horizontal and vertical positions. This is very 6. Replace the road wheel and lower the vehicle. important at time of assembly. 7. Tighten the wheel nuts. (Refer to Section 204-04.) 8. Check the park brake adjustment. (Refer to Section 206-05.)
M86 Limited Slip Differential Special Tool(s) Spreader E9255
Indicator Set or Equivalent Removal NOTE: On Dana Spicer axles it is recommended that the complete axle assembly be removed from the vehicle when it becomes necessary to remove the M86 LSD from the housing.
5. Mount spreader to housing. Locate a dial indicator with a magnetic base on cover face as shown. Locate tip of indicator on housing as shown. 6. Set dial indicator at zero ("0"). Turn forcing screw of spreader until indicator records .015" (.38 mm).
CAUTION: Do not spread carrier in excess of 015" (.38 mm). 1. Remove wheels, brake drums, brake backing plate screws and axle shafts. Brake backing 7. Remove Indicator. plates can normally be wired to frame without loosening the hydraulic brake line connection at the wheel cylinder if desired. Use caution to avoid damage to brake line. 2. Remove axle assembly and place in rack or stand to serve as a holding device.
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01/2003 2003.0 BA Falcon
205-02A-21
Rear Drive Axle / Differential — Beam Axle
205-02A-21
REMOVAL AND INSTALLATION (Continued) 8. Remove differential using two pry bars as shown. Use caution to avoid damage to ring and pinion. It will not be necessary to remove the differential bearings at this time, however, the bearing cups should be marked or tagged to indicate from which side of the case they were removed. After differential case has been removed, remove spreader.
Axle Housing and Differential Assembly Removal 1. Loosen the rear wheel nuts. 2. Raise the vehicle and support it on the axle. 3. Remove the rear wheels. 4. Detach the shock absorbers from the spring plates as follows. (Refer to Section 204-02B.) 5. Support the vehicle on the underbody. (Refer to Section 100-02.)
6. Mark the relationship of the driveshaft and the pinion flanges and disconnect the driveshaft from the pinion flange. (Refer to Section 205-01.) 7. Detach the park brake cable from the drum (park) brake and remove from rear axle Remove the calipers and suspend from the underbody. Leave the hydraulic lines attached. Remove the discs. Remove ABS sensor (if ABS fitted). Remove the splash shields. (Refer to Section 206-04.) Remove the axle shafts as described in this Part. NOTE: Do not strain the brake lines and/or hoses. (Refer to Section 206-04.)
G98785 en
01/2003 2003.0 BA Falcon
205-02A-22
Rear Drive Axle / Differential — Beam Axle
205-02A-22
REMOVAL AND INSTALLATION (Continued) 8. Remove the ’U’ bolts, spring plates and the lower spring insulator. (Refer to Section 204-02B.) 9. Remove the axle housing from the vehicle. 10. Drain the oil from the axle housing through an axle tube. Installation 1. Position the axle housing on the springs. Ensure that the insulators are correctly located on the springs. Install the ’U’ bolts, lower insulator, spring plate and ’U’ bolt nuts. (Refer to Section 204-02B.) 2. Install the axle shafts as described in this Section. 3. Install the splash shields. 4. Install ABS sensor (if ABS fitted). Install the discs. Install the calipers. Route the park brake cable and connect to rear drum (park) brake. 5. Align the marks on the driveshaft and the pinion flanges and connect the driveshaft. (Refer to Section 205-01.) 6. Raise the rear axle and install the lower shock absorber to the spring plate (Refer to Section 204-02B.). Install the rear wheels. 7. With the vehicle in the curb load position fill the axle to the bottom of the filler plug hole with the correct oil.
Item 1 2 3 4 5 6 7
Description Screw (Torque to 6Nm) Tube - Rear axle housing vent Clip Screw Clip Clamp Tube assy. - Brake fluid
CAUTION: Use of unspecified lubricant may lead to premature gear failure. 8. Lower the vehicle and tighten the wheel nuts. (Refer to Section 204-04.) 9. Check park brake adjustment. (Refer to Section 206-05.)
Item 1 2 3 4 5 6
Description Screw - M6 Shield Bolt - M12 Caliper Rotor Axle Assy.
G98785 en
01/2003 2003.0 BA Falcon
205-02A-23
Rear Drive Axle / Differential — Beam Axle
205-02A-23
REMOVAL AND INSTALLATION (Continued)
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01/2003 2003.0 BA Falcon
205-02A-24
Rear Drive Axle / Differential — Beam Axle
205-02A-24
DISASSEMBLY AND ASSEMBLY
Rear Axle Wheel Bearing and Seal Replacement NOTE: Refer to special tools in this section. NOTE: When a bearing is replaced a complete assembly must be installed. Bearings are manufactured with a built-in adjustment of 0.25 to 0.53 mm "bench" end play or axial clearance. This "bench" end play is reduced when the bearing is pressed on the axle shaft. The final assembled end play on the shaft of 0.04 to 0.5 mm is dependent on the dimensions of the interference fit between the cone and the axle shaft. The standard recommended cone fit is 0.025 to 0.055 mm tight. The cups are a snug fit in the housing. Used bearings may have a maximum of 0.7 mm end play.
Item 1 2 3 4 5
Description Cup Cup rib ring Rollers Cone Cage
1. The bearing is held on the shaft by the interference fit of the bearing cone and the retaining collar. The cup and rib ring are clamped together in the axle housing through the seal by the retaining plate. The axle seal wipes on the rotating axle shaft and at the same time functions as a static seal to prevent lubricant from escaping between the housing and seal outside diameter. 2. It is important to note that the seal also acts as a "spacer" in the clamp up of the bearing in the axle housing. It is imperative that the specified seal is used.
G98786 en
3. The bearing cone assembly should not be pulled from the axle shaft unless: 1. The seal is to be replaced. 2. The retaining plate has to be replaced due to damage or distortion. 3. The bearing is to be replaced. 4. A used bearing assembly should have all parts completely covered with rear axle oil prior to re-installation into the axle housing. Quarter fill the cavity between the seal lips with grease. Disassembly 1. Remove the retaining collar. This can be easily achieved by drilling a 6 mm hole in the outside diameter of the collar to a depth approximately three-quarters of the thickness of the collar. Do not drill all the way through the collar as the drill could damage the axle shaft, necessitating replacement of the shaft. After drilling the retaining collar, position a chisel across the drilled hole and strike sharply to break the collar. Support the shaft on the collar opposite the drilled hole. NOTE: Retaining collars are not reusable after having once been installed and must be scrapped after removal even if some removal method is used which does not cause obvious damage to the collar. 2. Slide the retaining plate and seal toward the axle flange. 3. Using special tools, press the bearing from the shaft. The special tools support the bearing behind the bearing cone face and prevent damage to the bearing and the seal surface of the shaft. NOTE: Do not heat or cut the bearing assembly as damage to the axle shaft will result. 4. Likewise, using special tools, press the tone wheel from the shaft being careful to avoid damaging the tone wheel location diameter shaft surface. Assembly 1. When installing new bearings, new seals and retaining collars must be used. 2. Check the retaining plate for damage or distortion with a straight edge. If the plate is distorted, replace it. 3. Clean the axle shaft, ensuring that there are no burrs or nicks on the tone wheel location diameter surface, bearing seat, seal surface, cone backing shoulder and chamfer leading to the seal seat. Sharp edges or nicks on the chamfer leading to the seal surface will damage the seal lips during installation of the seal on the shaft. To avoid damage to the wheel studs, place the axle shaft flange face on a support. 01/2003 2003.0 BA Falcon
205-02A-25
Rear Drive Axle / Differential — Beam Axle
205-02A-25
DISASSEMBLY AND ASSEMBLY (Continued) 4. Using Special Tools, press the tone wheel onto 9. Install a new retaining collar on the axle shaft and the axle shaft so that it is seated hard against the press it down to ensure it is in contact with the flange shoulder. bearing cone assembly. NOTE: Ensure that the large access hole in the 10. Press the bearing and the retaining collar on the tone wheel is aligned with the large access hole in axle shaft simultaneously using the relevant the axle shaft flange before pressing to ensure special tool. Apply sufficient load to assure the tool access for installation of the retaining plate proper seating of all parts. Check for proper bolts during reassembly of the axle shaft seating of the bearing cone assembly against the assembly into the tube assembly is maintained. shaft shoulder and the retaining collar against the Refer to Figure for tone wheel orientation for cone face by using feeler gauges. pressing. Check for proper seating of the tone NOTE: When pressing the bearing and retaining wheel on the axle shaft by checking with feeler collar on to the axle shaft, be sure all faces of the gauges. installation tubes are square, parallel and free from any burrs. Installing the retaining collar in a 5. Install the retaining plate on the axle shaft, skewed manner can reduce its holding ability by ensuring that it is positioned with the clamping as much as 50%. face of the plate towards the bearing. Apply grease to the cavity between the seal lips and carefully slide the seal into position on the seal seat. When installed, the outer face of the seal must be toward the axle flange. 6. Do not wash a new bearing prior to installation. The new bearing has protective grease that provides initial lubrication until the rear axle lubricating oil reaches the bearing. If the new bearing has to be washed for any reason, it must then be completely lubricated with rear axle oil prior to installation.
Item 1 2 3 4
Description Tool E1721 - Remove/Installer axle bearing and bearing retainer (Collar) Seal Bearing Bearing retainer (Collar)
Item 1 2 7. Place the lubricated bearing on the axle shaft ensuring the cup rib ring is facing toward the axle 3 flange and that the bearing is in hard contact with 4 the axle shaft shoulder. 5 8. Clean the journal diameter of any grease that may 6 have been left on the shaft during the pressing of 7 the bearing.
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Description Seal Bearing Assembly Bearing Retaining Collar Axle Housing Brake Anchor Bracket Bearing Retaining Plate Tone Wheel (ABS)
01/2003 2003.0 BA Falcon
205-02A-26
Rear Drive Axle / Differential — Beam Axle
205-02A-26
DISASSEMBLY AND ASSEMBLY (Continued) 3. Refer to General Procedures for Inspection before removal. NOTE: Refer to special tools in this section. 4. Identify the bearings, caps and remove the bearing cap bolts and bearing caps. Disassembly 5. Use the differential housing special spreading tool NOTE: All hardware must be correctly installed and to facilitate the removal of the differential case, torqued to specification. bearings and spacers. Spread the carrier the minimum amount which will allow the removal of 1. Remove the axle shafts as described previously in the differential assembly. Usually 0.1 to 0.2 mm this Section. will be adequate. (Spread is measured across the 2. Loosen the cover plate attaching bolts and drain carrier adjacent to the bearings.) the oil. The lowest cover bolt is a drain plug. Remove the cover plate. CAUTION: Under no circumstances should the carrier be spread more than 0.5 mm. 6. Mark the relationship of the driveshaft and the pinion flanges and disconnect the driveshaft. (Refer to Section 205-01.) 7. Mark the relationship of the pinion flange to the pinion shaft. Hold the pinion flange and remove the pinion nut. 8. Remove the pinion flange. 9. With a soft-faced hammer, drive the pinion out of the front bearing cone and remove it through the rear of the carrier casting. 10. Drive the pinion flange seal and the bearing cone out of the carrier casting. 11. If the pinion bearing cups are to be replaced, remove them from the carrier using the special tool. NOTE: It is essential to renew the cups one after the other so that in each Instance the other cup serves as a guide for the replacer tool.
Differential and Drive Pinion
12. If the pinion rear bearing cone and roller is to be replaced, lubricate the pinion shaft and remove the bearing cone from the pinion. Discard the bearing whenever it has been removed from the pinion.
Item 1 2
Description Tool E9255 - Differential housing spreader Tool E9255 - Adaptor Differential housing spreader
G98787 en
01/2003 2003.0 BA Falcon
205-02A-27
Rear Drive Axle / Differential — Beam Axle
205-02A-27
DISASSEMBLY AND ASSEMBLY (Continued)
Item 1 2 3
Description Tool - Push/puller with legs Tool - Stepped plug Tool - Knife edge puller
Differential Bearing Preload Spacer Selection NOTE: Refer to special tools in this section. NOTE: 1. Select any two spacer washers and place one against each of the differential bearing cups. Place the cups on the bearing cones and install the differential assembly in the carrier. When installed, there should be a small amount of end play. 2. With the differential held firmly against one side of the carrier, use a feeler gauge on each side of the centre line of the case to measure the end play between the cup and the spacer. Rotate the carrier to seat the bearing with the feeler gauges in position, and check to see that the end play has not been increased by this procedure. Remove the assembly and measure the spacers.
Item 1 2
Description Tool - Push/puller with legs Tool - Knife edge puller
G98788 en
01/2003 2003.0 BA Falcon
205-02A-28
Rear Drive Axle / Differential — Beam Axle
205-02A-28
DISASSEMBLY AND ASSEMBLY (Continued) 3. To establish the thickness of the spacers required:- Total the thickness of the two spacers Add the gap measured with the feeler gauges. Add 0.15 mm when using new bearings or 0.1 mm when using used bearings to preload the bearings. 4. Select two spacers, each half the thickness of the value determined in Step 3. 5. Fit the carrier spreader adaptors and the spreader to the carrier, together with a dial indicator positioned over the carrier differential opening, as close as possible to the centre line of the axle shafts. This may be done by using a pilot stud screwed into the side bearing lower stud hole, with the dial indicator plunger in contact with the opposite side of the carrier opening. 6. Use the spreader to expand the case until the differential assembly with bearings and selected spacers will fit into the carrier. A spread of 0.25 to 0.3 mm is usually sufficient. Under no circumstances should the carrier be spread more than 0.50 mm. 7. The differential assembly, with bearing cups and selected spacers held against the bearing cones, may now be fitted to the carrier, after removing the dial indicator. 8. Release and remove the spreader tool leaving adaptors in position. 9. Fit the bearing cups in their original positions, tightening the bolts to 55 Nm torque. 10. Rotate the differential assembly at least six full turns to seat the bearing rollers in the bearing cups. 11. Check the preload using a spring balance. Measure the tension required to revolve the assembly when a string is wrapped around the differential case on the larger diameter, just behind the drive gear. Balance readings must be within the following limits: New bearings 25 ± 10 N. Used bearings 13 ± 5 N. These balance readings are equivalent to the preload torques in the Specifications.
12. Remove the assembly from the carrier using the spreader. If the preload is correct, tie the selected spacers to the bearing cups to have them available for use in determining gear backlash. If correct preload is not obtained, a variation of 0.025 mm on spacers will alter preload 8 N for new bearings and approx. 4 N for used bearings. Repeat steps 5-12.
Drive Pinion Position — Shim Selection NOTE: The drive pinion and ring gear set identification marking (number 5K-25) is the matching number that appears on both the drive pinion and the ring gear. When a new gear set is being installed in an axle, be sure that the same matching number appears on both the drive pinion and the ring gear.
Pinion/Ring Gear Identification
NOTE: The ring gear and pinion are manufactured within a tolerance of a specified distance. On the end of each pinion, there is marked a plus (+) number, a minus (-) number, or a zero (0) number which indicates the best running position for each particular gear set. This dimension is controlled by the shimming behind the rear pinion bearing cup. When the shim thickness is decreased, the pinion gear is moved away from the ring gear. When the shim thickness is increased, the pinion is moved closer to the ring gear. A positive (+) number on the drive G98788 en
01/2003 2003.0 BA Falcon
205-02A-29
Rear Drive Axle / Differential — Beam Axle
205-02A-29
DISASSEMBLY AND ASSEMBLY (Continued) pinion means that a thinner shim should be installed to move the pinion gear away from the ring gear. A negative (-) number means that a thicker shim should be used to move the drive pinion closer to the ring gear. To select the correct shim thickness follow these steps:
increments from .008 to .030 in (0.2 to 0.75 mm NOTE: The marking on the pinion is in Imperial measurement. 5. Remove the tools from the carrier. 6. Remove the rear pinion bearing cup from the housing.
NOTE: Lubricate all differential parts with the recommended rear axle lubricant, before they are installed.
Drive Pinion and Bearings
NOTE: The exact same rear pinion bearing that is to be used in the vehicle, is to be installed when using the dummy pinion.
NOTE: All hardware must be correctly installed and torqued to specification.
1. Install the front and rear pinion bearing cups into the axle housing. Fit the pinion bearing cone and rollers to the dummy pinion tool. Install the dummy pinion to the axle housing. Fit the pinion front cone and roller to the dummy pinion. Install the tool thrust collar and the nut to the dummy pinion.
2. Tighten the nut until a bearing preload of 1.4 to 2.4 Nm (new bearing), 0.7 to 1.2 Nm (used bearing) is achieved while rotating the dummy pinion back and forth to ensure correct seating of the bearing rollers. 3. Position the depth gauge cylinder in the carrier and fit the bearing caps, tightening lightly. 4. Determine the size of pinion shim that will pass between the depth gauge and the dummy pinion head. Examine the drive pinion installation marking. The size of the pinion shim should then be altered as follows: A positive (e.g. +0.002 inch) marking means that this pinion has to be set at this number of thousandths of an inch further from the drive gear, i.e. a shim this amount thinner must be used. A negative (e.g. - 0.002 inch) marking means that a shim this size thicker must be used. A zero (0) marking indicates that the shim selected with the gauge is the correct one for this carrier/pinion combination. Position shims are available in .001 in (0.025 mm) G98790 en
NOTE: Refer to special tools in this section.
1. Place the pinion rear bearing cone on the pinion shaft. Press the bearing against the pinion shaft shoulder. 2. Install the shims (previously established), between the rear bearing cup and the housing and install the new cups using the Special Tool. Make sure the cups are properly seated in their bores. If a 0.025 mm feeler gauge can be inserted between a cup and the bottom of its bore at any point around the cup, the cup is not properly seated.
Item 1 2 3
Description Tool - E3C10AER Installer Drive pinion rear bearing Bearing cone and roller Drive pinion
3. Lubricate the pinion rear bearing with axle lubricant. 4. Position the pinion in the carrier and install a new collapsible pinion spacer. 5. Lubricate the front pinion bearing and install the bearing onto the pinion while supporting the pinion under the head. 6. Lubricate the seal lips and the seal outside diameter, and install the seal from flush to 0.25 mm below the carrier surface.
01/2003 2003.0 BA Falcon
205-02A-30
Rear Drive Axle / Differential — Beam Axle
205-02A-30
DISASSEMBLY AND ASSEMBLY (Continued) 7. Install the pinion flange and nut. Tighten the nut Differential Case — Conventional Type while rotating the pinion backwards and forwards M78 and M86 to seat the bearings. Check the bearing preload frequently while tightening the nut. Tighten the nut NOTE: Refer to special tools in this section. until the specified bearing preload is achieved. 1.4 Nm to 2.4 Nm with new bearings. 0.7 Nm to 1.2 Disassembly Nm with used bearings. NOTE: If the preload is exceeded the collapsible 1. Remove the bolts that attach the ring gear to the differential case. spacer must be replaced.
Differential Installation and Backlash Check NOTE: All hardware must be correctly installed and torqued to specifications. 1. Install the differential assembly with the tentatively selected spacers in the carrier, following the procedure in Differential Bearing Preload Spacer Selection steps 4 to 9 inclusive. 2. Measure the backlash as detailed in this section. Measure the backlash on several teeth around the ring gear to find the minimum position. Backlash here should be 0.13 to 0.18 mm. If the backlash is not within the range, decrease the thickness of one differential bearing spacer and increase the other by the same amount. The amount of change of each spacer is approximately equal to the amount of change required to correct the backlash reading. It is most important that the total thickness of both spacers be the same after backlash adjustment as before, so that correct preload is retained. 3. Check the gear tooth contact pattern as detailed in Section 308-03. 4. Fit the rear cover to the carrier using silicone rubber sealant. Fit the park-brake cable clips. On Wagon models fit the protection bracket to the differential cover. 5. Install the axle shafts as described in this Section. 6. Align the marks on the driveshaft and pinion flanges and connect the driveshaft. (Refer to Section 205-01.) 7. With the vehicle in the curb load position fill the axle to the bottom of the filler plug hole with the correct lubricant.
2. 3. 4. 5. 6. 7.
CAUTION: All axles use LH thread ring gear bolts - identified by L on bolt head. Press the ring gear from the case or tap it off with a softfaced hammer. With a suitable drift, drive out the differential pinion cross shaft retainer pin. For M78 use a soft drift to separate the two piece differential case. Drive out the differential pinion cross shaft from the larger section of the case. Lift the pinion gears and thrust washers from the case. Remove the side gears and thrust washers from each section of the case. Remove the differential bearings. Discard bearings whenever they have been removed from the carrier. For inspection after removal and dismantling refer to Section 204-02b.
Assembly NOTE: All hardware must be correctly installed and torqued to specification. 1. Lubricate all the differential parts with the recommended rear axle lubricant, before installation. 2. Place the side gear thrust washers over the side gear journals.
Item 1 2 3
G98790 en
Description Tool - Push/puller with legs Tool - Stepped plug Tool - Knife edge puller
01/2003 2003.0 BA Falcon
205-02A-31
Rear Drive Axle / Differential — Beam Axle
205-02A-31
DISASSEMBLY AND ASSEMBLY (Continued) 3. Position a side gear in the larger section of the differential case. 4. Position the two differential pinions and the thrust washers in the large section of the case. 5. Drive the pinion cross shaft into position. Ensure that the retainer pin hole is in line with the hole in the case. Take care not to damage the differential pinion thrust washers. 6. Drive the pinion locking pin through the differential case and pinion shaft. Ensure the pin does not protrude from the underside of the larger differential case. 7. Install the second side gear and thrust washer in the smaller section of the case. 8. Holding the side gear in position through the case bore, push the two sections of the case together locating on the retaining pin. Rotate the side gear, if necessary, to ensure that the gear and pinions are meshing correctly. 9. Place the ring gear in position on the case. Install and torque the bolts. 10. Press the differential side bearings onto the case journals.
6. For the cone/ side gear sub-assemblies, slide the cone off the splines on the side gear, this will reveal one thrust washer and two spring washers. NOTE: Ensure the mating cone, side gear, thrust washer and spring washers are not interchanged with components of the other cone/ side gear sub-assembly. 7. For inspection after removal refer to the General Procedures. Assembly NOTE: All hardware must be correctly installed and torqued to specification (see Specifications section).
1. Lubricate all the differential parts with the recommended rear axle lubricant before installation. 2. Place a side gear face down. Slide two spring washers onto the gear’s splines with the convex side facing up. Next, slide one side gear thrust washer onto the splines. Finally, slide a cone face down over the gear splines. 3. Clamp an axle shaft in a vice with approximately 75mm of the splined end extending above the vice jaws. Limited Slip Differential — M78 4. Place the cap section of the differential case, with the interior facing upwards, over the extended NOTE: Refer to special tools in this section. tool/ axle shaft spline. 5. Place the assembled cone/ gear sub-assembly Disassembly face up into the differential case. 1. Place the assembly in a vice equipped with 6. Install the pinion shaft locking pin into the pinion copper jaws. shaft seat on the differential case. 2. Remove the bolts holding the cap and flange 7. Install the pinion shaft, together with the pinions sections of the differential case together and and thrust washers, onto the locking pin and the separate the sections. differential case. NOTE: Ensure the cone/ side gear 8. Assemble the remaining cone/ side gear sub-assemblies are not interchanged during sub-assembly, as per Step 2, and place face up reassembly of the differential. Mark the mating into the flange section of the differential case. cone/ side gear and the corresponding side of the 9. Bring the cap and flange sections of the case differential case with a daub of paint. together, insert two case bolts in opposite holes 3. Remove the cone/ side gear sub-assembly from and tighten the bolts evenly to 40Nm. the flange section of the case. 10. Install the axle shaft, into the flange section of the 4. Remove the differential pinion shaft/ pinion gears/ case. thrust washers and the pinion shaft locking pin 11. Using Special Tool E6662 check that the torque from the cap section of the case. required to continuously rotate the side gears is 5. Remove the remaining cone/ side gear between 50 and 130Nm. sub-assembly from the cap section of the case. 12. Remove the tools or axle shaft from the assembly and install the remaining case bolts. NOTE: If the tool or axle shaft binds in the spline, a light tap with a hammer may be necessary.
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01/2003 2003.0 BA Falcon
205-02A-32
Rear Drive Axle / Differential — Beam Axle
205-02A-32
DISASSEMBLY AND ASSEMBLY (Continued) Disassembly 1. Place one of the axle shafts, which was removed from the assembly, into a vise. Tighten shaft in vise firmly. The spline end of the shaft is not to exceed 2.750" (69.85 mm) above the top of the vise. This will prevent the shaft from fully entering into the side gear and causing interference with the step plate during disassembly of the pinion mate gears, etc. Caution should be used that the vise jaws do not locate on axle splines or any machined surfaces.
Item 1 2 3 4
Description Tool E6662 - LSD torque check Axle shaft bearing Differential assembly Axle shaft
2. Place a few shop towels over vise to prevent any damage during disassembly of ring gear: Assemble the differential on the axle shaft with the ring gear screw heads up. Assembling the differential onto the shaft will serve as a holding device to remove the ring gear and to disassemble the internal parts of the case. Remove the ring gear screws. NOTE: LSD units that operate smoothly but with excessively low torque should be checked as follows. With the limited slip differential unit fully dismantled examine the parts for wear and general condition. If the components appear in good condition and the cone surfaces have a mirror like finish, then the following rework procedure should be followed. If the cone surfaces are scored then the components should be replaced and the normal set up procedure followed as in the repair manual.
Limited Slip Differential — M86 Tool Kit #C-4487 Special Tool(s) Tool Kit C-4487
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01/2003 2003.0 BA Falcon
205-02A-33
Rear Drive Axle / Differential — Beam Axle
205-02A-33
DISASSEMBLY AND ASSEMBLY (Continued) 3. Remove ring gear. It will be necessary to remove 6. It is recommended that when referring to the the ring gear to allow clearance for the removal of Trac-Lok, obtain the complete part number and the cross pin. Tap ring gear with rawhide hammer build date. To do this it will be necessary to wipe to free it from case. off the lubricant from the case. NOTE: It is recommended that on spicer axles 7. Reposition differential case onto axle shaft as whenever the ring gear screws are removed they shown. Remove the two snap rings from the cross are to be replaced with new ones. pin. Use two screwdrivers and push the rings free from the cross pin. Place a shop towel behind the case to prevent the snap rings from flying out of the case. Snap Ring Retained Version
4. Remove differential case from the axle shaft and remove ring gear. 5. All Spicer Trac-Loks are identified with a manufacturing date and the complete part number stamped on the barrel of the case. If the axle 8. For roll pin retainer version, use a small drift to assembly is equipped with a Trac-Lok Limited Slip remove the roll pin retaining the cross shaft. Differential a special tag will be located on the Roll Pin Retained Version bottom right hand side of the cover plate specifying the use of limited slip lubricant. In this figure the Trac-Lok is identified with 0.125" (3.17 nim) high numbers stamped on the case. For example:
The number 1-21-77A is the manufacturing or build date of the Trac-Lok and is interpreted as follows. The first number is the month, second number is the day of the month, third number is the year, the letter is the shift. For example: Jan. 21, 1977 first shift. The number stamped above the manufacturing date is the complete Trac-Lok assembly part number.
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01/2003 2003.0 BA Falcon
205-02A-34
Rear Drive Axle / Differential — Beam Axle
205-02A-34
DISASSEMBLY AND ASSEMBLY (Continued) 9. Remove the cross pin. Use a hammer and punch as shown to remove the cross pin from the case.
11. Lubricate threads of threaded adapter and forcing screw.
10. Assemble the adapter plate into the bottom side gear. Apply a small amount of grease to the centering hole of the adapter plate. Tool #C-4487-1 (adapter plate).
12. Assemble threaded adapter into top side gear. Thread forcing screws into threaded adapter until it becomes centered into adapter plate. Use a small screwdriver, position it in slot of threaded adapter. This will prevent the adapter from turning. Tools #C-4487-3 (threaded adapter), C-4487-2 (forcing screw).
13. Torque forcing screw until it becomes slightly tight. This will collapse the Belleville plates and allow a loose condition between the side gears and pinion mate gears.
G98794 en
01/2003 2003.0 BA Falcon
205-02A-35
Rear Drive Axle / Differential — Beam Axle
205-02A-35
DISASSEMBLY AND ASSEMBLY (Continued) 14. Remove both pinion mate spherical washers. Use 18. Remove top side gear and clutch pack. Keep the a shim stock of .030" (.76 mm) thickness or an stack of plates and discs intact in exactly the equivalent tool to push out the spherical washers. same position while they are being removed. 15. Relieve the tension of the Belleville springs by loosening the forcing screw. 16. Insert small O.D. end of turning bar into cross pin hole of case. Pull on bar and the case will rotate until the pinion mate gears can be removed from opening. NOTE: It might be necessary to adjust the forcing screw slightly to allow the case to rotate. Tool #C-4487-4 (turning bar).
19. Remove the case from the axle shaft. Turn case with the flange or ring gear side up and allow the step plate, side gear and clutch pack to be removed from the case. Remove the retainer clips from both clutch packs to allow separation of the plates and discs. Keep the stack of plates and discs exactly as they were removed.
17. Hold top clutch pack with one hand and remove tools. It might be necessary to hold threaded adapter with screwdriver.
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Assembly 1. Prior to assembly, prelubricate each disc and plate with Friction Modifier by presoaking for a minimum of 20 minutes. 2. After assembly into carrier housing, fill axle assembly with the proper amount and specified lubricant, refer to Specifications section.
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Rear Drive Axle / Differential — Beam Axle
205-02A-36
DISASSEMBLY AND ASSEMBLY (Continued) 3. Prelubricate the thrust face of the side gears and the plates and discs.
4. Assemble plates and discs in exactly the same position as they were removed, regardless of whether they are new parts or the original parts. Be sure lubricant that is used is of the specified lubricant. NOTE: Your unit may be equipped with the new design limited slip disc and plates or your replacement unit may contain them. If so follow directions below. The new design can be identified by a smooth surface. Olderdesigns have radial grooves in plates and discs.
7. Reposition case on bench as shown. Assemble the adapter plate into the side gear. Apply a small amount of grease into the centering hole of the step plate.
5. Assemble the retainer clips to the ears of the plates. Make sure both clips are completely assembled or seated onto the ears of the plates. 8. Assemble the other clutch pack and side gear as shown. Make sure the clutch pack stays assembled to the side gear splines, and that the retainer clips are completely seated into the pockets of the case.
6. With the differential case positioned as shown, assemble the clutch pack and side gear into the case. Make sure the clutch pack stays assembled to the side gear splines, and that the retainer clips are completely seated into the pockets of the case. To prevent pack from falling out of the case, it will be necessary to hold them in place by hand 9. Hold the clutch pack in position and insert the while repositioning case on bench. threaded adapter into top side gear, insert forcing screw. Tighten forcing screw into bottom plate. This will hold both clutch packs in position.
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205-02A-37
Rear Drive Axle / Differential — Beam Axle
205-02A-37
DISASSEMBLY AND ASSEMBLY (Continued) 10. With tools assembled into the case, position case onto the axle shaft by aligning the splines of the side gear with those of the shaft.
15. For snap ring retained versions, be sure the snap ring grooves of the cross pin shaft are exposed to allow assembly of the snap rings. Assemble snap rings.
11. Loosen forcing screw slightly. Assemble both pinion mate gears as shown. Hold gears in 16. Remove case from axle shaft. Assemble ring gear position by hand. to case. Line up the ring gear screw holes with those of the case. 12. While holding gears in place, insert turning bar NOTE: Use new ring gear screws. Assemble new into case. Pull on bar to rotate case allowing ring gear screws finger tight. gears to turn. Make absolutely sure that the holes of the pinion mate gears are in alignment with holes of the case.
13. Prelubricate spherical washers. Torque forcing screw until it is tight. This will collapse the Belleville plates and allow clearance between gears. Assemble spherical washers into case. Use a small screwdriver to push washers into place. CAUTION: Be sure the holes of the washers and gears are lined up exactly with those of the case. 14. Remove tools.
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01/2003 2003.0 BA Falcon
205-02A-38
Rear Drive Axle / Differential — Beam Axle
205-02A-38
DISASSEMBLY AND ASSEMBLY (Continued) 17. For roll pin retainer version, use a small drift to replace the roll pin that retains the cross shaft.
19. Reposition case onto axle shaft as shown. Torque screws alternately and evenly. Torque grade 8 screws to 45-65 lb. ft. (61-88 Nm). NOTE: If grade 9 screws are used (special for high strength), torque 75-85 Lb. Ft. (102-115 Nm).
20. Mount spreader onto housing. Locate a dial indicator with a magnetic base on cover face as shown. Locate tip of indicator on housing as shown. Set dial indicator at zero. Turn forcing screw of spreader until indicator records .015" (.38 mm). CAUTION: Do not spread housing over .015"
18. When roll pin bottoms out, stake (peen) a little metal over the edges in two places 180’ degrees apart.
21. Remove dial indicator. 22. Prelubricate differential bearings with the specified lubricant. Assemble differential bearing cups to differential cones. 23. Install differential assembly into housing. Make sure teeth of ring gear are meshed with those of pinion. 24. Use a rawhide hammer to seat differential assembly into cross bore of housing. Care should be taken to avoid nicking the teeth of the ring gear and pinion during assembly. 25. Remove spreader.
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205-02A-39
Rear Drive Axle / Differential — Beam Axle
205-02A-39
DISASSEMBLY AND ASSEMBLY (Continued) 26. Install bearing caps. Make sure the letters stamped on the caps correspond with those stamped on the housing in horizontal and vertical position. NOTE: Torque cap screws to 70-90 Lb. Ft. (96-122 Nm).
27. The cover face of the carrier and the flat surface of the rear cover must be free from any oil of foreign material. Fit the rear cover to the carrier using silicone rubber sealant. NOTE: Ensure that the sealant bead is laid on the inside of the cover screw holes. The bead is not to pass through the holes or outside of the holes.
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01/2003 2003.0 BA Falcon
205-02B-1
Independent Rear Suspension — Full Floating Axle
205-02B-1
SECTION : 205-02B Independent Rear Suspension — Full Floating Axle VEHICLE APPLICATION : 2003.0 BA Falcon CONTENTS
PAGE
SPECIFICATIONS Specifications .......................................................................................................................205-02B-2 DESCRIPTION AND OPERATION Description And Operation ..................................................................................................205-02B-4 Drive Unit Identification ......................................................................................................205-02B-4 Drive Unit Differential .........................................................................................................205-02B-4 Conventional Differential ....................................................................................................205-02B-4 Limited Slip Differential ......................................................................................................205-02B-4 Diff and Pinion Bearings ....................................................................................................205-02B-4 M78 & M86 IRS (Sedan) ...................................................................................................205-02B-4 GENERAL PROCEDURES Drive Unit Oil Change ..........................................................................................................205-02B-8 In Vehicle Torque Check .....................................................................................................205-02B-8 Differential Case Preload Setting ........................................................................................205-02B-8 Backlash and Tooth Contact Setting ...................................................................................205-02B-8 IN-VEHICLE REPAIRS Pinion Oil Seal Replacement ...............................................................................................205-02B-9 REMOVAL AND INSTALLATION Half Shaft ...........................................................................................................................205-02B-10 Drive Unit Assembly ..........................................................................................................205-02B-10 Differential Assembly .........................................................................................................205-02B-10 DISASSEMBLY AND ASSEMBLY Inner Axle Shaft Seal Replacement ..................................................................................205-02B-11 Pinion & Pinion Bearings ...................................................................................................205-02B-11 Drive Pinion Selection — Shim Selection ..........................................................................205-02B-12
01/2003 2003.0 BA Falcon
205-02B-2
Independent Rear Suspension — Full Floating Axle
205-02B-2
SPECIFICATIONS General Specifications Description Specification Rear Axle Lubrication (Level with bottom of filler plug hole with vehicle at curb height.) Model 78 CONVENTIONAL Grade SAE 90 Hypoid Ford Specification ESW-M2C108-A Capacity 1.70 litre LIMITED SLIP Grade SAE 90 EP Ford Specification ESW-FM2C-1006-B Capacity 1.60 litre + 100ml Sturaco 7098 Additive Model 86 CONVENTIONAL Grade Mobilube SHC ID Ford Specification ESZ-FM2C190-A Capacity 1.9 litre LIMITED SLIP Grade Mobilube SHC ID Ford Specification ESZ-FM2C190-A Capacity 1.86 litre + 40ml Duraphos Mobil M3022 BEARING PRELOADS BEARING PRELOADS New Bearings Nm Differential — Measured without axle 1.1-2.8 shafts or pinion Pinion — With oil seal 1.4-2.4 — Without oil seal 1.4-2.0 Used Bearings Differential — Measured without axle 0.5-1.4 shafts or pinion Pinion — With oil seal 0.7-1.2 — Without oil seal 0.7-1.0 ADJUSTMENTS Pinion bearing preload Collapsible spacer adjustment. Differential bearing Selective spacer preload adjustment. Pinion depth of mesh Selective shim adjustment. Backlash between ring 0.13 to 0.18 mm gear and pinion. G567879 en
Description Specification Backlash variation 0.05 mm max. between teeth. Maximum ring gear run 0.13 mm out (assembled) Limited slip differential Selective shim adjustment. (separate cone type) Limited slip differential Non adjustable (integral cone type) Limited slip differential torque New: 80-140 Nm Used: 50-130 Nm (Separate cone type) 45-130 Nm (Integral cone type) To be constant within 6 Nm (continuously rotating) General Specifications Item Spring Rate E169 SWB E169 XR and FPV E169 SFLPG E169 Fairmont Ghia E169 Heavy Duty E169 Sport SFLPG E169 T Series E169 LWB Design Load E169 SWB E169 XR and FPV E169 SFLPG E169 Fairmont Ghia E169 Heavy Duty E169 Sport SFLPG E169 T Series E169 LWB Design Height E169 SWB E169 XR and FPV E169 SFLPG E169 Fairmont Ghia E169 Heavy Duty E169 Sport SFLPG E169 T Series E169 LWB
Specification 28N/mm 38 N/mm 32 N/mm 30 N/mm 32 N/mm 34 N/mm TBA 28 N/mm 4800 N 4140 N 5576 N 4660 N 5860 N 5145 N TBA 5400 N 5400 N 190 mm 201 mm 190 mm 190 mm 190 mm 190 mm TBA 190 mm
01/2003 2003.0 BA Falcon
205-02B-3
Independent Rear Suspension — Full Floating Axle
205-02B-3
SPECIFICATIONS (Continued) Torque Specifications Description Nm Ring gear bolts (L.H. Thread) 140 Bearing cap bolts 55 Differential case bolts (L.S.D.) 40 Rear cover bolts 30 Axle bearing retainer plate bolts 45 Spring ’U’ bolt nuts (Wagon) 60 * Track arms to body 75 * Track arms to pivot link 75 * Pivot link to axle housing cover 15 * Suspension arms to axle housing 75 * Suspension arms to body 75 * Shock absorber to spring plate 75 Caliper to bracket pin nuts 20 Splash shield screws 10 Shock absorber to spring plate nut 45 Stabiliser bar clamp bolt 20 Universal joint bolts 10 Vent - Rear axle housing 15 Pinion flange nut — Tighten to achieve — specified bearing pre-load Filler Plug 30 Drain Plug 30 Screw Adjusters (IRS) — Tighten to — achieve differential bearing preload Final drive assy rear mounting bolt 200 ± 40 Final drive assy front mounting bolt 140 ± 28 * Items marked thus are to be tightened with the vehicle in the curb load position.
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01/2003 2003.0 BA Falcon
205-02B-4
Independent Rear Suspension — Full Floating Axle
205-02B-4
DESCRIPTION AND OPERATION Torque is transferred from the drive shaft to the rear axle assembly via the companion flange which is splined to the hypoid pinion. The torque is then Drive Unit Identification transferred from the pinion through the ring gear, A label identifying the drive unit assembly part differential case, pinion spider, differential pinions and number, model, serial number, and final drive ratio is side gears to the axle shafts. The differential case fixed to the carrier casting. houses two cone type clutches which are integrated IRS final drive units (3.23 or 3.45:1) have a 7 3/4 inch with side gears. These cones are splined to the axle shafts, their tapered faces bearing on the differential (189.9 mm) diameter ring gear. case. CAUTION: IRS drive units use a synthetic Thrust springs pre-load the gears/cones, forcing the lubricant that is not compatible with standard tapered face of the cones into contact with the polyacrylic pinion seals. Viton pinion seals must differential case. The partial locking action, due to the be used in this axle. spring load on the cones is automatically increased by the inherent separating forces between the side gears A metal tag carrying the words ’HIGH and pinion. This locking action directs portion of the PERFORMANCE USE APPROVED LUBRICANT driving force to the wheel with the greater traction. ONLY’ is attached under the filler plug for LSD. A Decal is also attached to the right hand front door When the rear wheels are under extreme unbalance hinge pillar. (LSD only). tractive conditions, such as one wheel on dry road and the other in mud or ice, with the conventional Drive Unit Differential differential, wheel spin will occur if over acceleration is The drive unit should be removed from the vehicle for attempted. However, with the limited slip differential, overhaul. Before disassembling the unit the following when the tendency for wheel spin occurs, the friction generated between the cones and the differential inspection should be carried out: 1. Remove the rear cover, clean and visually inspect case transfers portion of the driving force to the the moving parts for chipped or scuffed surfaces. non-spinning wheel. in the event of continued spinning a whirring sound is produced due to NOTE: The differential bearing lock plates are over-running of the cones; such a condition or sound removed when the ABS location mounts are does not indicate failure of the unit. removed. Axle shaft end play is pre-set and is not adjustable. 2. Use a torque wrench to check the ring gear bolt Oil seals are located between the inner axle shafts and pinion flange nut torques. and the screw adjusters. 3. Check the run-out and backlash. Refer to Section Diff and Pinion Bearings 205-00. 4. Carry out the Gear Tooth Contact Pattern Check Construction design is a single row, pre-set tapered roller bearing capable of accepting thrust loads in outlined in Section 205-00. either direction and radial loads in any combination. Conventional Differential The tapered roller unit type bearing consists of five basic parts: the cup or outer race, the cup rib ring, the The four pinion gear split differential case and the cone, or inner race, the tapered rollers which roll drive pinion are mounted in opposed taper roller freely between the cup and cone, and the cage which bearings in the carrier. Differential bearing preload adjustment is provided by the screw adjusters Pinion serves as a retainer to maintain the proper spacing between the tapered rollers grouped around the cone. bearing preload is provided by a collapsible spacer. Torque is transferred from the drive shaft to the drive When the bearing is manufactured, the cup and rib ring are bonded together with an adhesive to facilitate unit assembly via the companion flange which is bearing handling and installation. Since the cup and splined to the hypoid pinion. The torque is then rib ring are clamped together in the axle housing, transferred from the pinion through the ring gear, there is no need for a permanent bond. When the differential case, differential pinion cross shaft, bearing is serviced the cup will usually be separated differential pinions and side gears to the axle shafts. from the rib ring. Axle shaft end play is pre-set and is not adjustable. Oil seals are located between the inner axle shafts M78 & M86 IRS (Sedan) and the screw adjusters. NOTE: A label identifying the drive unit assembly part number, serial number, final drive ratio and model is Limited Slip Differential fixed to the carrier casting. The four pinion gear split differential case and the Two different model final drive units are used in sedan drive pinion are mounted in opposed taper roller vehicles: bearings in the carrier. Differential bearing preload adjustment is provided by the screw adjusters. Pinion M78 final drive units are fitted with 3.23 or 3.45 bearing preload is provided by a collapsible spacer. 7.75" (197mm) diameter gear sets, with or without
Description And Operation
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01/2003 2003.0 BA Falcon
205-02B-5
Independent Rear Suspension — Full Floating Axle
205-02B-5
DESCRIPTION AND OPERATION (Continued) LSDs. All M78 final drive units should be filled with synthetic oil as per Part 4-5 Specifications. Conventional M78 differentials are fitted with a metal tag marked "HIGH PERFORMANCE. USE APPROVED LUBRICANT ONLY" that is attached under the filler plug on the rear cover. For Limited Slip Differentials (LSD) units, the metal tag is marked "LSD - HIGH PERFORMANCE. USE APPROVED LUBRICANT ONLY". M86 final drive units are fitted with 3.23 or 3.46 8.6" (220mm) diameter gear sets, with or without LSDs. M86 final drive units are fitted to all sedan vehicles powered by a V8 or turbo I6 engine. All M86 final drive units should be filled with mineral oil as per Part 4-5 Specifications. Conventional M86 differentials are not fitted with a metal tag. For LSD units, a metal tag marked "SPIN RESISTANT DIFF. USE APPROVED LUBRICANT ONLY" is attached under the filler plug on the rear cover. NOTE: Upgrading the lubricating oil to synthetic type is recommended for vehicles fitted with a M86 final drive unit where the vehicle will be regularly used for towing.
to rotation, providing torque transfer to the rear wheel with the least traction. With a conventional differential, when the rear wheels are under extreme unbalance tractive conditions, such as one wheel on dry road and the other in mud or ice, wheel spin will occur if over acceleration is attempted. However, with the limited slip differential, when the tendency for wheel spin occurs, the friction generated between the cones and the differential case (M78) or between the friction plates (M86) transfers a portion of the driving torque to the non-spinning wheel. NOTE: For M78 LSDs: In the event of continued spinning a whirring sound is produced due to over-running of the cones; such a condition or sound does not indicate failure of the unit.
This axle is a hypoid type of unitised carrier construction. The two pinion differential case and the drive pinion are mounted in opposed taper roller bearings in the carrier. Differential bearing preload adjustment is provided by the screw adjusters. Pinion bearing preload is regulated by a collapsible spacer and adjusted using the pinion nut. Torque is transferred from the propshaft to the final drive assembly via the constant velocity type companion flange that is splined to the hypoid pinion. The torque is then transferred from the pinion through the ring gear, differential case, differential pinion cross shaft, differential pinions and side gears to the constant velocity joint halfshafts for conventional differentials. Halfshaft end play is pre-set and is not adjustable. Oil seals are located between the haflshafts and the screw adjusters. M78 Limited Slip Differentials (LSDs), the differential case houses two cone type clutches behind the side gears. These cones are splined to the halfshafts, their tapered faces bearing on the differential case. Thrust springs pre-load the gears and cones, forcing the tapered face of the cones into contact with the differential case. The partial locking action due to the spring load on the cones is automatically increased by the inherent separating forces between the side gears and pinion. This locking action directs a portion of the driving force to the wheel with the least traction. M86 LSDs transfer torque in a similar manner as M78 LSDs, except that a multiplate oil bath type design is utilised where alternate plates are splined to the differential case and side gear. Compressive preloading of the plates provides frictional resistance
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01/2003 2003.0 BA Falcon
205-02B-6
Independent Rear Suspension — Full Floating Axle
205-02B-6
DESCRIPTION AND OPERATION (Continued) M78 IRS Drive Unit
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01/2003 2003.0 BA Falcon
205-02B-7
Independent Rear Suspension — Full Floating Axle
205-02B-7
DESCRIPTION AND OPERATION (Continued) M86 IRS Drive Unit
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01/2003 2003.0 BA Falcon
205-02B-8
Independent Rear Suspension — Full Floating Axle
205-02B-8
GENERAL PROCEDURES
Drive Unit Oil Change
Differential Case Preload Setting
1. Raise the vehicle so that it remains level. 2. Remove the bottom rear cover flanged bolt from the drive unit to drain oil. NOTE: It is preferable to drain the oil while it is warm so that any debris can drain out more easily.
1. Hold the differential case in position while inserting screw adjusters until the differential is supported by the bearings. Use special tool 205-463 to fit the screw adjusters.
3. Refit the cover bolt and tighten to 23-31 Nm. 4. Remove the lubrication tag, gasket and filler plug (located on the left-hand side of the drive unit housing ahead of the axle shaft). 5. Fill drive unit with 1.6 litres of the appropriate lubricant. 6. Check the condition of the gasket to ensure proper oil sealing function of filler plug. 7. Replace lubrication tag, gasket and filler plug and tighten to 23-31 Nm.
In Vehicle Torque Check Torque Testing 1. To test the Limited Slip differential for correct operation proceed as follows: 1. Drive vehicle 10 km to warm up axle oil. 2. Raise one rear wheel and attach the Special Tool No. E6662. 3. Place the transmission in neutral and release the park brake. 4. Ensure that there is no brake drag affecting wheel rotation. 5. Chock the front wheels. 6. Attach a torque meter to the special tool, and rotate the axle.
2. Rotate the differential several times to seat bearings while the screw adjusters are being tightened. 3. Measure the bearing preload. 4. Tighten the screw adjusters until the bearing preload is within the required range. Record the torque required on the screw adjusters to obtain the required preload.
Backlash and Tooth Contact Setting 1. Replace the differential assembly using the spacers selected earlier. 2. Ensure that the pinion nut and bearing cap bolts are tightened to the specified torque. 3. Check the backlash on the ring gear as described in Section 205-00. 4. If backlash is excessive decrease the size of the spacer on the pinion side of the ring gear and increase the gear side spacer by the same amount by turning the screw adjusters. If the backlash is insufficient increase the size of the spacer on the pinion side and decrease the size of the spacer on the ring gear side by the same amount by turning the screw adjusters. NOTE: The total thickness of both spacers should not change.
5. Recheck the tooth contact pattern as described in Section 205-00. 6. Make necessary adjustments until tooth contact is appropriate. 7. The torque required to rotate the axle shaft for 7. Replace/Install new seals and silicone sealant a used L.S.D. unit should be between 50 and that are not already in place. 130 Nm. Reading should be steady within 6 Nm. 8. Install rear cover and torque to specification. 8. If the torque required to continuously rotate the wheel is outside the specification check the differential for improper assembly and/or rework. G567881 en
01/2003 2003.0 BA Falcon
205-02B-9
Independent Rear Suspension — Full Floating Axle
205-02B-9
IN-VEHICLE REPAIR 3. Lubricate the seal lips and the outside diameter with oil and install the seal, using the special tool. Correct seal location is from flush to 0.25 mm Removal below the carrier surface. CAUTION: Axles on vehicles with V8 or I6HO 4. Align the pinion flange spline mark with the pinion engines use a synthetic lubricant that is not shaft spline mark and install the flange with a compatible with standard polyacrylic pinion seals. smear of lubricant on the splines. Tighten the nut Viton pinion seals must be used in this axle. until the marks previously made on the pinion Synthetic seals must not be soaked or washed in flange and the nut are in alignment re-establishing cleaning solvents. the pinion bearing preload. 1. Raise the vehicle on a hoist. Disconnect the drive 5. Install the driveshaft with the marking on the drive shaft from the drive pinion flange after marking shaft and the pinion flange in alignment. the drive shaft and pinion flange to ensure correct 6. Check axle lubricant level and top up if necessary positioning on reassembly. with specified lubricant. 2. Mark the pinion shaft and the pinion flange to 7. Remove the vehicle from the hoist. ensure correct positioning on reassembly. Mark the pinion flange and the pinion nut to establish bearing preload on reassembly.
Pinion Oil Seal Replacement
Item 1 2
Description Oil Seal Tool E9055 Drive Pinion Oil Seal
3. Hold the pinion flange using tool EN1205B and remove the self locking nut. 4. Place a drain pan beneath the pinion housing. 5. Mark the ends of the pinion shaft and the pinion flange spline for correct re-alignment during installation. 6. Clean the pinion bearing housing around the oil seal. 7. Remove the pinion flange using tool number E9258B. Under no circumstances should a hammer be used. 8. Remove the pinion oil seal by prying it out with a suitable tool. Installation NOTE: Refer to, Section 205-00 for Special Tool(s). 1. Check the splines on the pinion shaft and pinion flange for burrs and if necessary clean up with fine crocus cloth. Wipe the flange and shaft clean. 2. Clean the oil seal seat. The lubricant return passage must be clear. G567885 en
01/2003 2003.0 BA Falcon
205-02B-10
Independent Rear Suspension — Full Floating Axle
205-02B-10
REMOVAL AND INSTALLATION
Half Shaft
3. Remove the differential assembly.
Removal and Installation Refer to section 205-05.
Drive Unit Assembly Removal 1. Remove knuckle assembly, refer to Section 204-02a. 2. Remove Rear Drive Halfshafts, refer to Section 205-05. 3. Remove IRS Module, refer to Section 204-02a. 4. Unclip handbrake cables. 5. Remove breather tube. 6. With the Drive Unit Assembly supported, remove the front and rear support bolts.
Item 1 2 3
Description Tool-Push/Puller with Legs Tool-Stepped Plug Tool-Knife Edge Puller
Installation 1. Installation procedure is the reverse of the Removal procedure. NOTE: Ensure all bolts are torqued to specifications.
Differential Assembly Removal and Installation 1. Remove the rear cover, ABS mounts and screw adjuster lock plates. 2. Remove the screw adjusters using special service tool 205-463.
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01/2003 2003.0 BA Falcon
205-02B-11
Independent Rear Suspension — Full Floating Axle
205-02B-11
DISASSEMBLY AND ASSEMBLY
Inner Axle Shaft Seal Replacement Disassembly 1. Drain lubricant from unit via bottom cover bolt. 2. Remove the half shafts from the assembly. Refer to ’Half Shaft’ in this section. 3. Clean around the seal area ensuring there is no ingress of dirt into the axle shaft needle roller bearing. 4. Carefully remove the seal. Assembly NOTE: Before installation of a new seal examine the
Pinion & Pinion Bearings Disassembly and Assembly 1. Carry out the following procedure with the differential assembly removed: 1. Mark the relationship of the companion flange. Hold the companion flange and remove the pinion nut. 2. Remove the companion flange. 3. With a soft hammer, drive the pinion out of the front bearing cone and remove it through the rear of the carrier casting. 4. Drive the pinion seal and the bearing cone out of the carrier casting. 5. If the pinion bearing cups are to be replaced, remove them from the carrier using the special tool. NOTE: It is essential to renew the cups one after the other so that in each instance the other cup serves as a guide for the replacer tool.
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surface of the axle shafts on which the seal runs and remove any nicks or burrs. Should this surface be irreparable, a new half shaft should be fitted. Examine the housing bore and remove any nicks and burrs. 1. Lubricate the seal lips and the outside diameter and install. The seal is to be seated on the screw adjuster. 2. Install the half shafts ensuring that the splines do not come into contact with the seal lips. Refer to ’Half Shaft’ in this section. 3. Shafts should withstand a pull out force of 1200N. 4. Check lubricant level, top up as required.
6. A pinion depth adjusting shim is installed between the rear pinion bearing cup and the axle housing. Discard damaged shims.
01/2003 2003.0 BA Falcon
205-02B-12
Independent Rear Suspension — Full Floating Axle
205-02B-12
DISASSEMBLY AND ASSEMBLY (Continued) 7. In the pinion rear bearing cone and roller is to Pinion & Ring Gear Identification be replaced, lubricate the pinion shaft and remove the bearing cone from the pinion. Drive the bearing whenever it has been removed from the pinion.
Item 1 2
Description Tool-Push/Puller with Legs Tool-Knife Edge Puller
Drive Pinion Selection — Shim Selection Disassembly and Assembly NOTE: The drive pinion and ring gear set identification marking (e.g. number 5K-25) is the matching number that appears on both the drive pinion and the ring gear. When a new gear set is being installed in an axle, be sure that the same matching number appears on both the drive pinion and the ring gear.
1. The ring gear and pinion are manufactured within a tolerance of a specified distance. On the end of each pinion, there is etched a plus (+) number, a minus (-) number, or a zero (0) number which indicates the best running position for each particular gear set. This dimension is controlled by the shimming behind the rear pinion bearing cup. 2. When the shim thickness is decreased, the pinion gear is moved away from the ring gear. When the shim thickness is increased, the pinion is moved closer to the ring gear.
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01/2003 2003.0 BA Falcon
205-02B-13
Independent Rear Suspension — Full Floating Axle
205-02B-13
DISASSEMBLY AND ASSEMBLY (Continued) 3. A positive (+) number on the drive pinion means that a thinner shim should be installed to move the pinion gear away from the ring gear. A negative (-) number means that a thicker shim should be used to move the drive pinion closer to the ring gear. 4. Lubricate all differential parts with the recommended rear axle lubricant, before they are installed. 5. To select the correct shim thickness follow these steps: NOTE: The exact same rear pinion bearing that is to be used in the vehicle, is to be used when using the dummy pinion. 1. Install the front and rear pinion bearing cups into the axle housing. 2. Fit the pinion bearing cone and rollers to the dummy pinion tool. Install the dummy pinion to the axle housing. Fit the pinion front cone and roller to the dummy pinion. Install the tool thrust collar and the nut to the dummy pinion. 3. Tighten the nut until a bearing preload of 1.4 to 2.4 Nm (new bearing), 0.7 to 1.2 Nm (used bearing) is achieved while rotating the dummy pinion back and forth to ensure correct seating of the bearing rollers. 4. Position the depth gauge cylinder in the carrier and fit the bearing caps, tightening lightly. Determine the size of pinion shim that will pass between the depth gauge and the dummy pinion head. Examine the drive pinion installation marking. The size of the pinion shim should then be altered as follows:- A positive (e.g. +0.002 inch) marking means that this pinion has to be set at this number of thousandths of an inch further from the drive gear, i.e. a shim this amount thinner must be used. A negative (e.g. - 0.002 inch) marking means that a shim this size thicker must be used. A zero (0) marking indicates that the shim selected with the gauge is the correct one for this carrier/pinion combination. Position shims are available in .001 in (0.025 mm) increments from .008 to .030 in (0.2 to 0.75 mm). NOTE: The marking on the pinion is in Imperial measurement. 5. Remove the tools from the carrier. 6. Remove the rear pinion bearing cup from the housing.
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01/2003 2003.0 BA Falcon
205-05-1
Rear Drive Halfshafts
205-05-1
SECTION : 205-05 Rear Drive Halfshafts VEHICLE APPLICATION : 2003.0 BA Falcon CONTENTS
PAGE
SPECIFICATIONS Specifications .........................................................................................................................205-05-2 DESCRIPTION AND OPERATION Rear Drive Halfshafts .............................................................................................................205-05-3 Halfshaft Handling ................................................................................................................205-05-3 DIAGNOSIS AND TESTING Rear Drive Halfshafts .............................................................................................................205-05-4 REMOVAL AND INSTALLATION Halfshaft .................................................................................................................................205-05-5 DISASSEMBLY AND ASSEMBLY Halfshaft Joint ........................................................................................................................205-05-6
01/2003 2003.0 BA Falcon
205-05-2
Rear Drive Halfshafts
205-05-2
SPECIFICATIONS General Specifications Description Constant Velocity Joint Grease (High Temp) E43Z-19590-A Torque Specifications Description Ball joint nuts Knuckle bolt Rear axle wheel hut nut
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Specification ESP-MIC207-A
Nm 115 115 290
01/2003 2003.0 BA Falcon
205-05-3
Rear Drive Halfshafts
205-05-3
DESCRIPTION AND OPERATION
Rear Drive Halfshafts CAUTION: An inspection of the outer and inner boots is necessary so that if damage or grease leakage is evident, installation of a new halfshaft can take place immediately. Continued operation with damage or grease leakage will result in CV joint wear and noise due to contamination and loss of the CV joint grease. 1. Inboard and outboard CV joints connect to a splined shaft. A circlip stopper holds the cross groove inboard race assembly (inboard CV joint) together. 2. An axle circlip (4B422) retains the splined inboard CV joint to the differential side gear. Install a new axle circlip each time the halfshaft is removed from the vehicle. 3. A rear axle wheel hub nut secures the side shaft assembly (interconnecting shaft and outboard CV joint) the rear hub. Install a new rear axle wheel hub nut each time the halfshaft is removed from the vehicle.
Halfshaft Handling CAUTION: Never pick up or hold the halfshaft only by the inboard or outboard CV joint. CAUTION: Do not over-angle the CV joints. CAUTION: Damage will occur to an assembled inboard CV joint if it is over-plunged outward from the joint housing. CAUTION: Never use a hammer to remove or install the halfshafts. CAUTION: Never use the halfshaft assembly as a lever to position other components. Always support the free end of the halfshaft. CAUTION: Do not allow the boots to contact sharp edges or hot exhaust components. CAUTION: Handle the halfshaft only by the interconnecting shaft to avoid pull-apart and potential damage to the CV joint. CAUTION: Do not drop assembled halfshafts. The impact will cut the boots from the inside without evidence of external damage. Handle all halfshaft components carefully during removal and installation procedures.
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01/2003 2003.0 BA Falcon
205-05-4
Rear Drive Halfshafts
205-05-4
DIAGNOSIS AND TESTING
Rear Drive Halfshafts For additional information, refer to Section 205-00.
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01/2003 2003.0 BA Falcon
205-05-5
Rear Drive Halfshafts
205-05-5
REMOVAL AND INSTALLATION
Halfshaft Removal 1. Disconnect park brake cable, ABS sensor, brake caliper and rotor and knuckle assembly (Refer to Section 204-02a Rear Suspension Knuckle Removal).
2. Holding the halfshaft securely remove by applying an axial load. CAUTION: Never use a hammer to remove or install halfshaft. CAUTION: Handle the halfshaft only by the interconnecting shaft to avoid pull-apart and potential damage to the CV joint. Installation 1. Refit the halfshaft using the reverse of the removal procedure taking care not to over-articulate the CV joints.
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01/2003 2003.0 BA Falcon
205-05-6
Rear Drive Halfshafts
205-05-6
DISASSEMBLY AND ASSEMBLY 4. Slide the inboard halfshaft boot off the inboard CV joint housing.
Halfshaft Joint Special Tool(s) CV Boot Clamp Installer 205-343 (9T95P-3514-A)
Disassembly V8 Inboard 1. Remove the halfshaft. Refer to Section 205-02b. 2. Secure the halfshaft and constant velocity (CV) joint in a vice using protective jaw covers. 5. If reinstalling the original inner joint, mark the inner joint and the halfshaft to make sure of correct installation.
3. Remove the inboard halfshaft boot clamp. The V8 inboard joint has only one large boot clamp. Refer to Section 205-02b. 6. Spread the retainer and using a hammer and punch separate the halfshaft from the inboard joint housing by tapping on the inner race.
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01/2003 2003.0 BA Falcon
205-05-7
Rear Drive Halfshafts
205-05-7
DISASSEMBLY AND ASSEMBLY (Continued) 7. Remove and discard the bearing retainer circlip. The retainer should have remained with the inner race during the removal process.
8. Remove the inboard halfshaft boot from the halfshaft. Disassembly V8 Outboard and I6 Inboard & Outboard
There are at least two methods to achieve this - refer to following illustrations.
2. Slide the outboard boot back out of the way exposing the CV joint.
1. Remove the two outboard halfshaft boot clamps. There is a small and large boot clamp associated with this boot.
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01/2003 2003.0 BA Falcon
205-05-8
Rear Drive Halfshafts
205-05-8
DISASSEMBLY AND ASSEMBLY (Continued) 3. If reinstalling the original CV joint, mark the outboard CV joint and halfshaft to make sure of correct installation.
4. Use a soft-face hammer to separate the outboard CV joint by gently tapping it off the halfshaft. 5. Remove the halfshaft retainer-circlip and discard.
2. Install the inboard halfshaft boot. This is most easily achieved by inserting the large opening from the outboard end. And sliding the boot along the shaft to the other side.
3. Replace the inboard joint retainer ring. A retainer on the shaft is not required.
6. Slide the outboard halfshaft boot off the halfshaft.
Assembly V8 Inboard 1. Lubricate the inboard and outboard CV joint with joint grease.
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01/2003 2003.0 BA Falcon
205-05-9
Rear Drive Halfshafts
205-05-9
DISASSEMBLY AND ASSEMBLY (Continued) 4. Use a soft-face hammer to install the inboard CV joint by gently tapping it onto the halfshaft.
5. Remove any excess grease on the mating surfaces and slide the inboard halfshaft joint boot forward onto the inboard CV joint. 6. Remove any excess air trapped in the inboard halfshaft boot using a cloth covered screwdriver after adjusting the outboard halfshaft boot spacing.
2. Position the halfshaft boot.
3. Install the snap ring.
4. Using a soft face hammer, install the halfshaft on the joint.
7. Ensure that the small end of the boot is positioned as shown in adjacent picture - that is, such that the small end is located in the groove in the shaft and that the shape of the shaft adjacent to the boot is as shown. 8. The air pressure within the boot is self -adjusting for this type of boot. Assembly V8 Outboard and I6 Inboard & Outboard 1. Slide the small boot clamp onto the shaft.
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5. Position the halfshaft boot.
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205-05-10
Rear Drive Halfshafts
205-05-10
DISASSEMBLY AND ASSEMBLY (Continued) 6. Ensure that the small end of the boot is positioned as shown in adjacent picture - that is, with one of the small grooves visible.
7. Remove any excess air trapped in the halfshaft boot using a cloth covered screwdriver after adjusting the halfshaft boot spacing. 8. Using the special tool, install two new joint boot clamps. The outboard joint has an ABS rotor attached as shown.
9. Install the halfshaft. Refer Section 205-02b.
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Brake System — General Information
206-00-1
SECTION : 206-00 Brake System — General Information VEHICLE APPLICATION : 2003.0 BA Falcon CONTENTS
PAGE
SPECIFICATIONS Specifications .........................................................................................................................206-00-2 DESCRIPTION AND OPERATION Brake System .........................................................................................................................206-00-4 Load Proportioning Valve 1 Tonne Ute ................................................................................206-00-5 DIAGNOSIS AND TESTING Brake System .........................................................................................................................206-00-6 Inspection and Verification ...................................................................................................206-00-6 Symptom Chart ....................................................................................................................206-00-7 Components Tests ...............................................................................................................206-00-9 GENERAL PROCEDURES Hydraulic System Bleeding ..................................................................................................206-00-11 Manual System Bleeding .....................................................................................................206-00-11 System Pressure Bleeding ...................................................................................................206-00-11 Service Precautions .............................................................................................................206-00-12 Changing Brake Fluid ..........................................................................................................206-00-12 Brake Pedal Clearance Check .............................................................................................206-00-12 Caliper ..................................................................................................................................206-00-12 Brake System Leak Check ...................................................................................................206-00-13
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Brake System — General Information
206-00-2
SPECIFICATIONS General Specifications Description Lining wear limit (above backing plate or rivets ) Lubricants High Performance SUPER DOT 4 Brake Fluid High Temperature Nickel Anti-Seize Lubricant F6AZ-9L494-AA Disc Brakes Brake disc maximum run out Brake disc maximum thickness variation Brake Booster Dual Diaphragm Diameter Master Cylinder Type Main Bore Diameter Fast Fill Bore Diameter Min. Total Stroke Split Point (non EBD only)
Displacement (min.) Caliper(Front) Type AI Head Bore Diameter Caliper(Rear) Type Bore Diameter Rotor (Front) Type Diameter Thickness (New) Max. Runout Thickness Variation Min. Thickness Refaced (overall) Min. Thickness Refaced (individual) Braking Surfaces
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Specification 1.0 mm (0.040 in)
ESA-M6C25-A ESE-M12A4-A
0.035 mm (0.001 in) 0.009 mm (0.0004 in)
230 mm
PBR Dual Line 23.8 mm 31.75 mm 32.52 mm 3/4 Tonne Ute with prop valve = 2.5mPa 1 Tonne Ute with prop valve (Load levelling valve fitted to this varient) = 0MPa Primary - 9.0 cc Secondary - 5.12 cc PBR Twin Piston ’Collette’ Caliper 2 x 42.0 mm PBR Single Piston ’Collette’ Caliper 40.5 mm Cast Iron - Ventilated 298 mm 28 mm 0.035 mm 0.009 mm 26.0 mm
3.2 mm
Description Surface Finish (Ra) Balance Rotor (Rear) Type Diameter Thickness (New) Max. Runout Thickness Variation Min. Thickness Refaced (overall) Brake Face Surface Finish (Ra) Park Brake Bore Surface Finish (Ra) Max. Park Brake drum diameter Disc Pads Material Brake Pedal Height Minimum height without fluid in system and master cylinder Bottomed out ABS System System and motor dropout threshold Fuse Warning lamp Current draw - motor (under load) Front Wheel Sensor Resistance Rear Wheel Sensor Resistance
Specification 0.13-3.2 µm 54 gcm Cast Iron - Solid 0.05 mm 303 mm 16.2 mm 0.018 mm 14.5 mm 0.13-3.2 µm 0.13-3.2 µm 190.4 mm
JBUF85FF 25 mm
8.7V 30A 1.2W 50A 1.65 kOhm ± 0.2 kOhm 1.65 kOhm ± 0.2 kOhm
Torque Specifications Description Brake master cylinder tube fitting, front Brake master cylinder tube fitting, rear Caliper bleeder screw, rear Caliper bleeder screw, front Master cylinder bleeder screw Cruise control switch Master Cylinder to Booster Booster to Dash panel Brake Tube Nuts Brake Line Connector to Rear Axle Housing Brake Hose to Caliper
Nm 18 18 20 20 8-18 14-20 15 19 - 24 12 25 30
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Brake System — General Information
206-00-3
SPECIFICATIONS (Continued) Description Nm Splash Shield to Rear Anchor Bracket 10 Front Caliper Mounting Bolts 115 ± 17 Rear Caliper Mounting Bolt 68-92 Park Brake Control to Body 25 Park Brake Equalizer Nut 15 Pressure Differential Switch (where 1.8 fitted) Proportioning Piston Hex. Fitting 25 Wheel Nuts 140 Cable Bracket Nuts 8 Reservoir Attaching Bolt 4 Secondary Piston Stop 8 Modulator Nuts to Bracket 15 Brake Pipe Tube Nuts (modulator) 13 Wheel Speed Sensor Screws 9 Pump Motor earth strap screw 12 NOTE: All Hydraulic Lines must be tightened to the specified torque and be free from leakage.
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Brake System — General Information
206-00-4
DESCRIPTION AND OPERATION
Brake System Component Locator
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Brake System — General Information
206-00-5
DESCRIPTION AND OPERATION (Continued) When the vehicle carries its maximum load, the piston Description is postioned so that fluid can flow unresticted through Brake master cylinder and booster the sensing valve to the rear wheel calipers. assembly 2 Pedal box 3 Rear disc brake assembly 4 Front disc brake assembly 5 Anti-lock electronic control module The vehicle is equipped with a vacuum-assisted power braking system. For additional information, refer to Section 206-07. The braking system is a front-to-rear split hydraulic system. For additional information, refer to Section 206-06. The front brakes utilize a dual-piston brake caliper and disc brake system. For additional information, refer to Section 206-03. The rear brakes utilize a single piston caliper and disc brake system with the parking brake assembly located inside the drum and hat-type brake disc. For additional information, refer to Section 206-04. The parking brake system is a shoe and drum system that is located inside the drum and hat-type rear brake discs. For additional information, refer to Section 206-05. A 4-wheel anti-lock brake system (4WABS) is standard. For additional information, refer to Section 206-09. Item 1
Load Proportioning Valve 1 Tonne Ute The load proportioning valve regulates the rear brake system hydraulic pressure and is located at the rear of the vehicle.
The load proportioning piston is positioned by the use of two springs. the static spring applies a constant force on the piston while the sensing torsion spring applies a variable force depending on the axle load. When the vehicle is lightly loaded the sensing torsion spring has its maximum effect. The total force on the piston and plunger is greatest. This force postions the load sensing piston to restrict the flow of fluid through the outlet port to the rear brakes. G17360 en
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Brake System — General Information
206-00-6
DIAGNOSIS AND TESTING Rotor Wear and Runout
Brake System Special Tool(s) Vacuum Pump 416-D002 (D95L-7559-A) or equivalant
Inspection and Verification WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands throughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. Failure to follow these instructions may result in personal injuiry.
Remove the wheel to inspect the rotor. Check the rotor for scoring. Minor scores need not be removed. If the rotor is excessively scored, refinish it in accordance with the Specifications or replace the rotor. When checking front rotor runout, be sure to take the wheel bearing end play into account. Remove the rotor if necessary. Front wheel bearing end play is critical and must be within specifications. To check the rear rotor run-out either apply a load to the end of the axle shaft to remove the end float in the bearing or remove the axle shaft and rotor assembly from the housing and check the run-out by mounting the axle on its centres. Clamp a dial indicator to the caliper housing so that the stylus contacts the braking surface of the rotor approximately 32 mm from the outer edge for a front rotor or 3mm from the outer edge for a rear rotor. Rotate the rotor and take an indicator reading. If the total lateral run-out exceeds 0.08 mm for a front rotor or 0.05 mm for a rear rotor, resurface or replace the rotor. Refer to Specifications section for refinishing specifications. Refer to Section 206-03 or Section 206-04 for information regarding rotor replacement.
CAUTION: Do not spill brake fluid onto painted surfaces. If spilled, wipe it up immediately. NOTE: Always check the fluid level in the brake master cylinder before carrying out the test procedures. If the fluid level is not above the MIN line, add High Performance Motor vehicle brake fluid meeting Ford specification ESZ-M6C55-A or Disc Thickness Variation equivalant Super DOT4 fluid. This is the variation in thickness between the two NOTE: Prior to carrying out any diagnosis, verify that braking surfaces of the rotor measured the brake warning indicator is functional. Apply the circumferentially. parking brake. If the brake warning indicator does not Disc thickness variation may cause a pulsating pedal illuminate, refer to Brake fail warning light component or noisy operation. test. Two methods may be used to measure thickness NOTE: The primary indicators of brake system variation. concerns are a change in the feeling through the A micrometer can be used to measure the rotor brake pedal, the brake warning indicator, and the thickness at 12 points approximately 30 degrees apart brake fluid level. If a problem exists, refer to the and 25 mm from the outer edge of the rotor. following diagnosis guide. The other method is to mount the rotor on a precision lathe designed for machining disc brake rotors. Attach Pad Wear two dial indicators, one each side of the rotor, so that Remove the wheel to inspect the pads. Refer the stylus of each indicator contacts the rubbing Warning under Service Precautions. surface approximately 25 mm from the outer edge of the rotor. If a lining has worn to a thickness of 1.0 mm at any one of three measuring locations or if there is Zero both indicators and rotate the rotor while more than 3 mm taper from end to end replace all watching both dials. If the total readings of both (4) pad assemblies on both front or both rear indicators exceed the specified limit for thickness wheels to maintain even braking. Refer to Section variation, the rotor must be refinished or replaced. 206-03 or Section 206-04 for replacement of parts.
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Brake System — General Information
206-00-7
DIAGNOSIS AND TESTING (Continued) Rotor Thickness and Refinishing
Rear Disk Brake Resurfacing Limits
Measure the thickness of the rotor to determine if it is within the specifications. Use a disc brake lathe to refinish the disc brake rotors. Refer to Specifications for the remainder of the refinishing specifications. Front Disk Brake Resurfacing Limits
Symptom Chart Symptom Chart Condition Excessive effort needed to depress brake pedal or has a rough or raspy or sticky feel
Brake pedal does not return freely
No response from the brake lights when the brake pedal is pressed
No response from the cruise control when the brake pedal is pressed
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Source
Action
Brake pedal binds at pivot
INSTALL a new brake pedal
Brake booster
CHECK the brake booster and REFER to the Booster Section.
Return Booster spring damaged or incorrectly positioned
CHECK the brake booster and REFER to the Booster Section.
Worn or damaged brake pedal
INSTALL a new brake pedal.
Foreign object caught in brake pedal
CHECK the brake pedal.
Weak or broken Booster return spring
CHECK the brake booster and REFER to the Booster Section.
Foreign object caught in brake pedal
CHECK the brake pedal.
Unconnected light switch
CHECK the connection between the light switch and the light.
Faulty brake switch flag
INSTALL a new brake pedal.
Incorrect position of the light switch
CHECK the light switch. REPLACE or CHANGE light switch.
Unconnected cruise switch
CHECK the connection between the cruise switch and the cruise control.
Faulty brake switch flag
INSTALL a new brake pedal.
Incorrect position of the cruise switch
CHECK the cruise switch. REPLACE or CHANGE cruise switch.
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Brake System — General Information
206-00-8
DIAGNOSIS AND TESTING (Continued) Condition No deceleration when the brake pedal is pressed
Source
Action
Connection between the Booster rod and the brake pedal
CHECK connection PUT the booster rod in the cantilever pin of the brake pedal if the booster rod is not connected to the cantilever pin of the brake pedal. CHECK Booster clip, CHANGE it if necessary.
Faulty booster
CHECK the brake booster and REFER to the Booster Section.
Discomfort on Brake pedal
Brake pedal pad worn or loose
CHECK brake pedal pad and CHANGE it if necessary.
Padal feel
Brake Pedal Not Returning on Release
Go to PinPoint Test B
Excessive Pedal Travel
Braking System Diagnosis. Refer to Section 206-00.
"Raspy" feel
Go to PinPoint Test B
Pedal Binding at Pivot
Go to PinPoint Test A
Pedal Pad Worn
Replace Brake Pedal Pad. Refer to Section 206-00.
Obstruction at Pedal
Go to PinPoint Test B
Faulty Brake Booster
Braking System Diagnosis. Refer to Section 206-00.
Brake Disc Pads Worn
Refer to Section 206-03 and Section 206-04.
Poor braking efficiency
Cruise control not turning off when brake applied
Adjustable brake pedal
Stop lamp switch
Booster Rod Disconnected
Go to PinPoint Test ???
Vacuum Poor, Leaking or disconnection at the Brake Booster
Braking System Diagnosis. Refer to Section 206-00.
Brake Master Cylinder Leaking / Faulty
Braking System Diagnosis. Refer to Section 206-00.
Cruise Control Switch Faulty / Plug Disconnected
Go to PinPoint Test D
Stop Lamp Switch Faulty / Plug Disconnected
Go to PinPoint Test C
Cannot Adjust Pedals
Go to PinPoint Test E
Faulty Memory
Go to PinPoint Test E
Pedal "Step Over" Height Incorrect
Go to Section 310-02, Pinpoint test 5 & 6.
Stop Lamp Switch Faulty
Go to PinPoint Test C
Symptom Chart-(For adjustable pedal box only) Condition Unable to adjust the brake pedal
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Source
Action
Unconnected Adjustment motor
CHECK the connection between the motor and the MSC
Disengaged adjustment cable in the brake pedal
RECONNECT adjustment cable
Faulty Potentiometer (Memory Pedal Box Only)
REPLACE potentiometer
Faulty memory settings (Memory Pedal Box Only)
RESET memory
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Brake System — General Information
206-00-9
DIAGNOSIS AND TESTING (Continued)
Condition Incorrect step over between brake pedal and accelerator pedal
Source Incorrect-adjustment
Action Refer to disassembly and assembly instructions: Indexing pedals ( Section 206-06)
NOTE: Do not stall through accelerator transmission.
and brake chatter. For each of the symptoms encountered, check and eliminate the causes. To Components Tests check for brake chatter or surge apply the brakes lightly from approximately 80 km/h. Brake Booster If the preliminary tests show that the booster is With the transmission in neutral, stop the engine and inoperative or if a hard pedal condition exists the apply the parking brake. Depress the service brake trouble may be caused by vacuum leakage. pedal several times to exhaust all vacuum in the Disconnect the vacuum line at the booster, remove system. Then, depress the pedal and hold it in the the vacuum manifold and check valve assembly and applied position. Start the engine. If the vacuum look for a sticking or faulty check valve. Check all system is operating the pedal will tend to fall away vacuum connections for leakage or obstruction. Check under foot pressure and less pressure will be required all hoses for a leaking or collapsed condition. Repair to hold the pedal in the applied position. If no action is or replace as necessary. felt, the vacuum booster system is not functioning. If the trouble persists, replace the vacuum booster. Refer to the Diagnosis Guide. The booster is not a serviceable item and if found For booster removal and installation procedures refer defective must be replaced. to Section 206-07. Brake Master Cylinder For cleaning and inspection refer to the following pages in this part. CAUTION: The braking system should be filled with a special high boiling point (280°C) Brake Fail Warning Light Test brake fluid which must not be contaminated with Turn the ignition key to the ignition ON position, ordinary brake fluid. Ensure only approved brake the warning lamp should not illuminate. If the lamp fluid is used (refer Specifications section). illuminates a defect exists in the system and may Brake fluid is hygroscopic, which means that it takes be: in moisture from the air. Water-affected brake fluid a pressure differential in the hydraulic system. has a reduced boiling point. The heat generated by a defective differential valve switch (where repeated heavy braking causes the fluid to boil at a fitted). lower temperature, resulting in loss of braking. The water also helps corrosion start in the braking system. grounded switch wires. The brake fluid must be replaced at least every two Turn the key to the START position, the lamp years if the brakes are to remain fully effective. should illuminate while the key is held in this position. If the lamp does not light check the bulb If brake fluid is spilt on paintwork, the affected area must be washed down with cold water immediately. and wiring for defects.
Road Test The vehicle should be road tested only if the brakes will safely stop the vehicle. Apply the brakes at a speed of 40- 50 km/h to check for any of the trouble symptoms listed in the Diagnosis Guide with the exception of those resolved in the preliminary tests
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Brake System — General Information
206-00-10
DIAGNOSIS AND TESTING (Continued) Pressure Differential Valve (where fitted) To Centralize After any repair or bleeding of the brake systems the pressure differential valve will centre itself automatically when pressure is applied to the brake pedal. The warning light switch is self setting.
Item 1 2 3
Description Reservoir Cover Diaphram Reservoir Chamber
To Check Fluid Level To check the level of the brake fluid in the master cylinder, visually inspect the fluid level in the transparent plastic reservoirs, without removing the reservoir cover. The fluid level should be within the maximum and minimum marks on the Right Hand side of the chamber. The fluid level will decrease gradually as the linings wear. Any rapid change in fluid level should be investigated immediately. To reduce the possibility of fluid contamination, the reservoir cover should be removed only when absolutely necessary. To remove the cover, first clean all dirt from around the cover. Refill to the maximum level mark. Prior to installing the master cylinder cover ensure that the diaphragm gasket is correctly positioned in its original form in the reservoir cover. The cover should be fitted so that lettering on cover is the correct way when viewed from the right hand side of vehicle. Use only the specified brake fluid or equivalent. G17361 en
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206-00-11
Brake System — General Information
206-00-11
GENERAL PROCEDURES
Hydraulic System Bleeding 1. When any part of the hydraulic system has been disconnected for repair or replacement, air may get into the system and cause spongy pedal action. Bleed the hydraulic system after it has been properly connected to be sure that all air is expelled. Press the pedal several times and check for leakage. 2. The hydraulic system can be bled manually or with pressure bleeding equipment. 3. Bleed the longest line first on the individual system being serviced. NOTE: Clean all dirt from the master cylinder reservoir cover before removing the cover. The cover should be fitted so that lettering on cover is the correct way when viewed from the right hand side of the vehicle. Do not mix low temperature brake fluids with the specified fluid. Never re-use brake fluid which has been drained from the hydraulic system. When the bleeding operation is completed the reservoir should be filled to the MAX FLUID LEVEL mark on the R.H. side of the reservoirs. Be sure the diaphragm type gasket is properly positioned in the master cylinder cover and is positioned in the configuration as shown in Section 206-06 prior to installation. If brake fluid is split on the paintwork the affected area must be washed with water immediately.
Repeat this procedure at the wheel cylinder/caliper on the opposite side. Refill the master cylinder reservoir after each wheel cylinder/caliper is bled and install the master cylinder cover and diaphragm seal. If the front brake system is to be bled, repeat steps 1-5 at the left front brake caliper and ending at the right front brake caliper. Be sure that the caliper pistons are returned to their normal positions and that the pad assemblies are properly seated by depressing the brake pedal several times until normal pedal travel is established.
System Pressure Bleeding 1. The bleeder tank should contain enough new Brake Fluid to complete the bleeding operation. Never exceed 340 kilopascals pressure. 2. The tank should be charged with 70 to 200 kilopascals of air pressure.
WARNING: Ensure the adaptor is clamped securely to reservoir before applying pressure. 3. Install the pressure bleeder adaptor tool to the master cylinder and attach the bleeder tank hose to the fitting on the adaptor. 4. Master cylinder pressure bleeder adaptor tools can be obtained from the various manufacturers of pressure bleeding equipment. Follow the instructions of the manufacturer when installing Manual System Bleeding the adaptor. If the rear wheel calipers are to be bled, NOTE: When bleeding brakes do not pump the pedal. position a ring spanner on the bleeder fitting 1. The front and rear hydraulic brake systems are on the left wheel caliper. Attach a bleeder individual systems and are bled separately. tube to the bleeder fitting. The end of the tube During the complete bleeding operation, DO NOT should fit snugly around the bleeder fitting. allow the reservoir to run dry. Open the valve on the bleeder tank to admit To bleed the rear brake system, position a pressurised brake fluid to the master cylinder suitable ring spanner on the bleeder fitting on reservoir. the wheel cylinder/ caliper. Attach a drain tube Submerge the free end of the tube in a to the bleeder fitting. The end of the tube container partially filled with clean brake fluid, should fit snugly around the bleeder fitting. and loosen the bleeder fitting. Submerge the free end of the tube in a When air bubbles cease to appear in the fluid container partially filled with clean brake fluid. at the submerged end of the bleeder tube, Route the tube upwards from the nipple to the close the bleeder fitting and remove the tube. container, which should be positioned higher Repeat steps 3 to 7 at the right rear brake. than the nipple. Loosen the bleeder fitting approximately 3/4 of a turn. Repeat steps 4 to 7, starting at the left front caliper and ending at the right front caliper. Push the brake pedal down slowly through its full travel. Close the bleeder fitting, then return When the bleeding operation is completed, the pedal slowly to the full release position. close the bleeder tank valve and remove the Wait 5 seconds then repeat this operation tank hose from the adaptor fitting. until air bubbles cease to appear at the Be sure that the caliper pistons are returned submerged end of the bleeder tube. to their normal positions and that the pad When the fluid is completely free of air assemblies are properly seated by depressing bubbles, close the bleeder fitting and remove the brake pedal several times until normal the bleeder tube. pedal travel is established. G17364 en
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Brake System — General Information
206-00-12
GENERAL PROCEDURES (Continued) Remove the Pressure Bleeder Adaptor Tool.
Service Precautions 1. Do not attempt to clean or restore brake fluid, oil or grease soaked brake pads. When contaminated pads are found, brake pads must be replaced in complete axle sets. 2. Check the brake hoses for signs of softening, cracking, leaks or abrasions. Replace them if necessary. 3. If the vehicle caliper parts show signs of overheating are present when relining brakes, the wheel calipers should be disassembled and inspected for wear and dirt and an overhaul kit installed, thus avoiding future problems.
2. No brake pedal clearance adjustment is required or provided for. With the brake master cylinder outlet lines disconnected and the brake pedal fully depressed, the centre of the top surface of the brake pedal pad should be 25 mm from the floor surface. 3. If the pedal height is below specification make the necessary repairs.
WARNING: Under no circumstances should compressed air blow off be used to clean brakes and associated components. Breathing in dust from the pads is a health hazard. Remove dust and dirt with the rotunda brake vacuum (4-0009) or equivalent or the rotunda brake parts washer (65-0016) or equivalent. Caliper 4. If a piston is removed from a master cylinder or 1. Check the caliper attaching bolts torque. Torque caliper for any reason the piston seals must be them to specification, if required. replaced. 2. Visually check the caliper. If the caliper housing is All foreign material must be kept off braking leaking it should be replaced. If a seal is leaking surfaces and associated components. the caliper must be disassembled and new seals Handling of components should be done in a installed. If a piston is seized in the bore and upon way to avoid deformation, nicking or disassembly is found to be scored it must be scratching of brake pads or braking surfaces. replaced. If the caliper is found to be distorted or damaged or if the cylinder bores are excessively Changing Brake Fluid scored or worn replace the caliper assembly. Refer to Warning under Service Precautions. NOTE: Do not allow the reservoirs to empty. 3. Wash all parts with methylated spirits and dry with 1. If this procedure is adhered to, air will not enter compressed air or lint free cloth. the system and the time taken to change the fluid 4. Blow out the caliper bore and all drilled passages will be kept to a minimum. with compressed air. Proceed in the same manner and order as for bleeding the system using a transparent bleed 5. Inspect the piston for scoring, pitting, corrosion or areas where the chrome plating has worn off. If tube attached to a bleed screw and a glass any damage is present replace the piston. Black jar. Refer to Brake Bleeding in this section. stains, caused by the seal, will do no harm. Pump out most, but not all, of the fluid in the 6. Inspect the caliper bore for scoring, pitting, reservoirs. corrosion or damage and replace the caliper if any Top up the reservoirs with new unused fluid. of these factors are present. The caliper must not Ensure the reservoirs are kept topped up. be honed. When new fluid is seen in the transparent 7. Inspect all other components and replace if wear tube, continue to bleed for two full strokes of or damage exists. the pedal and close the bleed screw. 8. The calipers must not be interchanged from one Repeat the procedure at each bleed screw in side to the other. When the caliper is installed on turn. its proper side the bleeder screw will be at the top Top up the reservoir and road test vehicle. of the piston bore.
Brake Pedal Clearance Check 1. The brake system is designed to permit full stroke of the master cylinder when the brake pedal is fully depressed. G17364 en
9. Refer to Section 206-03 or Section 206-04 for detailed Caliper replacement information.
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Brake System — General Information
206-00-13
GENERAL PROCEDURES (Continued)
Brake System Leak Check 1. Check the brake fluid level. If the fluid level is below the MIN line on the brake master cylinder reservoir add the necessary amount of High Performance SUPER DOT 4 brake fluid meeting Ford Specification ESA-M6C25-A or SUPER DOT 4 equivalent.
2. Inspect the (1) brake line nuts and the (2) brake master cylinder reservoir for fluid leaks.
3. 4. 5. 6.
Inspect the brake lines and hoses for fluid leaks. Inspect the rear disk brake caliper for leaks. Inspect the front disk brake calipers for leaks. If a hydraulic leak is detected, refer to Section 206-06.
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01/2003 2003.0 BA Falcon
206-03-1
Front Disk Brake
206-03-1
SECTION : 206-03 Front Disk Brake VEHICLE APPLICATION : 2003.0 BA Falcon CONTENTS
PAGE
SPECIFICATIONS Specifications .........................................................................................................................206-03-2 DESCRIPTION AND OPERATION Front Disc Brake ....................................................................................................................206-03-3 Disc Pad Running Clearance ...............................................................................................206-03-4 Wear Adjustment ..................................................................................................................206-03-4 Rotor ....................................................................................................................................206-03-4 DIAGNOSIS AND TESTING Front Disc Brake ....................................................................................................................206-03-5 REMOVAL AND INSTALLATION Brake Pads ............................................................................................................................206-03-6 Front Brake Hose ...................................................................................................................206-03-7 Brake Caliper Body ................................................................................................................206-03-7 Brake Disc ..............................................................................................................................206-03-8 DISASSEMBLY AND ASSEMBLY Brake Caliper .........................................................................................................................206-03-9
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206-03-2
Front Disk Brake
206-03-2
SPECIFICATIONS General Specifications Description Minimum brake disc thickness(discard thickness) Fluid Brake fluid Lubricant High melting point grease Pad Material Lining wear limit Torque Specifications Description Brake hose bolts Disc brake caliper bolts Brake hose banjo bolt Caliper body bolt
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Specification 26.0
ESZ-M6C55-A Dow Corning 44/Niglube Rx2 JBUF85FF 1.0mm Nm 30 115 12-14 98-132
01/2003 2003.0 BA Falcon
206-03-3
Front Disk Brake
206-03-3
DESCRIPTION AND OPERATION
Front Disc Brake Front Disc Brake Components
Item Description 1 Front Disc Caliper Assembly 2 Front Wheel Knuckle 3 Brake Line Bracket 4 Caliper Retaining Bolt x 2 5 ABS Sensor and Elec. Cable 6 ABS Sensor Retaining Bolt 7 Wheel Hub and Tone Wheel 8 Brake Disc Rotor 9 Front Spinle Nut 10 Front Hub Cap Seal The dual piston hydraulic disc brake caliper is constructed from a single casting which contains two piston bores in the inboard section of the casting. (Inboard refers to the side of the casting which is nearest the centreline of the vehicle when the caliper is mounted.) The fluid inlet hole and bleeder valve hole are machined into the inboard section of the caliper and connect directly to the piston bores. Each cylinder contains a piston and seal. The seal has a square section, and is located in a groove which is machined in the cylinder bore. It fits around the outside diameter of the piston to provide a G96751 en
hydraulic seal between the piston and the cylinder wall. The top of the piston is machined to accept a sealing dust boot. The outside diameter of the boot is captured by a recess in the top of the cylinder bore and the piston. The inside diameter of the boot fits into the groove which is machined in the piston. The piston is precision ground and chrome plated steel, giving it a very hard and durable surface. The use of abrasives or any attempt to re-machine the piston will destroy the required surface finish. The sliding caliper feature automatically compensates for lining wear. The abutment bracket is rigidly fixed to the steering knuckle while the housing slides within the abutment bracket by means of two guide pins bolted to the housing. Each caliper contains two pad assemblies. They are constructed of a stamped metal shoe with the lining integrally moulded to the shoe. When the brake pedal is applied, brake fluid is displaced into the cylinders moving the pistons outward. This action forces the inner pad and lining assembly against the rotor. The resultant reaction forces the caliper housing and outboard pad assembly inward against the rotor. The resultant forces of the pads on the rotor are equal. Braking torque is transferred from the outer brake pad abutments 01/2003 2003.0 BA Falcon
206-03-4
Front Disk Brake
206-03-4
DESCRIPTION AND OPERATION (Continued) through the caliper housing into the abutment bracket. Guide Pin Adjustments Braking torque from the inner brake shoe is taken directly into the abutment bracket. When the brake pedal is released the seal retracts the piston into the cylinder and the caliper housing slides outward releasing the brake.
Disc Pad Running Clearance Piston Adjustment Brakes Applied
Item 1 2 3
Description Piston Seal Distorted Caliper Housing Piston
Brakes Released
Item Description 1 Pad Abutment Bracket 2 Guided pin and boot assembly 3 Guide pin bolt 4 Piston 5 Piston dust boot 6 Pad abutment shim 7 Pads The figure above shows the guide pin installation. Running clearance - the caliper head moves back and forth on low friction guide pins. These guide pins and intended to accommodate disc runout and bearing float. If friction in the guide pin slide is high, instead of the caliper head sliding back and forth, the disc will knock the piston into the head, causing a spongy pedal on subsequent applications.
Wear Adjustment Pad wear is taken up during brake application as follows: by the piston sliding past the seal to a new position. by movement of the caliper head on the slide pin.
Rotor The cast iron disc is of the ventilated rotor-type and is separated from the front hub. Item Description 1 Piston Seal Relaxed 2 Piston 3 Caliper Housing The figures above show what happens to the pistons and the seals during usage. The piston seals perform the self-adjusting action. When the pistons are pushed out by hydraulic pressure the piston seals distort. When the hydraulic pressure is relieved the seals relax and drag the pistons in, creating a disc to pad running clearance. G96751 en
01/2003 2003.0 BA Falcon
206-03-5
Front Disk Brake
206-03-5
DIAGNOSIS AND TESTING
Front Disc Brake Refer to Section 206-00
G96752 en
01/2003 2003.0 BA Falcon
206-03-6
Front Disk Brake
206-03-6
REMOVAL AND INSTALLATION
Brake Pads Removal WARNING: Although original equipment pad material is asbestos free. If non genuine pads are used, the following applies: Asbestos fiber dust may be present on brake and clutch assemblies and is hazardous to health if inhaled. Brake and clutch assemblies should be cleaned using a vacuum cleaner recommended for use with asbestos fibers such as a brake/clutch/service vacuum. The bag must be labeled per OSHA instructions, sealed, and the trash hauler notified as to the bag’s contents. If the vacuum suitable for asbestos is not available, cleaning should be done wet. If dust generation is still possible, technicians should wear goverment-approved toxic dust purifying respirators. Failure to follow these instructions may result in personal injury. 1. Clean and remove master cylinder reservoir cap. Loosen front brake line connection at the master cylinder, allowing fluid to bleed into a container until master cylinder reservoir is one-third full. Re tighten line connection and replace master cylinder cap. WARNING: Brake fluid will damage paintwork. NOTE: Do not completely remove brake line or empty the reservoir or it will be necessary to bleed the system. NOTE: Discard the fluid removed. DO NOT RE-USE.
3. Using (G-clamps as shown), tighten until each piston bottoms on each bore. NOTE: Ensure that one end of the G-clamp rests on (or is adjacent to) the brake hose attaching bolt head, and the other against the outer pad. DO NOT exert excess force on the clamps as damage to steel pistons may result.
Item 1 2 3 4 5 6 7
Description Pad Abutment Bracket Guided pin and boot assembly Guide pin bolt Piston Piston dust boot Pad abutment shim Pads
4. Using a suitable size open-end spanner to hold the lower guide pin (7), remove and discard the guide pin bolt (3). NOTE: Old bolts must not be re-used, as they are vital safety components that have a micro encapsulated adhesive on the bolt thread.
NOTE: Removal of the fluid is necessary to prevent reservoir overflow when the caliper piston 5. Disengage brake hose grommet from bracket is pushed back in its bore during pad attached with caliper mounting bolt. replacement. 6. Swing caliper housing about the existing guide pin 2. With vehicle raised evenly on a hoist or jack until housing is clear of pads. stands, mark relationship of wheel to hub and 7. Remove worn pads (7&8) from abutment bracket remove the front wheels. (7) and inspect condition of brake disc. Discard Using wheel nuts secure rotor to hub during work. end abutment shims (6). NOTE: If more than one brake requires service, 8. Check guide pins for free movement in abutment work on only one brake at a time. Pad bracket. If there is restriction of movement, assemblies, must always be replaced in both replace guide pins and/or guide pin boots. brakes. Including high lube grease. 9. Clean any dirt from both the piston face, which contacts the inner pad, and the caliper head area that contacts the outer pad. 10. Inspect caliper assembly for fluid leaks or damage.
G96753 en
01/2003 2003.0 BA Falcon
206-03-7
Front Disk Brake
206-03-7
REMOVAL AND INSTALLATION (Continued) Installation Front Brake 1. Replace end abutment shims (6) in abutment bracket (1), ensuring they are secure and clear of Removal the rotor being careful not to bend them. 2. Install the inner (7) and outer (8) pads to the abutment bracket (1), against the inner and outer surface of the brake disc respectively. 3. Lower the brake calliper housing, ensuring that: the piston boots (4&5) do not get caught between the piston and inner pad (7). 4. Install and tighten the new guide pin bolt (3) to the correct torque specification. NOTE: Do not wedge anything between the guide pin hex and the caliper as it could cause incorrect alignment of the free sliding of the caliper relative to the anchor plate. 5. Refit brake hose grommet to bracket attached to caliper bracket, as previously positioned. 6. Replenish the brake fluid in the master cylinder with fresh specified fluid. 7. Pump the brake pedal several times to position the pad assemblies. 8. Check for fluid leakage at all connections under pedal pressure. 9. Re-check fluid level in master cylinder reservoir. 10. Remove wheel nuts. 11. Reinstall wheels, aligning marks made prior to removal and remove jack stands or lower hoist. 12. Tighten wheel, securing nuts to the specified torque. 13. Road test vehicle and make several light 60-0km/h stops to seat the linings. (The vehicle may pull slightly to one side for the first few applications. This is normal until linings are seated)..
Item 1 2 3 4
Hose
Description Clip Brake tube connector Banjo bolt Grommet
1. Remove banjo bolt and washers. 2. Remove grommer from hose positioning bracket. 3. Disconnect the brake tube connector. 4. Remove clip (4). 5. Remove hose assembly. Installation 1. Install banjo bolt and new washers. Torque to specification. 2. Install grommet into hose positioning bracket. 3. Install hose into body bracket and install clip. NOTE: Ensure hose is engaged to bracket prior to fitment of banjo bolt. Check routing for correct clearance on completion. 4. Connect brake tube and torque to specification. 5. Bleed as outlined in procedure.
Brake Caliper Body Removal 1. Raise and support the vehicle to ensure it is stable and secure. Mark the relationship of the wheel and the rotor and remove wheel. 2. Place a drain tray beneath caliper assembly. Loosen and remove attaching bolt and hose end. Discard washers and plug caliper body inlet port and hose end to prevent contamination or fluid loss.
G96755 en
01/2003 2003.0 BA Falcon
206-03-8
Front Disk Brake
206-03-8
REMOVAL AND INSTALLATION (Continued) 3. Disconnect hose. Discard copper sealing rings.
2. Remove the caliper assembly from the spindle and the rotor, as previously described in this section. If the caliper does not require servicing, it is not necessary to disconnect the brake hose. Position the caliper out of the way, and support it with a wire to avoid damaging the caliper or the hose. Handle the rotor, linings and caliper assemblies carefully to avoid deformation, nicking, scratching or contamination. 3. Remove the rotor from hub. Installation 1. Position the rotor on the axle flange. NOTE: Ensure that all mounting surfaces are clean and free from contamination which could cause possible disc runout.
Installation 2. Mount the caliper assembly on the spindle following the Disc Brake Caliper Assembly 1. Assemble caliper body to abutment bracket (1) by Installation procedure in this section. securing upper guide pin using a new guide pin bolt (3). 3. Install the wheel. 2. Lower the brake caliper housing, ensuring that: 1. the piston boots (4&5) do not get caught between the piston and inner pad (7). 3. Install and tighten the new guide pin bolt (3) to the correct torque specification. NOTE: Ensure hose is engaged to bracket prior to fitment of banjo bolt. Check routing for correct clearance on completion. NOTE: Do not wedge anything between the guide pin hex and the caliper as it could cause incorrect alignment of the free sliding of the caliper relative to the anchor plate. 4. Reconnect new brake hose, using new, dry, sealing washers. Tighten attaching bolt to the correct torque specification ensuring hose routing is removed. 5. Bleed brake system, refer to Brake system Bleed in this section.
Brake Disc Removal 1. Remove the wheel and tyre from the hub. G96755 en
01/2003 2003.0 BA Falcon
206-03-9
Front Disk Brake
206-03-9
DISASSEMBLY AND ASSEMBLY
Brake Caliper Disassembly
Item 1 2 3 4 5 6 7 8 9 10 11 12 13
Description Sealing Ring Caliper Body Guide Pin Bolt Bleed Screw Sealing Ring Bleed Screw Guide Pin Guide Pin Boot Piston Boot Piston Inner Pad Assembly Outer Pad Assembly Pad Abutment Shim Abutment Bracket
2. Remove brake pads (10&11) from abutment bracket.
3. Remove abutment bracket from mounting knuckle. Remove abutment shims (12) from 1. Remove Brake Caliper. For additional information, abutment bracket. refer to Section 206-03. NOTE: Ensure hose is engaged to bracket prior to 4. Withdraw guide pins (6) and boots (7) from anchor plate. Separate boots from pins. fitment of banjo bolt. Check routing for correct clearance on completion.
G96757 en
01/2003 2003.0 BA Falcon
206-03-10
Front Disk Brake
206-03-10
DISASSEMBLY AND ASSEMBLY (Continued) 5. Remove pistons (9) by placing a spacer between the pistons and the caliper fingers and applying air at the inlet port of the caliper housing until each piston is forced out of the bores. CAUTION: Inject air lightly and progressively increase the pressure until the piston is forced out of the bore. This procedure is advisable to avoid physical injury, as the pistons may develop considerable force due to sudden pressure increases. 6. Remove rubber piston boot (8) from bore. 7. Remove piston seal (1) from bore taking care not to damage bore or seal locating groove.
4. Coat piston boots (8) in specified grease and place boot over end of piston. Position each piston into caliper housing, seating each boot into groove in caliper bore. Ensure the boot is squarely and firmly seated in groove.
5. Push each piston squarely into each bore by hand until fully seated.
6. Ensure boot is fully seated in piston a caliper grooves.
8. Remove bleed screw (5). Discard bleed screw seal ring (4). 9. Inspect all parts as described in Cleaning and Inspection. Assembly 1. Place caliper assembly on a clean bench area with the open end of caliper body (2) up. 2. Lubricate cylinder bores and pistons (9) with specified fluid. 3. Fit new seals (1) by positioning seal at one area in the groove and gently work around the cylinder bore with a finger until properly seated. Check to be sure the seal is not twisted or rolled in its groove. G96757 en
7. Fit new bleed screw sealing ring (4).Reinstall bleed screw (5). 8. Lubricate guide pins (6) with specified grease. Install new guide pin boots (7) onto the guide pins.
01/2003 2003.0 BA Falcon
206-03-11
Front Disk Brake
206-03-11
DISASSEMBLY AND ASSEMBLY (Continued) 9. Reinstall guide pins into anchor plate, pushing the guide pin boot over its groove. Ensure there is no air trapped inside the boot. 10. Ensure abutment bracket mounting surfaces are clean. Reinstall abutment bracket over brake disc, securing anchor plate to mounting knuckle.
G96757 en
01/2003 2003.0 BA Falcon
206-04-1
Rear Disc Brake
206-04-1
SECTION : 206-04 Rear Disc Brake VEHICLE APPLICATION : 2003.0 BA Falcon CONTENTS
PAGE
SPECIFICATIONS Specifications .........................................................................................................................206-04-2 DESCRIPTION AND OPERATION Rear Disc Brake.....................................................................................................................206-04-3 Service Brake ......................................................................................................................206-04-3 Parking Brake .......................................................................................................................206-04-3 DIAGNOSIS AND TESTING Brake Calipers .......................................................................................................................206-04-4 Inspection .............................................................................................................................206-04-4 REMOVAL AND INSTALLATION Brake Caliper Body ................................................................................................................206-04-5 Brake Caliper Assembly .........................................................................................................206-04-5 Rear Brake Hose ...................................................................................................................206-04-5 Brake Pads ............................................................................................................................206-04-6 Brake Disc ..............................................................................................................................206-04-7 Beam Axle Brake Disc ...........................................................................................................206-04-7 DISASSEMBLY AND ASSEMBLY Brake Caliper .........................................................................................................................206-04-8
01/2003 2003.0 BA Falcon
206-04-2
Rear Disc Brake
206-04-2
SPECIFICATIONS General Specifications Description Rear disc brake minimum thicknessª Lubricants High melting point grease Pad Lining wear limit Material Torque Specifications Description Brake caliper bolts Brake disc shield bolts
G86750 en
Specification 14.5mm (0.57in)
Dow Corning 44/Niglube Rx2 1.0mm JBUF85FF Nm 103 11
01/2003 2003.0 BA Falcon
206-04-3
Rear Disc Brake
206-04-3
DESCRIPTION AND OPERATION
Rear Disc Brake Rear Disc Brake System Components
Parking Brake Item Description 1 Knukle 2 Wheel hub 3 Washer 4 Nut 5 Rotor 6 Brake Caliper 7 Bolt The rear wheel disc brake assembly consists of a rotor mounted on the outer face of the axle shaft flange and a single piston floating head caliper. A splash shield, used primarily to prevent road contaminants from contacting the inboard rotor and pad surface is also mounted on the anchor bracket. The outboard rotor and pad surfaces are protected by the road wheel.
The parking brake utilizes a cable operated rear drum system. For additional information, refer to Section 206-05.
Service Brake When the brake pedal is applied, brake fluid is displaced into the caliper bore moving the piston outward. This action forces the inner pad assembly against the rotor. The resultant reaction forces the caliper body and outboard pad assembly inward against the rotor. Braking torque is transferred from the outer and inner pad assemblies to the caliper mounting bracket. When the brake pedal is released, the piston seal retracts the piston a small amount allowing the pads to release the clamping force.
G86751 en
01/2003 2003.0 BA Falcon
206-04-4
Rear Disc Brake
206-04-4
DIAGNOSIS AND TESTING
Brake Calipers Refer to Section 206-00.
Inspection 1. Clean all residue from disc pad guide surfaces on anchor bracket and caliper housing assembly. NOTE: Always replace both axle caliper pads as a set. 2. Inspect inner and outer pads. Lining wear limit is 1.0 mm. 3. Inspect anchor bracket. Replace anchor bracket if corroded, worn or damaged. 4. Clean piston, housing and bleed screw. Use only clean denatured alcohol for cleaning. Dry, filtered compressed air should be used to dry all components and blow out all passages in the caliper housing and bleed screw. Care should be taken to keep alcohol and debris away from eyes.
5. 6. 7. 8.
CAUTION: All components must be kept away from any type of mineral oil as it will damage rubber components. Inspect piston. Replace piston if scoring, nicks, corrosion, wear or damage is evident. Inspect housing. Replace housing if bore is scored, corroded, worn or damaged. Lubricate seal and housing bore with silicone grease or brake fluid. Lubricate piston with brake fluid.
G86752 en
01/2003 2003.0 BA Falcon
206-04-5
Rear Disc Brake
206-04-5
REMOVAL AND INSTALLATION
Brake Caliper Body
2. Remove caliper mounting bolts.
Removal NOTE: Where the use of brake fluid is required, use only new, clean fluid to the correct specification, from a sealed container. 1. Raise the vehicle and remove the wheel. 2. Use wheel nut to hold disc in place. 3. Remove banjo bolt and hose end. Discard washers. Plug housing inlet port and hose end to prevent contamination ingress or fluid loss. 4. Remove guide pin bolts (items 1 and 2) and discard. Installation 1. Place caliper housing assembly into its operating 3. Lift caliper free of rotor. 4. To install reverse steps 1-3. position. If springs are sticking through caliper housing inspection hole, lift caliper housing and make necessary corrections to ensure springs are Rear Brake Hose fully retained by housing. Removal 2. Install new guide pin bolts. 3. Assemble banjo bolt, washers and hose end then screw into housing inlet port. Torque guide bolts to 28-34 Nm. Torque banjo bolt to specification. NOTE: Ensure hose is engaged to bracket prior to fitment of banjo bolt. Check routing for correct clearance on completion. 4. Bleed brakes ensuring that fluid reservoir is not emptied. Start engine and pump brake pedal slowly and firmly three times to ensure piston and disc pads resume normal operational position. Torque bleed screw to 9-14 Nm. Check for fluid leakage and rectify if any found. Check fluid level in master cylinder reservoir and fill to specified level with new brake fluid. NOTE: All hardware must be correctly installed and torqued to specification. 5. Install wheel and torque nuts to specification.
Brake Caliper Assembly
Item 1 2 3 4
Description Rivot Rear Tube Connection Grommet Banjo Bolt
Removal and Installation 1. Disconnect rear brake tube connection. 1. Repeat steps 1 & 2 of brake caliper body removal. 2. Drill out rivot. 3. Remove grommet. 4. Remove banjo bolt.
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01/2003 2003.0 BA Falcon
206-04-6
Rear Disc Brake
206-04-6
REMOVAL AND INSTALLATION (Continued) Installation 1. Install high tensile rivot.
4. Position a C-clamp so that one end rests on rear of caliper housing and the other end against outer disc pad. Tighten clamp until piston bottoms in base of caliper housing.
2. Connect tube to hose end. 3. Install hose grommet into bracket. 5. Remove and discard upper guide pin bolt. 4. Install banjo bolt through hose and into caliper. 6. Rotate caliper housing about lower caliper NOTE: Ensure hose is engaged to bracket prior to mounting bolt and guide pin. Be careful not to fitment of banjo bolt. Check routing for correct strain hose. clearance on completion. 7. Remove inner and outer pads. NOTE: Ensure fitment of new copper washers. NOTE: Always replace both axle caliper pads as a set.
Brake Pads
Removal
8. Clean all residue from disc pad guide surfaces on anchor bracket and caliper housing. 9. Inspect guide pins for free movement in anchor bracket. Replace guide pins or boots if corroded or damaged. Installation 1. Install new pads on anchor bracket. Apply approximately 0.1 gram of AKB-100 grease (or equivalent) to pad abutment surfaces on the anchor bracket.
WARNING: Although original equipment pad material is asbestos free. If non genuine pads are used, the following applies: Asbestos fiber dust may be present on brake and clutch assemblies and is hazardous to health if inhaled. Brake and clutch assemblies should be cleaned using a vacuum cleaner recommended for use with asbestos fibers such as a brake/clutch/service vacuum. The bag must be labeled per OSHA instructions, sealed, and the trash hauler notified as to the bag’s contents. If the vacuum suitable for asbestos is not available, cleaning should be done wet. If dust generation is still possible, technicians should wear goverment-approved toxic dust purifying respirators. Failure to follow these instructions may result in personal injury. 1. Siphon approximately two-thirds of the total fluid capacity from the master cylinder reservoir. Discard the fluid (different to front brake). 2. Rotate caliper housing into its operating position. 2. Raise the vehicle and remove wheels. 3. If springs are sticking through caliper housing 3. Install two wheel nuts to retain rotor. inspection hole, lift caliper housing and make necessary corrections to ensure springs are fully retained by housing. 4. Install new upper guide pin bolt and torque to 28-34 Nm. G86755 en
01/2003 2003.0 BA Falcon
206-04-7
Rear Disc Brake
206-04-7
REMOVAL AND INSTALLATION (Continued) 5. Top up master cylinder. 6. Start engine and pump brake pedal slowly and firmly three times to ensure piston and disc pads resume normal operating position. 7. Check for fluid leakage and rectify if any found. Check fluid level in master cylinder reservoir and fill to specified level with new brake fluid. 8. Remove nuts retaining rotor and install wheels. 9. Lower vehicle and torque wheel nuts to specification.
Brake Disc Removal 1. Raise the vehicle and remove the rear wheels. 2. With the park brake control released disconnect the park brake cable at the equalizer.
Beam Axle Brake Disc Removal 1. Raise the vehicle. 2. Wipe all dirt and grease from the brake pipe union and disconnect the union. 3. Detach the flexible hose from the splash shield bracket and plug the pipe and hose. 4. Remove the three screws attaching the splash shield to the axle flange. Installation 1. Position the splash shield and install the attaching screws. 2. Fit the flexible hose to the splash shield bracket and secure it with the locknut. 3. Remove the dust plugs and fit the pipe to the hose. 4. Bleed the brakes as described in Section 206-00. 5. Lower the vehicle.
3. Disconnect the cable from the levers. 4. Remove the caliper head attaching bolts and remove the caliper assembly from the rotor and mounting bracket. CAUTION: Do not allow the caliper to hang from the hydraulic line. 5. Remove the screw securing the rotor to the axle flange and remove the rotor (for beam axle only). Installation 1. Position the rotor on the axle flange, ensuring that all mounting surfaces are clean and free from contamination which could cause possible disc run-out. Install the securing screw. 2. Position the caliper correctly over the rotor and slide straight into location until caliper head bolt holes align with their respective holes in the mounting bracket. 3. Install caliper mounting bolts and torque to specification. 4. Connect the park brake cables to the levers and the equalizer. Adjust the park brake as described in Section 206-05
G86757 en
01/2003 2003.0 BA Falcon
206-04-8
Rear Disc Brake
206-04-8
DISASSEMBLY AND ASSEMBLY
Brake Caliper Disassembly
Item 1 2 3 4 5 6 7 8 9 10 11 12 13
Description Bleed Screw Caliper Housing Anchor Bracket Outer Disc Pad Boot Guide Pin Inner Disc Pad Boot Piston Seal Lower Mounting Bolt Inlet Port Upper Guide Pin Bolt
1. Remove brake caliper as described in this section. 2. Remove housing assembly (item 9), guide pins (items 3 and 4) and boots (items 5 and 6). Discard boots. Plug anchor bracket (10) colette pinholes (A) to prevent contamination ingress. 3. Remove disc pads (items 7 and 8).
G86759 en
4. Remove piston (item 12). Pack a clean shop towel between piston and housing finger then apply low air pressure at housing inlet port to remove piston. CAUTION: Apply light air pressure initially and progressively increase until piston is forced out of bore. While removing piston keep hands away from piston/housing region to avoid personal injury, as the piston may develop considerable force due to air pressure. 5. Remove boot and seal using a small, pointed tool as per Section 206-03. Be careful not to damage the bore or seal groove. Discard. 6. Remove bleed screw (item 15) and dust cover (item 16). Discard dust cover. Assembly 1. Lubricate seal (item 13) and housing bore with silicone grease or brake fluid. 2. Lubricate piston with brake fluid. 3. Install new seal (item 13) into housing bore seal groove and ensure that it is not twisted. NOTE: Ensure hose is engaged to bracket prior to fitment of banjo bolt. Check routing for correct clearance on completion.
01/2003 2003.0 BA Falcon
206-04-9
Rear Disc Brake
206-04-9
DISASSEMBLY AND ASSEMBLY (Continued) 4. Install new boot (item 14) and piston. Install boot over open end of piston and feed along piston length towards closed end. Fully extend boot away from piston closed end with boot still on piston ground surface. Install boot into housing bore boot groove and ensure full engagement.
8. Install disc pads on anchor bracket with outer disc pad with clip-on insulator toward caliper housing finger and inner disc pad with lining wear sensor toward caliper piston.
5. Slowly enter piston into bore by hand, then apply steady pressure by hand to piston and press until piston is fully seated in the bore. This process will ensure that boot and seal are correctly positioned in conjunction with no piston/housing bore scoring.
6. Inspect piston and boot. Check that boot is properly engaged in piston groove correctly.
7. Assemble dust cover and bleeder screw, then screw into housing. G86759 en
01/2003 2003.0 BA Falcon
206-05-1
Parking Brake and Actuation
206-05-1
SECTION : 206-05 Parking Brake and Actuation VEHICLE APPLICATION : 2003.0 BA Falcon CONTENTS
PAGE
SPECIFICATIONS Specifications .........................................................................................................................206-05-2 DESCRIPTION AND OPERATION Parking Brake — Sedan ........................................................................................................206-05-3 Parking Brake — Ute/Wagon .................................................................................................206-05-3 GENERAL PROCEDURES Parking Brake Cable Adjustment ...........................................................................................206-05-4 Parking Brake Shoe Adjustment ............................................................................................206-05-4 Major Parking Brake Service .................................................................................................206-05-5 REMOVAL AND INSTALLATION Parking Brake Shoes .............................................................................................................206-05-6 Parking Brake Handle ............................................................................................................206-05-6 Parking Brake Lever (Wagon), Column Shift (Ute) ................................................................206-05-7 IRS Parking Brake Cable Routing .........................................................................................206-05-7 Beam Axle Parking Brake Cable Routing ..............................................................................206-05-8
01/2003 2003.0 BA Falcon
206-05-2
Parking Brake and Actuation
206-05-2
SPECIFICATIONS Torque Specifications Description Nm Adjustment Nut 2—3 Parking Brake Screw-M6 (first 1000 10.4—12.4 vehicles only) Parking Brake Screw-M8 20—30 Torquing of hardware is significiant to the operation of the system.
G87680 en
01/2003 2003.0 BA Falcon
206-05-3
Parking Brake and Actuation
206-05-3
DESCRIPTION AND OPERATION
Parking Brake — Sedan The parking brake is hand operated. The parking brake utilises a dedicated rear drum brake system. The service brake rotor also serves as the parking brake drum. The operating cable is routed from the parking brake control assembly to the equalizer. The rear cables connect the equalizer assembly to the rear drum brakes. NOTE: The following shoe and cable adjustment procedures are to ensure correct cable/shoe settings, the five click position to check for locking wheels is not directly related to the effort/travel to hold the vehicle on a grade, which will vary dependent on a number of factors and could exceed five clicks.
Parking Brake — Ute/Wagon Floor shift vehicles have a hand operated parking brake. Column shift utility vehicles have a seat mounted, hand operated park brake with a return latch which allows the lever to return to the rest postion after being engaged.The engagement status of the park brake is indicated by a warning lamp which is illuminated when the park brake is on. An audible warning chime is activated if the vehicle is driven away with the park brake engaged. The parking brake utilises a dedicated rear drum brake system. The service brake rotor also serves as the parking brake drum. The operating cable is routed from the parking brake control assembly to the equalizer. The rear cables connect the equalizer assembly to the rear drum brakes. NOTE: The following shoe and cable adjustment procedures are to ensure correct cable/shoe settings, the four click position to check for locking wheels is not directly related to the effort/travel to hold the vehicle on a grade, which will vary dependent on a number of factors and could exceed 4 clicks.
G87682 en
01/2003 2003.0 BA Falcon
206-05-4
Parking Brake and Actuation
206-05-4
GENERAL PROCEDURES
Parking Brake Cable Adjustment
Parking Brake Shoe Adjustment
Hand–Operated (Floor Shift)
Adjustment
1. Adjust the parking brake shoes as described in this section. 2. Fully release the park brake lever. Re-apply lever one click only. 3. Tighten cable adjuster nut (under vehicle) until minimum drag is first felt on the rear wheels when rotating wheels by hand. 4. Apply the lever a further 3 clicks. 5. Check that the rear wheels cannot be rotated by hand. 6. Fully release the park brake lever and check rear wheels are free to turn by hand. 7. Check operating levers at park brake are in the ‘OFF’ position and that there is minimum clearance only between levers and cable eye.
1. Raise the vehicle and suitably support. 2. Remove rear wheel. 3. Remove service disc brake caliper from the mounting plate. Refer to Section 206-04. 4. Remove brake rotor by slowly turning and pulling outwards simultaneously keeping the brake rotor square with the axle. If the brake rotor jams whilst removing, do not force it off. Push the brake rotor back to its original position and attempt removal again. 5. Disconnect parking brake cable from the operating lever at the parking brake. Inspect any parts of doubtful strength or quality due to discolouration from heat or overstress, or are worn, they should be replaced. 6. Using a vernier caliper, measure shoe assembly diameter as close as practical to the centre of the lining material.
Sedan
Ute/Wagon Item 1 2 3 4 5 6
8. Check torque on p/clip tube mounting hardware. 9. Check P/B warning light operates by first click. 10. Check P/B returns to floor of it’s own accord when in OFF position.
G87683 en
Description Adjusting Screen Adjusting Nut Shoe Hold Down Spring Screw Tappet
7. Adjust shoe diameter to 189.6-189.8 mm by turning the adjuster nut clockwise to increase diameter. 8. Inspect brake rotor for wear and damage. Discard worn or damaged brake rotors. 9. Install brake rotor. 10. Install service disc brake caliper and torque mounting bolts to specification. 11. Install rear wheel. 12. Connect parking brake cable to the operating lever.
01/2003 2003.0 BA Falcon
206-05-5
Parking Brake and Actuation
206-05-5
GENERAL PROCEDURES (Continued) 13. Repeat 2 to 12 for the opposite side parking 8. Install adjustment pawl to the backing plate with brake. pop rivet provided. 14. Adjust the parking brake cable in accordance with 9. Adjustment pawls are left and right hand. Ensure the procedure described in this section. correct fitment. 10. Install parking brake adjustment screw to fully Major Parking Brake Service home position in notched adjusting nut. 1. Raise the vehicle. 11. Back off 1/4 of a turn. 2. Remove rear wheel, disc brake caliper and rotor. 12. Install screw and nut assembly into the backing plate on the adjustment pawl side. Keep the shoe 3. Remove and discard: slot parallel with the backing plate face. Adjusting Nut 13. Install pushrod into tappet. Adjusting Screw 14. Install pushrod and tappet into backing plate. Adjusting Pawl Ensure pushrod set correctly in lever socket by Tappet holding the lever into the backing plate whilst Pushrod inserting pushrod and tappet. 4. Remove and discard the operating lever and dust 15. Clean excess grease away using a clean rag. cover assembly. 16. Install shoe and lining assembly. Refer to Parking 5. Clean backing plate. The cleaning fluid must be a Brake Shoe Replacement in this section. high flash point oil-free solvent such as 17. Repeat 2 to 14 for opposite side parking brake. tricloroethylene or acetane. These cleaning fluids are usually highly flammable and harmful if vapours are inhaled for prolonged periods. Manufacturer warnings and recommendations should be strictly adhered to. Ensure actuation cavity in backing plate is free from grease and any other contamination. 6. Install lever and dust cover assembly. Slide the lever onto the dust cover notches. Insert the lever and dust cover assembly into the backing plate with the lever cable retainer end positioned downward. Refit the dust cover by stretching it over the cast retainer on the back plate.
Item 1 2 3 4
Description Dust Cover Lever Cable Retainer Dust Cover Notches
7. Lubricate actuation cavity and tappet. CAUTION: Ensure cavity internal bore is fully covered with grease. G87685 en
01/2003 2003.0 BA Falcon
206-05-6
Parking Brake and Actuation
206-05-6
REMOVAL AND INSTALLATION
Parking Brake Shoes
8. Install new shoe assembly. CAUTION: Ensure hands are clean. Position shoe assembly over the axle shaft. The shoe will be on the outboard side of the actuation mechanism. Slide the shoe towards the hold-down spring engaging the shoe tips in both the adjusting screw and the tappet slots. The shoe assembly must be resting against 3 pads on the backing plate with the branding facing outboard. 9. Install new hold-down springs and their attaching screws. Tighten screw to 2-5 Nm.
Item 1 2 3 4 5 6 7 8 9 10 11
Description Boot Adjuster Nut Adjuster Screw Adjuster Pawl Shoe & Lining Self tapping Screw Hold Down Spring Back Plate Tappet Pushrod Lever
Removal and Installation 1. Raise the vehicle. 2. Remove rear wheel, disc brake caliper, rotor and cable. 3. Remove or disconnect hold-down springs by undoing its attaching screw. 4. Remove the parking brake shoe by gently lifting the shoe over the axle flange, the shoe will pivot from the actuation mechanism. Once clear of the flange, disconnect from the actuation mechanism and discard.
CAUTION: Ensure the spring and screw are fully seated. Inspect shoe assembly position. Shoe must be central on the backing plate and both tips located in the slots correctly. Check the actuation mechanism. Manually apply the parking brake operation lever. If the mechanism does not operate, the parking brake must be disassembled and reassembled. 10. Adjust shoe diameter. Refer to parking brake shoe adjustment in this section. 11. Repeat procedure for the opposite side parking brake.
Parking Brake Handle Removal 1. Remove driver seat. 2. Remove 3 M8 Screws from handle. 3. Remove HEX Screw 32x14. 4. Remove P-Clip. Ute/Wagon
CAUTION: Ensure the actuation mechanism is not disturbed. An elastic band may be used to contain the mechanism. 5. Clean debris and dust away from the backing plate using a clean rag. 6. Adjust parking brake adjustment screw to fully home position in the notched adjustment nut then back off 1/4 of a turn. 7. Align the shoe slots in both the adjusting screw and the tappet to be parallel with the backing plate face.
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REMOVAL AND INSTALLATION (Continued) Sedan
5. Release cable from park brake.
4. Rotate P-Clips. 5. Release cable from park brake.
Installation 1. Reverse removal procedure.
IRS Parking Brake Cable Routing Removal 1. Remove parking brake handle as shown previously in this section. 2. Route Park Brake cable to rear of Differential.
Installation 1. Reverse removal procedure.
Parking Brake Lever — Column Shift (Ute) Removal 1. Remove 2 retaining bolts. 3. Unclip cable as shown.
2. Remove bracket outboard of RH front seat assembly. 3. Remove 2 HEX Screws 32x14.
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REMOVAL AND INSTALLATION (Continued)
Installation 1. Reverse removal procedure.
Beam Axle Parking Brake Cable Routing Removal 1. Loosen and remove adjuster nut. 2. Disconnect cables from equaliser bracket, support brackets and from Banksia lever. Wagon
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REMOVAL AND INSTALLATION (Continued) Ute - Petrol
Ute - LPG
NOTE: Note on LPG Ute there are two sets of cotton reels to support cable over the lenght of the LPG tank. Installation 1. Route cables per diagrams above. 2. Ensure cable ferrules and white clips are seated into equaliser. 3. Fit adjuster nut and adjust system as per sedan.
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SECTION : 206-06 Hydraulic Brake Actuation VEHICLE APPLICATION : 2003.0 BA Falcon CONTENTS
PAGE
SPECIFICATIONS Specifications .........................................................................................................................206-06-2 DESCRIPTION AND OPERATION Hydraulic Brake Actuation ......................................................................................................206-06-3 Hydraulic Brake System .......................................................................................................206-06-3 Dual Hydraulic Brake System ..............................................................................................206-06-3 Brake Master Cylinder .........................................................................................................206-06-3 Dual Master Cylinder Brake System (where fitted) ..............................................................206-06-3 Power Brake Booster ...........................................................................................................206-06-4 Acronyms and Abbreviations ...............................................................................................206-06-5 DIAGNOSIS AND TESTING Hydraulic Brake Actuation ......................................................................................................206-06-6 Inspection and Verification ...................................................................................................206-06-6 Function Test .......................................................................................................................206-06-7 Symptom Chart ....................................................................................................................206-06-7 Connector Circuit Reference ................................................................................................206-06-8 Pinpoint Tests ....................................................................................................................206-06-10 GENERAL PROCEDURES Adjustable Brake Indexing ...................................................................................................206-06-16 System Bleeding ..................................................................................................................206-06-16 Power Brake Booster Testing ..............................................................................................206-06-16 Hydraulic Line Repair ...........................................................................................................206-06-16 Brake Hose Replacement ....................................................................................................206-06-16 Brake Tube Replacement ....................................................................................................206-06-16 REMOVAL AND INSTALLATION Brake Box Assembly ............................................................................................................206-06-17 Brake Pedal Adjustment Motor ............................................................................................206-06-20 Brake Pedal Motor Cables ...................................................................................................206-06-20 Brake Pedal Control Switch (where fitted) ...........................................................................206-06-21 Brake and Cruise Pedal Switch Setting ...............................................................................206-06-21 Brake Pedal Pad ..................................................................................................................206-06-22 Accelerator Pedal Pad .........................................................................................................206-06-22 Power Brake Booster ...........................................................................................................206-06-22 Dual Master Cylinder ...........................................................................................................206-06-23 DISASSEMBLY AND ASSEMBLY Electronic Throttle Control Module .......................................................................................206-06-24 Dual Master Cylinder ...........................................................................................................206-06-24
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SPECIFICATIONS General Specifications Description Brake Fluid (Ford)
Specification Mobil ESZ - M6C55A
Torque Specifications Description Adjuster Motor Retaining Bolts (adjustable pedal) Pedal Box Housing Brake Booster Retaining Nuts
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Nm 5 ± 0.5 22.5 ± 3.4 22.5 ± 3.4
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DESCRIPTION AND OPERATION
Hydraulic Brake Actuation Hydraulic Brake System
Dual Master Cylinder Brake System (where fitted)
WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes for 15 minutes with cold running water. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately.
Dual Hydraulic Brake System The hydraulic brake system is a pedal operated, front/rear split, dual line brake system that consists of the following; Power brake booster Brake master cylinder Brake pressure control valves (where fitted) Front disc brake caliper assemblies Front disc brake rotors Rear disc brake calipers Brake pipes and hoses Anti-lock Brake System (ABS) components
Brake Master Cylinder The brake master cylinder is a dual piston type. The master cylinder operates as follows; When the brake pedal is applied, pressure is transferred by mechanical linkage to the primary and secondary systems. Brake master cylinder pistons apply hydraulic pressure to the two circuits. The master cylinder consists of; Primary and secondary pistons. Brake master cylinder reservoir with integral fluid level warning indicator (on all ABS cars and pressure differentiated switch on non ABS utes). Fixed proportioning valve on non ABS cars.
The system consists of a dual master cylinder which incorporates a proportioning valve, on some models only a pressure differential valve assembly, a ‘fast fill’ valve assembly and a switch. The switch on the differential valve or fluid level switch activates a brake fail warning light, located on the instrument panel. The primary system operates the front brakes and secondary the rears.
Fast Fill Valve The ‘fast fill’ (fast pressure build up) valve provides reduced pedal travel by rapidly overcoming the large low pressure displacements associated with roll-back disc brakes that allow for the elimination of pad to rotor drag. As well as a conventional secondary piston, the cylinder incorporates a stepped primary piston located nearest the booster. The fluid moved by the larger diameter stepped piston is pushed over the primary seal of the smaller diameter primary piston so bringing the brakes into operation earlier. The ‘fast fill’ valve incorporates a pressure seal in one direction, a one-way ball valve in the other and a by-pass bleed groove. In operation, the ball valve retains fluid in the master cylinder until a pre-set line pressure is reached, after which all further increases in pressure are exhausted back into the reservoir, reverting the operation of the master cylinder to that of a normal unit. Recuperation is achieved by fluid by-passing the pressure seal. The by-pass bleed groove allows fluid to by-pass the ball valve ensuring that a fluid passage is maintained between the brake pressure circuit and reservoir in the brakes-off position.
Pressure Differential and Proportioning Valve Proportioning Valve (where fitted on non ABS ¾ tonne Utes) The proportioning valve regulates the rear brake system hydraulic pressure and is located between the G22113 en
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DESCRIPTION AND OPERATION (Continued) rear brake system inlet and outlet ports of the master cylinder.
Operation
The Booster Servo Unit is designed to assist the effort applied by the driver’s foot on the brake pedal. It uses the vacuum created in the engine inlet manifold to boost force applied at the master cylinder push rod in an exact and controlled manner. The assembly is mounted between the brake pedal and the master cylinder, with the push rod from the rear of the unit connected to the brake pedal, and a push rod from the front of the unit abuts the master cylinder piston. The force which assists the pedal effort is obtained by admitting atmospheric pressure to one side of the diaphragm which is suspended in a vacuum. The difference in pressure moves the diaphragm/s and this movement is used in a controlled manner to augment the driver’s pedal effort. Pressure Differential Valve (where fitted on non In the case of a vacuum failure, the valve and rod ABS vehicles) assembly of the servo and the master cylinder push The brake fail warning light switch is mounted in the rod act as a single push rod. The brakes will, valve body with the spring-loaded plunger fitting into a therefore, work in the conventional manner, but more tapered groove in the centre of the spool. With the effort will be required on the brake pedal. spool in a centralized position the switch contacts Adjustable Pedal Box remain open. When the brake pedal is applied, the full rear brake fluid pressure passes through the proportioning valve to the rear brake hydraulic system until the valve split point is attained. Above the split point, the proportioning valve reduces hydraulic pressure to the rear brakes for balanced braking. The proportioning valve for ¾ tonne non ABS utes has a 2.5 MPa split point, on the end face of the master cylinder body. NOTE: For 1 tonne non ABS utes, the master cylinder does not contain proportioning valve, split point is shown as ‘C000’ stamped on outside of cylinder. Proportioning in this case is handled via a load sensing proportioning valve located over rear axle.
Should there be a loss of pressure in either the front or rear brake system, when the brake pedal is applied, the spool will move off centre closing the switch contacts and turning on the warning light on the instrument panel. After repairs have been made and the brake system bled, when the brakes are applied the pressure in the front and rear systems will equalize, centralizing the spool and opening the switch contacts thus turning off the warning light. Fluid Level Warning Switch (All ABS cars only) All ABS models have a fluid level warning switch and no differential switch. The warning switch is dipped into the fluid reservoir and interacts with a float within the fluid. When the fluid level drops below a predetermined level the switch activates, resulting in a warning light on the instrument panel.
Power Brake Booster Description Both 6 and 8 cylinder vehicles are equipped with a twin diaphragm brake booster. The brake booster is a self-contained vacuum-hydraulic braking unit mounted on the engine side of the dash panel. The brake booster is of the vacuum suspended type which utilizes engine intake manifold vacuum and atmospheric pressure for its power. The booster unit is to be replaced, not repaired, if found to be defective. G22113 en
Description The pedal box assembly is a unit construction comprising a reinforced plastic structure upon which the pedals, switchgear and adjustment motors are mounted. The complete pedal box assembly can be removed from the vehicle as a single unit. The pedal assembly incorporates the ETC or drive by wire accelerator sender unit. In the adjustable version the brake and accelerator pedals are height adjustable via a aswitch on the side of the steering column. Where applicable pedal adjustment is achieved by a single drive motor attached directly to the accelerator pedal with a drive cable running to a gear box on the brake pedal, adjustment of brake and accelerator pedals is simultaneous.
Acronyms and Abbreviations APM PCM BEM Step Over MSC PPS
Accelerator Pedal Module Power Train Module Body Electronic Module Height Difference Between Brake and Accelerator Pedal Memory Seat Controller Pedal Position Sensor
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DESCRIPTION AND OPERATION (Continued)
Item 1 2 3 4 5 6 7 8 9 10 11 12
Description Brake Pedal Transmission Adjusting Cable Potentiometer (Memory Only) Adjusting Motor APM Adjusting Motor Transmission Accelerator Pedal Transmission Drive Cable Brake Pedal Brake Lamp Switch Cruise Control Cut Off Switch (Brake) Brake Booster Rod Pivot
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DIAGNOSIS AND TESTING should have a thorough knowledge of brake system operation and accepted general performance guidelines in order to make good comparisons and Inspection and Verification detest performance problems. Preliminary checks Select a road that is reasonably smooth and level. Gravel and bumpy roads, except to demonstrate ABS NOTE: Always check the fluid level in brake master cylinder before carrying out the test procedures. If the function are not suitable. The surface does not allow the tires to grip the road equally. Avoid crowned fluid level is not at the correct level, fill the reservoir roads. with specified brake fluid. A key factor in evaluating brake concerns is the NOTE: Prior to carrying out any diagnosis, make deceleration rate. This varies from vehicle to vehicle certain that the brake warning indicator is functional. and with changes in operating conditions. It is evident Visually examine front and rear tires and wheel how well the brakes are working after just a few assemblies for damage such as uneven wear applications. patterns, tread worm out or sidewall damage. Check these items before entering Diagnostics. Make sure the tires are of the same size, type and, Topic Specification where possible, same manufacture. Install a new tire Brake Fluid Ensure that the Reservoir is Filled or wheel if it is damaged or excessively worm. Wheels Reservoir to the Max Point. Use Ford and tires must be cleared of any foreign material and Approved Brake Fluid Mobil ESZ tire pressures adjusted to the correct specification. M6C55A. If tires exhibit uneven wear or feathering, the cause must be corrected. Check steering and suspension CAUTION: Do not allow components for damage or wear and, if necessary brake fluid to contact vehicle check and adjust front alignment. paint work. A change in brake pedal feel is usually the first Vehicle Test Ensure That Your Local State indicator of a brake concern. The change may only be Drive to Speed Limits are Not Exceeded normal ABS function, but maybe sufficient cause for Confirm Fault further investigation. The brake warning indicator in Battery Voltage Must be Greater Than 12 Volts the instrument cluster and the brake fluid level in the Obstructions Check for Any Obstructions at the brake master cylinder reservoir are also indicators of Brake Pedal Area, Such as Floor the system concerns. Mats and Wiring Harnesses If the wheel is locked and the vehicle must be moved,
Hydraulic Brake Actuation
open the bleeder screw at the locked wheel to let out Visual Inspection Chart enough fluid to relieve the pressure. Close the bleeder screw. This bleeding operation may release the Mechanical Electrical brakes but it will not correct the locked wheel Brake Pedal Fuse(s) condition, repair the locked components before Pedal Pad Relay(s) proceeding. Adjustment Wiring harness mechanism Electrical connector(s) Brake Booster Brake pedal switches Inspect all hoses and connections, all unused vacuum MSC connectors should be capped. Hoses and their connections should be correctly secured and in good condition with no holes, soft or collapsed areas.
Road test Perform a road test to compare actual vehicle braking performance with the standard performances expected by the driver. The ability of the test driver to make valid comparisons and detect performance deficiencies will depend on experience. The driver
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DIAGNOSIS AND TESTING (Continued) Function Test Condition Pedal Feel
Brake Lamp Switch Lack of Braking Efficiency
Adjustable Pedal
Possible Source Pedal Slow or does not return Binding / Raspy pedal Worn Pedal Pad Not Functioning Adjustment Excessive Force Required Master Cylinder Leakage Brake Booster Tyre Wear Tyre Pressure Memory Adjustment Motor Fault No Pedal Response Adjustment Cable Brake and Accelerator Pedal Heights Incorrect
Function Test Manual Application Test of the Brake Pedal to confirm Manual Test Visual Inspection Visual Inspection Visual Inspection Manual Application Test of the Brake Pedal to confirm Visual Inspection Manual Application Test of the Brake Pedal to confirm Visual Inspection Pressure Check Manual Application Test of the Brake Pedal to confirm Measurement
Pin Point Test 206-06-B 206-06-B 206-06-C
206-06-E 310-02-C5 & 6
Symptom Chart Condition Pedal Feel
Poor Braking Efficiency
Cruise Control not turning off when brake applied
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Source
Action
Brake Pedal Not Returning on Release
Go to Pin Point Test 206-06-B
Excessive Pedal Travel
Braking System Diagnosis. Refer to this section.
"Raspy" feel
Go to Pin Point Test 206-06-B
Pedal Binding at Pivot
Go to Pin Point Test 206-06-A
Pedal Pad Worn
Replace Brake Pedal Pad. Refer to procedure in this section.
Obstruction at Pedal
Go to Pin Point Test 206-06-B
Faulty Brake Booster
Braking System Diagnosis. Refer to this section.
Brake Disc Pads Worn
Refer to Brake section 206-03, 206-04.
Booster Rod Disconnected
Go to Pin Point Test E.
Vacuum Poor, Leaking or disconnection at the Brake Booster
Refer to Braking System Diagnosis. Refer to this section.
Brake Master Cylinder Leaking / Faulty
Refer to Braking System Diagnosis. Refer to this section.
Cruise Control Switch Faulty / Plug Disconnected
Go to Pin Point Test D
Stop Lamp Switch Faulty / Plug Disconnected
Go to Pin Point Test C
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DIAGNOSIS AND TESTING (Continued)
Condition
Source
Adjustable Brake Pedal
Cannot Adjust Pedals
Go to Pin Point Test E
Faulty Memory
Go to Pin Point Test E
Pedal "Step Over" Height Incorrect
Go to section 310-02, Pin Point Test C.
Stop Lamp Switch Faulty
Go to Pin Point Test C
Stop Lamp Switch
Action
Connector Circuit Reference CONNECTOR C - 378 PEDAL POSITION SENSOR (POTENTIOMETER)
Pin Number(s) 1 2 3
Circuit Designation/Description Normal Condition/Measurement BLANK 1491A (Blue / Yellow) Resistance / Voltage Pedal Position Sensor A 1491 (White) Resistance / Voltage Pedal Position Sensor B
CONNECTOR C - 191 BRAKE LAMP SWITCH
Pin Number(s) 1 2
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Circuit Designation/Description 10AA (Green / Red) Brake Switch High 10Y (Green / Red) Brake Switch Signal
Normal Condition/Measurement Ohms - Continuity (only with pedal depressed) Ohms - Continuity (only with pedal depressed)
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DIAGNOSIS AND TESTING (Continued) CONNECTOR C - 379 PEDAL ADJUSTING MOTOR NOTE: Ignition to be "ON" for Voltage Tests. NOTE: Battery to be disconnected for resistance checks.
Pin Number(s) 1 2
Circuit Designation/Description Normal Condition/Measurement 1489 (R), 1494 (L) Voltage less than 2 Volts 1490 (W), 1495 (R) Voltage less than 2 Volts
CONNECTOR C - 36 CRUISE CONTROL SWITCH (BRAKE PEDAL)
Pin Number(s) 1 2
Circuit Designation/Description Normal Condition/Measurement 10AC (Green/Red) Ohms - Continuity Cruise Control - High 511 (Blue/Green) Ohms - Continuity Cruise Control - Signal
CONNECTOR C - 111 CRUISE CONTROL SWITCH (CLUTCH)
Pin Number(s) 1 2
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Circuit Designation/Description 10AC (Green/Red) Cruise Control - Signal 57FH ((Blue) Cruise Control - High
Normal Condition/Measurement Ohms - Continuity (Yes - nominal state) Ohms - Continuity (Yes - nominal state)
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DIAGNOSIS AND TESTING (Continued) CONNECTOR C - 395 PEDAL BOX HARNESS NOTE: Depending on the vehicle level some of the terminals listed below will be blank. High series connector shown. Values given are with connector C-395 connected, ignition on and back probing the terminals.
Pin Number(s) 1 2 3 4 5
Circuit Designation/Description 10AB (Green/Red) Brake and Cruise switch (High) 1489 (Red) Pedal adjusting motor - A 1490 (White) Pedal adjusting motor - B 57 H (Black) Clutch switch 511 (Blue/Green) Cruise control deactivation switch signal 10Y (Green/Red) Brake switch - signal 1491 (White) Pedal position sensor - B 1491A (Blue/Yellow) Pedal position sensor - A BLANK 92 (Blue/Yellow) Clutch switch - signal
Normal Condition/Measurement 12 - 14 Volts Using adjustment switch - Centre =0 Volts, Upwards = 12-14 Volts. Downwards = 0.1 Volt Using adjustment switch - Centre =0 Volts, Upwards = 0.1 Volt. Downwards = 12-14 Volts N/A 12-14 Volts (Brake pedal pushed - 0 Volts) 0 Volts (Brake pedal pushed - 12-14 Volts) N/A N/A
N/A
Pinpoint Tests PINPOINT TEST A : EXCESSIVE BRAKE PEDAL MOVEMENT AT PIVOT Test Step A1
Result / Action to Take
PEDAL MOVEMENT CHECK Grasp the Brake pedal pad area with your hand. Move the pedal from side to side to check for movement at the upper pivot area. Carry out check in the applied and not applied brake pedal position.
Yes
Go to A2
No
Okay
Is the pedal movement more than the maximum of ± 3.5 mm?
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DIAGNOSIS AND TESTING (Continued) Test Step A2
Result / Action to Take
PIVOT PIN HOUSING DAMAGE Carry out this check the same as described in test step A 1. Using a Torch visually inspect for any cracks around the pivot pin housing as the pedal is moved side to side and applied towards floor. Were any cracks found?
Yes
Replace the pedal box assembly. Refer to removal and installation instructions in this chapter.
No
Okay
PINPOINT TEST B : PEDAL FEEL INCORRECT CAUTION: Step B2, Remember to tighten the Booster retaining nuts to (22.5 +/- 3.4 NM) when the test is completed. Test Step B1
Result / Action to Take
OBSTRUCTIONS AT PEDAL Yes
Check for obstructions at and / under the brake pedal, such as a floor mat or wiring harness fouling the upper mechanism.
Remove the obstruction and recheck
Did you find an obstruction?
No
Go to B2
B2
BRAKE PEDAL RETURN Loosen the Four nuts used to retain the brake booster to the pedal box. Remove the pin used to retain the booster rod to the brake pedal. Detach the booster rod from the brake pedal. Move the brake pedal up and down slowly, looking for evidence of binding.
Yes
Replace the pedal box assembly. Refer to removal and installation instructions in this chapter.
No
Go to the brake booster. Refer to removal and installation instructions in this chapter
Did the brake pedal bind when moving up and down?
PINPOINT TEST C : STOP LAMP SWITCH Test Step C1
STOP LAMP OPERATIONAL CHECK Ignition ON. Apply brake pedal. Do the rear Stop lamps illuminate?
C2
Result / Action to Take
Yes
Stop lamp circuit Okay
No
Go to C2
STOP LAMP CIRCUIT FUSE Check the 15 Amp Fuse # 7. Was Fuse blown?
Yes
Replace Fuse and recheck. NOTE: If Fuse blows again, this could indicate an electrical system fault.
No
Go to C3
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DIAGNOSIS AND TESTING (Continued) Test Step C3
Result / Action to Take
PCM CHECK Back probe an earth at the PCM connector terminal B25 B00 (G-R wire).
Yes
Ignition ON.
No
PCM issue. Refer to Section 303-14.
Go to C4
Apply brake pedal. Do the rear stop lamps now illuminate?
C4
STOP LAMP SWITCH CONTINUITY Remove the Stop lamp switch. Refer to Section 417-01. Carry out a continuity test. With the stop lamp switch plunger Out = Continuity. Push the stop lamp switch plunger Inwards = Open circuit.
Yes
Stop lamp switch Okay
No
Replace the stop lamp switch. Refer in this Section.
Is the stop lamp switch continuity check Okay?
PINPOINT TEST D : CRUISE CONTROL BRAKE PEDAL CUT OFF SWITCH Test Step D1
Result / Action to Take
STOP LAMP CIRCUIT FUSE Check the 15 Amp Fuse ??? Was Fuse blown?
Yes
Replace Fuse and recheck. NOTE: If Fuse blows again, this could indicate an electrical system fault.
No
Go to D2
D2
CRUISE CONTROL SWITCH CONTINUITY Yes
Remove the cruise control switch, colour Green. Refer to Section 303-14.
Go to D3
Carry out a continuity test.
No
With the switch pin Out = Open circuit. Push the switch pin Inwards = continuity.
Replace the cruise control switch. Refer to Section 303-14.
Is the cruise control switch continuity check Okay?
D3
SWITCH EARTH CIRCUIT CONTINUITY Disconnect the electrical connector at the cruise control switch and the PCM. Check the LG wire (511) from the switch connector to the PCM terminal B32 RBS.
Yes
PCM issue. Refer to Section 303-14.
No
Check and repair wiring or terminal fault
Was there continuity?
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DIAGNOSIS AND TESTING (Continued) PINPOINT TEST E : ADJUSTABLE PEDAL ISSUES NOTE: The Pedal adjustment motor is equipped with a Thermal cutout feature. If the motor is operated for an extended period this Thermal cutout will open circuit (trip). In this case wait for 5 Minutes to allow resetting of the Thermal cutout device. Test Step E1
Result / Action to Take
NO ADJUSTMENT RESPONSE - PART 1 Yes
Check to see if the electric wiring connector C-379 is connected, to the pedal adjustment motor.
Go to E2
Is C-379 connected?
No
Reconnect the connector and retest
E2
PEDAL BOX HARNESS Check to see if the electrical wiring connector C-395 is connected. Is C-395 connected?
Yes
Go to E3
No
Reconnect the connector and retest
E3
NO PEDAL RESPONSE Remove the electrical connector C-379 from the pedal adjustment motor.
Yes
Ignition On.
No
Using a multimeter, check the Voltage at the terminals, Red (+) and White (-) wires at the vehicle harness connector C-379.
Go to E4
Electrical issue at the vehicle harness. Refer to Section 418-00 & Wiring Supplement.
Is the Voltage less than 2 Volts?
E4
ADJUSTMENT SWITCH VOLTAGE CHECK Remove the electrical connector C-379 from the pedal adjustment motor.
Yes
Using a multimeter, check the Voltage at the terminals, Red (+) and White (-) wires at the vehicle harness connector C-379.
No
Go to E5 (reconnect connector C-379).
Go to E6
Ignition On. Hold down the Brake pedal adjustment switch (at steering column).
NOTE: The voltage polarity will change when the switch is held in the opposite direction.
Is the voltage reading equal to or greater than 12 volts?
E5
BRAKE PEDAL ADJUSTMENT SWITCH Ignition On. Ensure that the "thermal cutout has not "tripped" (will have to wait 5 Minutes for reset). Operate Pedal adjustment switch. Does the motor emit a "click" sound when the switch is operated?
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Yes
Go to E7
No
Replace the Adjustment Motor. Refer to procedure in this section.
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DIAGNOSIS AND TESTING (Continued) Test Step E6
Result / Action to Take
PEDAL ACTIVATION SWITCH Remove the lower section of the steering shroud. Refer to Section 211-04. Disconnect the electrical connector from the activation switch harness. Push the activation switch to the forward position. Using an Ohms meter check for continuity between the Black, Blue/Black and Blue/Orange wires.
Yes
Carry out vehicle wiring harness testing. Refer to the appropriate wiring diaghram.
No
Replace the pedal activation switch. Refer to Section 211-05.
Push the activation switch to the downwards position. Using an Ohms meter check for continuity between the Black, Yellow and Blue/Orange wires. Did the activation switch have continuity in the forward / downward Ohms check?
E7
MEMORY FUNCTION NOT OPERATING (MEMORY UNIT ONLY) NOTE: Pedal position sensor faults should have been set by error code from the memory seat control.
Disconnect the Potentiometer electrical connector C-378 from the adjustment cable. Using a multimeter, check the resistance at the terminals, L - Y (+) and White (-) wires at the vehicle harness connector C-378. Reconnect connector C-378.
Yes
Replace the adjustment cable assembly. Refer to procedure in this section.
No
If the resistance reading was greater than 10 K Ω. Replace the adjustment cable. Refer to procedure in this section. Otherwise. Go to E8
Was the resistance less than 1.5 KΩ?
E8
POTENTIOMETER - RESISTANCE FEED BACK STAGE-1 (MEMORY ONLY) Adjust pedals to the fully forward position. Using a multimeter, check the resistance at the terminals, L - Y (+) and White (-) wires at the vehicle harness connector C-378. Adjust pedals to the fully rearward position. Using a multimeter, check the resistance at the terminals, L - Y (+) and White (-) wires at the vehicle harness connector C-378.
Yes
Go to E9
No
Replace the adjustment cable. Refer to procedure in this section.
Is the resistance value between the fully forward and rearward positions greater than 600 Ω?
E9
POTENTIOMETER - RESISTANCE FEED BACK STAGE2 (MEMORY ONLY) Using the resistance readings taken in E 7. Was the resistance reading for "full forward " position between 1.5 and 4.5 KΩ?
Yes
Go to E10
No
Adjustment cable incorrectly adjusted. Refer to procedure in this section.
E10
ADUSTMENT CABLE Check the adjustment cable for jamming, crushed, twisted or caught condition. Did any of the above occur?
Yes
Remove the adjustment cable. Refer to procedure in this section. Grasp the inner cable to see if it turns freely, if not replace the cable. Refer to procedure in this section or the cause of twisting, jamming etc.
No
Go to E11
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DIAGNOSIS AND TESTING (Continued) Test Step E11
Result / Action to Take
BRAKE PEDAL ADJUSTMENT TRANSMISSION / CABLE Gently disconnect the drive cable from the adjustment motor transmission (located top of brake pedal). Using your fingers fully rotate the inner cable 10 times clockwise and 10 times anticlockwise. View the brake pedal for movement while turning the inner cable.
Yes
Go to E12
No
Replace pedal box assembly. Refer to procedure in this section.
Clockwise - Rearward pedal movement, anticlockwise - Forward pedal movement.
NOTE: When turning the inner cable the pedal will only move very slightly. Care should be taken when viewing movement. Does the pedal move when cable turned?
E12
ACCELERATOR ADJUSTMENT TRANSMISSION. PART 1 Disconnect the brake pedal transmission drive cable from the brake pedal transmission.
Yes
Ignition On.
No
Operate the adjustment switch.
Go to E14
Go to E13
Does the accelerator pedal move?
E13
ACCELERATOR ADJUSTMENT TRANSMISSION. PART2 Remove the pedal box assembly from the vehicle. Refer to procedure in this section. Remove the adjusting motor. Refer to procedure in this section. Using your fingers, fully rotate the accelerator pedal transmission "short" cable 10 times clockwise and 10 times anti-clockwise. View the accelerator pedal for movement while turning the cable.
NOTE: When turning the cable the accelerator pedal will only move
Yes
Pedal adjustment transmission operating okay. Replace the adjusting motor. Refer to procedure in this section.
No
Replace the pedal adjustment transmission. Refer to procedure in this section.
very slightly. Care should be taken when viewing pedal movement. Did the cable turn?
E14
STEP OVER HEIGHT CHECK PART 1 Measure the Step over height between the Brake and Accelerator pedal. Is the measured height distance more than 40mm?
Yes
Rectify the pedal Indexing. Refer to procedure in this section.
No
Go to E15
E15
STEP OVER HEIGHT CHECK PART 2 Measure the Step over height between the Brake and Accelerator pedal. Is the measured height distance less than 30mm?
Yes
Rectify the pedal Indexing. Refer to procedure in this section.
No
Step Over height okay, no further work required.
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01/2003 2003.0 BA Falcon
206-06-16
Hydraulic Brake Actuation
206-06-16
GENERAL PROCEDURES
Adjustable Brake Indexing
Brake Hose Replacement
1. Refer to Section 310-02.
A flexible brake hose should be replaced if it shows signs of softening,cracking,leaks or abrasion. When installing a brake hose,position the hose to avoid contact with other chassis parts. Brake hoses should be installed as shown on the installation drawings. Hoses must not be twisted. New copper gaskets must be installed in all applicable locations.
System Bleeding 1. Refer to Section 206-00.
Power Brake Booster Testing 1. Check the hydraulic brake system for leaks or insufficient fluid. 2. With the transmission in neutral, stop the engine and apply the parking brake. Depress the brake pedal several times to exhaust all vacuum in the system. 3. With the engine shut off and all vacuum in the system exhausted, depress the pedal, and hold it in the applied position. Start the engine. If the vacuum system is operating, the pedal will tend to fall away under foot pressure and less pressure will be required to hold the pedal in the applied position. If no action is felt, the vacuum booster system is not functioning. 4. Remove the vacuum hose from the brake booster check valve connection. Manifold vacuum should be available at the check valve end of the hose with the engine at idle speed and the transmission in neutral. Be sure that all unused vacuum outlets are properly capped, hose connectors properly secured, and that vacuum hoses are in good condition. When it is established that manifold vacuum is available to the booster, test the check valve and replace if necessary. With the engine shut off disconnect the vacuum hose from the check valve. Connect a piece of tubing to the check valve and blow into the check valve. No air should pass through the valve. Connect the vacuum hose to the booster and repeat Step 3. If no downward movement of the brake pedal is felt, replace the brake booster. 5. Operate the engine a minimum of 10 seconds at fast idle. Stop the engine and let the vehicle stand for 10 minutes; then, depress the brake pedal with approximately 80 N force. The pedal feel (brake application) should be the same as that noted with the engine operating. If the pedal feels hard (no power assist), replace the brake booster. NOTE: If the brake pedal movement feels spongy, bleed the hydraulic system to remove air from the system.
Brake Tube Replacement If a section of the brake tubing becomes damaged,the entire section should be replaced with tubing of the same type,(special doublewall steel tubing conforming to specification ASTM-A 254-6T),size,shape and length. Copper tubing should not be used in a hydraulic system. Brake lines should be installed as shown on the installation drawings. Use Special Tools when bending brake tubing to fit underbody or rear axle contours.Be careful not to kink or crack the tube. All brake tubing should have the ends formed identical to the existing ends (using Special Tools)to provide leak-proof connections.Clean the brake tubing by flushing with clean brake fluid before installation.
Hydraulic Line Repair Always bleed the applicable primary or secondary brake system after hose or line replacement. Install the lines and retaining clips as shown on the illustrations.
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01/2003 2003.0 BA Falcon
206-06-17
Hydraulic Brake Actuation
206-06-17
REMOVAL AND INSTALLATION
Brake Box Assembly
5. Dislodge brake booster pin clip by pulling rear and upward.
Removal WARNING: Wait at least one minute after disconnecting the battery ground cable before disconnecting any electrical connector. CAUTION: Battery must be disconnected prior to removing brake box assembly. NOTE: This is not a dealer serviced item Pedal box must be replaced if brake pedal requires replacement because this is a safety critical assembly. NOTE: There are four variants of the pedal box, which include three variants to the brake pedal. Removal and replacement is similar for all Pedal Boxes. Removal of Pedal Box Assembly is required to service 6. Remove rotator de-coupler. components. 7. Undo four brake booster mounting bolts. NOTE: The steering column must first be removed to allow removal of the pedal box. 1. Remove the lower dash panel.
8. Disconnect booster rod from brake pedal by sliding the booster rod toward the passenger side of the vehicle. 2. Remove side kick panel (Refer to Section 501-12). 3. Remove steering column (Refer to Section 211-04). 4. If Pedal Box is adjustable then drive brake pedal down to lowest position as shown.
Item 1 2
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Description Pin Clip Rotator De-coupler
01/2003 2003.0 BA Falcon
206-06-18
Hydraulic Brake Actuation
206-06-18
REMOVAL AND INSTALLATION (Continued) 9. Lightly pull brake pedal away from floor until clear 12. Unbolt steering intermediate shaft and pull of booster rod. forward (away from firewall).
10. If the vehicle has a manual transmission then undo two clutch master cylinder bolts.
13. Disconnect connectors C-317 and C-379 from pedal box assembly.
11. Disconnect accelerator electrical connection.
14. Remove fuse box out of the way.
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01/2003 2003.0 BA Falcon
206-06-19
Hydraulic Brake Actuation
206-06-19
REMOVAL AND INSTALLATION (Continued) 15. Undo two nuts holding pedal box to body.
2. Ensure yellow plastic clip is in place and not damaged during assembly. WARNING: The yellow plastic clip is part of the pedal anti-intrusion system and MUST be refitted if the brake booster rod has been detached from the pedal shaft.
16. Carefully remove Pedal Box Assembly by pulling from the points shown on the diagram.
3. Check that the rotator de-coupler is correctly positioned on the pedal pin. The decoupling mechanism must be correctly positioned as shown, with 1-2 mm clearance between the lower end of the de-coupler blade and the rotator de-coupler. WARNING: After any service procedures that involve removal of the pedal box. It is important to check that the breakaway components have not been dislodged. WARNING: Do not apply loads on the accelerator, brake pedal or accelerator when removing the pedal box assembly from the vehicle. Loading pedals during installation or removal can misalign or damage components. WARNING: Remove and install pedal box carefully and ensure that fingers are not pinched in the process. Installation 1. Install components in reverse order.
Item 1 2
G22120 en
Description De-coupler Blade Rotator De-coupler
01/2003 2003.0 BA Falcon
206-06-20
Hydraulic Brake Actuation
206-06-20
REMOVAL AND INSTALLATION (Continued)
Brake Pedal Adjustment Motor
6. Remove motor, ensure inserts remain in place.
Removal 1. Remove pedal box assembly from car Refer to Section 206-4. 2. Remove Accelerator assembly Refer to Section 310-02 3. Rotate cable connect plug anti-clockwise and pull plug out of motor as shown.
Installation 1. Install components in reverse order.
Brake Pedal Motor Cables Removal 1. Rotate cable connect plug anticlokwise and pull plug at motor end as shown. 4. Remove gear box assembly from pedal box.
5. Remove two screws holding motor to pedal box.
2. Disconnect plug at brake pedal end as shown using pliers.
Installation 1. Install components in reverse order.
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01/2003 2003.0 BA Falcon
206-06-21
Hydraulic Brake Actuation
206-06-21
REMOVAL AND INSTALLATION (Continued)
Brake Pedal Control Switch (where fitted) Removal 1. Undo three screws underneath the lower shroud. Move the steering column adjustment lever about half way through its travel. Gently spread the lower shroud to clear the key illumination ring.
Brake and Cruise Pedal Switch Setting Removal 1. Remove switch assembly from mount by rotating to release.
2. Pull plunger out to the full extension. Item 1 2
Description Screw Adjustment lever
2. Slide the shroud down and rearwards, ensuring the adjustment lever passes through the aperture in the lower shroud. Unclip the wire harness for the adjustable pedal switch.
3. Refit the switch by holding brake pedal down and reinserting switch in to housing and rotating to lock into position. NOTE: Hold brake pedal down while fitting switch.
3. Remove pedal adjust switch from the shroud by deflecting the steel retaining clips and pushing the switch outwards. Installation 1. Install components in reverse order. NOTE: Ensure the steering column adjustment lever passes under the pedal switch wire harness when installing the lower shroud. 4. Release brake pedal gently so it returns to the relaxed position. Lightly (less than 80N) pull brake pedal rearwards to ensure pedal fully returns switch. This will push the plunger in and correctly set the switch. G22123 en
01/2003 2003.0 BA Falcon
206-06-22
Hydraulic Brake Actuation
206-06-22
REMOVAL AND INSTALLATION (Continued)
Brake Pedal Pad
Power Brake Booster
Removal 1. Remove brake pad by peeling rubber from the pedal plate.
Removal 1. Remove nuts attaching master cylinder to booster tie rods and remove master cylinder. 2. Disconnect vacuum hose from vacuum check valve. 6 Cylinder
Installation 1. Install components in reverse order. NOTE: Heating the pad will assist replacement.
Accelerator Pedal Pad
8 Cylinder
Removal 1. Remove accelerator pad retention clip on the back of the pad by inserting a small screwdriver and prising the pedal pad over the tang of the pedal blade. Slide the pad from the blade. NOTE: If the pad is to be discarded, the plastic can be broken away to simplify removal.
Installation 1. Fit new pad by pushing onto pedal blade until the pad clips over the retaining tang.
G22123 en
3. Disconnect pushrod (part of valve assembly) from brake pedal. 4. Remove nuts from booster tie rods and remove booster. 5. Remove four nuts securing booster to firewall and pedal box. 6. Remove assembly. Installation 1. Attach booster to dash panel/pedal box with nuts. 2. Attach push rod (part of valve assembly) to brake pedal. 3. Connect vacuum hose to vacuum check valve. 4. Attach master cylinder with nuts to booster front shell.
01/2003 2003.0 BA Falcon
206-06-23
Hydraulic Brake Actuation
206-06-23
REMOVAL AND INSTALLATION (Continued) 3. Slide the master cylinder forward and upward from the vehicle. NOTE: Special rubber components are used in this Installation master cylinder, therefore the cylinder must be 1. Position the master cylinder assembly over the repaired using only genuine kits. These kits include booster push rod and onto the two studs on the new rubber components. Ensure all sections of the booster assembly. cylinder are repaired. For cleaning of internal parts of 2. Install the attaching nuts and torque to master cylinder use clean brake fluid or methylated specification. spirits. 3. Install the front and rear brake tubes to the master The split point pressure of the proportioning valve is cylinder outlet fittings. Connect the warning light stamped on the end face of the master cylinder body, switch. and it is most important that, should a cylinder need replacing an identical cylinder be used. 4. Fill the master cylinder with the specified brake fluid to the level marked on the side of the dual When removing the master cylinder from the booster, reservoirs. Use Motorcraft approved Brake Fluid. care must be taken not to disturb the pushrod and not Do not mix low temperature brake fluids with the to depress the brake pedal after the cylinder is specified fluids for the disc brake system as removed. Failure to observe this caution may result in specified in Section 206-00. the output rod becoming dislodged inside booster. 5. Bleed the brake system. Refer to Hydraulic Removal System Bleeding in this section for the proper 1. Remove the brake tubes from the outlet ports of procedure. While bleeding brake system, check the master cylinder. Disconnect the plug from the the brake failure warning light operates and warning light switch. resets. 2. Remove the two nuts attaching the master 6. Operate the brake several times, then check for cylinder to the brake booster assembly. external hydraulic leaks.
Dual Master Cylinder
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01/2003 2003.0 BA Falcon
206-06-24
Hydraulic Brake Actuation
206-06-24
DISASSEMBLY AND ASSEMBLY
Electronic Throttle Control Module 1. Refer to Section 310-02.
Dual Master Cylinder Disassembly Main Bore
Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
Description Reservoir cap Reservoir seal Reservoir Reservoir retaining screw Reservoir seal Circlip Fast fill valve ’O’ Ring Master cylinder body Secondary spring Secondary piston assembly Secondary piston stop pin Cup retainer Primary cup Recuperating guide
G22128 en
Item 16 17 18 19 20 21 22 23
Description Primary piston ’O’ Ring Differential switch assembly Proportioning valve assembly Prop housing sleeve ’O’ Ring ’O’ Ring End plug
1. Clean the outside of the master cylinder and remove reservoir cap. Pour out and discard any brake fluid that remains in the cylinder. 2. Unscrew reservoir-to-body retaining screw located at base of reservoir. 3. Separate, by hand, the plastic reservoir from the body. Remove the reservoir sealing grommets.
01/2003 2003.0 BA Falcon
206-06-25
Hydraulic Brake Actuation
206-06-25
DISASSEMBLY AND ASSEMBLY (Continued) 4. Invert the cylinder so that the reservoir wells face down. Depress the primary piston with a rod of wood dowel until fully bottomed in the bore. The secondary piston stop pin should freely fall out; if not, remove with long nose pliers.
3. Remove the valve sealing ‘O’ ring from bottom of reservoir port. The by-pass bleed groove allows fluid to by-pass the ball valve. This ensures that a fluid passage is maintained between the brake pressure circuit and reservoir in the Brakes Off position.
CAUTION: Slowly return pistons to avoid primary piston from sringing out of the bore. 5. Carefully remove primary piston assembly from main bore of master cylinder. 6. Remove secondary piston and return spring by using compressed air or lightly tapping the open end of the cylinder bore squarly onto a soft piece of wood. 7. Separate the secondary return spring from the secondary piston locating spigot. NOTE: The caged spring on the secondary piston has been set to a pre-determined length. DO NOT attempt to adjust the screw or remove the caged spring. If cups are damaged or badly worn, the complete seconary iston assembly MUST BE Item Description REPLACED (as supplied in repair kit). 1 Circlip 8. Remove the seal retainer from the primary piston 2 Fast fill valve by using a small screwdriver to carefully pry apart 3 O-Ring the seal retainer legs. 4 Master Cylinder Body 9. Remove the recuperating guide and seal from the primary piston. Pressure Differential Switch Assembly (Non ABS 10. Remove the O ring from the other end of the only) piston taking EXTREME CARE not to damage the 1. Remove end plug and ‘O’ ring from master piston. cylinder body. Fast-Fill Valve 2. Remove electric switch from master cylinder, 1. Using suitable circlip pliers, remove circlip ensuring the electrical earthing spring remains on retaining the fast-fill valve in the primary reservoir the switch plunger. port of the master cylinder. 3. Remove the proportioning valve assembly by 2. Face reservoir port down to allow the valve to fall gently bumping the master cylinder body against out. If valve is stuck in position, lightly tap cylinder a piece of wood to dislodge the proportioning on piece of wood to assist valve removal. valve assembly. Do not damage the assembly by attempting to pull it out with pliers. 4. Spring must remain attached to switch plunger.
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01/2003 2003.0 BA Falcon
206-06-26
Hydraulic Brake Actuation
206-06-26
DISASSEMBLY AND ASSEMBLY (Continued) Proportioning Valve (Non ABS only) DO NOT disassemble the proportioning valve assembly. The valve is serviced only as a complete assembly.
Item 1 2 3 4
1. Assemble the large ‘O’ ring onto the end of the primary piston. NOTE: All hardware must be correctly installed and torqued to specification. 2. Install primary seal onto the end of the primary piston, with sealing face away from guide already assembled. The primary seal can be identified by the 6 shallow grooves around the seal’s outer surface. 3. Assemble the cup retaining ring onto the primary piston. Using a small screwdriver clip the retainer legs into the groove on the piston. Care should be taken to avoid damage to the piston or seal. Secondary Piston
Description End plug ’O’ Ring Proportioning valve assembly Master cylinder body
Assembly 1. Extreme care must be taken to avoid damaging O-Rings when inserting proportioning value. 2. Before assembly, lubricate internal ports and master cylinder bore with recommended brake fluid from a sealed container. Prior to assembly, ensure primary piston (without seals) is free to move full piston stroke in the large bore. Primary Piston
Item 1 2 3 4 5
Description Cup retainer Primary cup Recuperating guide Primary piston Large ’O’ Ring
G22129 en
Item 1 2
Description Secondary spring Secondary piston
Item 1 2 3
Description Master cylinder body Secondary piston stop pin Secondary piston assembly
1. Assemble the small end of the secondary piston spring over the end of the secondary piston. This should be a slight interference fit.
01/2003 2003.0 BA Falcon
206-06-27
Hydraulic Brake Actuation
206-06-27
DISASSEMBLY AND ASSEMBLY (Continued) 2. To assemble the secondary piston assembly into the body, align the slot in the secondary piston with the reservoir wells. This must be done so that the stop pin can be inserted into the master cylinder body. Master Cylinder
Item 1 2 3 4 5 6 7 8 9
Description Fast fill valve Circlip ’O’ Ring - Larger Primary piston Split line ’O’ Ring Primary cup Secondary cup - ’L’ Type Secondary piston
protrude more than 6 mm above the bottom of the well. 2. Insert the primary piston into the main bore and against the secondary piston. Then carefully push both pistons down the bore until the primary piston is flush with the bore opening. 3. Stroke pistons and check primary piston fully returns to end of bore at end of each stroke. Ensure movement is not sticky. Differential Warning Switch Section (Non ABS only)
1. Before assembly, lubricate small bore master 1. Carefully insert the secondary piston, (caged cylinder and proportioning valve with clean brake spring end last), through the large bore and into fluid from a sealed container. the smaller bore until the spring “bottoms”. Ensure 2. Ensure spacer and ‘O’ ring are over proportioning the secondary spring is not dislodged from the valve spool, if they were removed, and check that piston assembly during this operation. Fully stroke spacer and ‘O’ ring are installed around the right the secondary piston using a soft dowel and while way. held at the bottom of the bore install the piston stop pin. The piston pin should easily fit in through the larger hole of the 2 holes in the secondary reservoir well. The top of the stop pin should not
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01/2003 2003.0 BA Falcon
206-06-28
Hydraulic Brake Actuation
206-06-28
DISASSEMBLY AND ASSEMBLY (Continued) 3. Insert proportioning valve (capped end first) into bore, EXTREME CARE should be taken when inserting valve to ensure ‘O’ rings are not damaged. If ‘O’ rings are damaged the master cylinder will not function correctly and will leak brake fluid. The proportioning valve assembly must be bottomed in the bore of the master cylinder. 4. Assemble a new ‘O’ ring onto the end plug, and screw end plug into body. Tighten end plug to 25Nm-30 Nm. Electrical Switch (Pressure Differential)
1. Carefully install the valve ‘O’ ring in the bottom shoulder of the primary reservoir port. 2. Fit the fast-fill valve, ensuring the rubber base with 6 dimples if faced downwards, and secure with circlip. Reservoir
1. Before installing the electrical switch, ensure earthing spring is installed on switch plunger as shown in diagram. NOTE: Electrical spring must remain firmly attached to the plunger. Small end of spring may need to be closed down to give required attachment.
1. Lightly smear reservoir bores and grommets with clean brake fluid. 2. Carefully assemble grommets into reservoir bores to locate against the shoulder in each bore. 3. Assemble reservoir into grommets. 4. Push on reservoir to align the retaining screw hole in the reservoir and cylinder body. Then assemble retaining screw, and tighten to 4-5 Nm. Screw should just protrude from hole in the master cylinder body. NOTE: Both reservoir and master cylinder holes must be aligned to avoid cross threading. Assemble new reservoir seal into reservoir cap.
2. Assemble electrical switch to the master cylinder by hand. Tighten to a torque of 2 Nm. (DO NOT OVER TIGHTEN.) Fast-Fill Valve
Item 1 2 3
Item 4
Description master cylinder body
5. Lubricate inside of reservoir lips with clean brake fluid to accept reservoir cap seal. 6. Push cap and seal assembly onto reservoir and secure by pressing clip at each end to locate on reservoir lugs. Caps should be fitted so that lettering on cap is correct way up when viewed from side of vehicle.
Description Circlip Fast fill valve ’O’ Ring
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01/2003 2003.0 BA Falcon
206-06x-1
Hydraulic Brake Actuation — Load Proportioning Valve (1 tonne option)
206-06x-1
SECTION : 206-06x Hydraulic Brake Actuation — Load Proportioning Valve (1 tonne option) VEHICLE APPLICATION : 2003.0 BA Falcon CONTENTS
PAGE
DESCRIPTION AND OPERATION Hydraulic Brake Actuation — Load Proportioning Valve ......................................................206-06x-2 REMOVAL AND INSTALLATION Load Proportioning Valve .....................................................................................................206-06x-3
01/2003 2003.0 BA Falcon
206-06x-2
Hydraulic Brake Actuation — Load Proportioning Valve (1 tonne option)
206-06x-2
DESCRIPTION AND OPERATION
Hydraulic Brake Actuation — Load Proportioning Valve Refer to Section 206-00.
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01/2003 2003.0 BA Falcon
206-06x-3
Hydraulic Brake Actuation — Load Proportioning Valve (1 tonne option)
206-06x-3
REMOVAL AND INSTALLATION
Load Proportioning Valve Removal The Load Proportioning Valve is located on the chassis rail above the rear axle.
Installation 1. Installation is the reverse of the removal procedure. Once installed, bleed the brake system. Refer to Hydraulic System Bleeding in Section 206-00. NOTE: The load proportioning valve is a non-serviceable component and must be replaced if faulty.
1. Remove all the brake tubes from the load proportioning valve. 2. Loosen the strap attaching the nut.
3. Support the strap and remove any force from the bracket, remove strap attaching nut.
4. Release strap support and remove load proportioning valve fastening nuts. 5. Remove assembly.
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01/2003 2003.0 BA Falcon
206-09-1
Anti Lock Control
206-09-1
SECTION : 206-09 Anti Lock Control VEHICLE APPLICATION : 2003.0 BA Falcon CONTENTS
PAGE
DESCRIPTION AND OPERATION Anti Lock Control ....................................................................................................................206-09-2 Applicable Models ................................................................................................................206-09-2 General Description .............................................................................................................206-09-2 Operation .............................................................................................................................206-09-4 Operating Modes ..................................................................................................................206-09-6 DIAGNOSIS AND TESTING Anti Lock Control ..................................................................................................................206-09-14 Principles of Operation .......................................................................................................206-09-14 Inspection and Verification .................................................................................................206-09-14 Diagnostic Trouble Code (DTC) Chart ...............................................................................206-09-18 Connector Circuit Reference ..............................................................................................206-09-19 Pinpoint Tests ....................................................................................................................206-09-21 REMOVAL AND INSTALLATION Rear ABS sensor — IRS .....................................................................................................206-09-27 ABS Wheel Speed Sensor — Rear (Beam Axle) ................................................................206-09-28 Front ABS Wheel Sensors ...................................................................................................206-09-29 Rear Tone Wheel .................................................................................................................206-09-29 Front Tone Wheel ................................................................................................................206-09-29 ABS Modulator Assembly ....................................................................................................206-09-29
01/2003 2003.0 BA Falcon
206-09-2
Anti Lock Control
206-09-2
DESCRIPTION AND OPERATION
Anti Lock Control Applicable Models The material in this section applies both to vehicles fitted with the 3 channel Anti-lock Braking System
(ABS) or with the 4 channel Anti-lock Braking System with Traction Control (TCS). Throughout this section, the presence of [square brackets] indicates that the information contained in the brackets applies only to vehicles fitted with TCS (Traction Control).
General Description ABS System Layout (3 Channel ABS)
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01/2003 2003.0 BA Falcon
206-09-3
Anti Lock Control
206-09-3
DESCRIPTION AND OPERATION (Continued) System Layout (4 Channel TCS)
The system is the Bosch ABS/TCS 5.3 system, and is basically designed to be an add-on system to the existing master cylinder and booster assembly. The system comprises of the following major components. hydraulic modulator / ECU assembly wheel speed sensors hydraulic and electrical connectors [electrical communication with the EEC] The 3 channel Anti-lock Braking System and 4 channel Anti-lock Braking System with Traction Control are quite similar in concept. Essentially, the same wheel speed sensors and a similar ECU/Hydraulic Modulator Assembly are used in each G23420 en
system. The TCS system includes additional hydraulic lines and components to provide traction control as an additional feature. The main difference is that the rear wheels are controlled as a pair with the 3 channel system whilst the 4 channel system controls them individually. The individual control of the rear (driven) wheels allows the system’s capabilities to be expanded to incorporate Traction Control.
01/2003 2003.0 BA Falcon
206-09-4
Anti Lock Control
206-09-4
DESCRIPTION AND OPERATION (Continued) Anti-lock Braking (ABS and TCS) Anti-lock braking systems are a significant safety feature designed to prevent wheel “lock-up” during hard brake applications. This results in improved vehicle stability, steerability and usually, shorter stopping distances. The ABS system uses wheel sensors to detect the approaching lock-up of a wheel. When detected, the system will automatically control the fluid pressure in the corresponding brake circuit. The pressure is firstly maintained (pressure hold) or if the tendency to lock is still present, reduced. As the wheel is re-accelerated the fluid pressure is increased, thus systematically slowing the vehicle. The increase/hold/decrease of fluid pressure will continue to occur until either the road surface changes, the brake pedal is released or brake pedal force reduced, or the vehicle stops.
Traction Control (TCS only) Traction Control, or Automatic Spin Reduction systems are a significant safety feature designed to prevent wheel spin during acceleration. This results in improved vehicle stability and steerability. If wheel spin is desired (this may be so in some sandy conditions to avoid becoming bogged) the driver can disable the traction control by pressing the button on the dash. The traction control can be enabled again by pressing the same switch again or by cycling the ignition. The TCS uses wheel speed sensors to detect the spinning of one, or both, of the drive wheels. When detected the system will automatically apply brake pressure to the spinning wheel(s), and will reduce engine torque. The brake pressure in the spinning wheel(s) is built up in small steps, so as not to over-brake the wheel(s), and will equalise the available torque between the two drive wheels according to the surfaces the wheels are on. The engine torque is reduced via the engine management system (EEC). The EEC will cut fuel injection and ignition to one or more cylinders depending on how much torque reduction is required. The brake and engine intervention will continue to occur until the wheel(s) are no longer spinning. During traction control operation the traction control warning lamp will flash to inform the driver that the vehicle is under traction control. This continues until traction control is finished.
are switched to pressure hold, in order to prevent a further increase in pressure at the rear brakes, thus electronically reproducing a pressure-proportioning function at the rear brakes.
Operation Anti-lock Braking (ABS and TCS) The rotational speed of each wheel is determined by inductive wheel speed sensors. When the brakes are applied, the change in rotational speed is used by the processor in the ABS - ECU to determine the deceleration, acceleration and the slip of the wheels. The front wheels are individually controlled with the rear wheels being controlled together. If one side of the road surface is slippery, the rear wheel braking on this surface determines the braking pressure of both rear wheels. While this may cause slightly reduced rear braking, it substantially increases rear end stability. WARNING: Despite this improvement to the braking system, you should continue to exercise caution in all hazardous driving situations, especially when driving on extreme road surfaces. The ABS system will assist in improved vehicle stability and steerability under severe braking, usually reducing the braking distance, but may not prevent an accident from occurring.
Traction Control (TCS only) The addition of a priming valve and a switching valve allow the brake pressure at the rear wheels to be applied independently of each other and of the driver. The rotational speed of each wheel is determined by inductive wheel speed sensors. Any change in rotational speed is used by the processor in the TCS ECU to determine the deceleration, acceleration, and the slip of the wheels. If one side of the road surface is slippery and the wheel on that surface spins, that rear wheel is controlled by brake pressure being applied, with perhaps some engine power reduction. If both wheels are on a slippery surface and spin, the wheels may be slightly braked but most of the control is through reduction of engine power. Use of brake intervention is limited when the vehicle speed is above 40km/h to prevent excessive brake temperatures being generated at the rear wheels.
WARNING: Despite this improvement to the power-train system, drivers should continue to Electronic Brake-Force Distribution (EBD) is a system exercise caution in all hazardous driving where by the amount of master cylinder Brake-Force situations, especially when driving on extreme road surfaces. The TCS will assist in improved pressure applied to the rear wheels is controlled vehicle stability and steerability during severe electronically as opposed to mechanically. acceleration, usually improving the vehicle EBD ensures that the rear wheels are sensitively acceleration, but may not prevent loss of vehicle monitored for slip with respect to the front wheels. If control from occurring. slip is detected, the inlet valves for the rear wheels
Electronic Brake-Force Distribution (EBD)
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Anti Lock Control
206-09-5
DESCRIPTION AND OPERATION (Continued) NOTE: LPG (Liquefied Petroleum Gas) conversions are not compatible with traction control. If an LPG conversion is performed it must conform with Ford recommendations and must be performed by an approved LPG installer. The traction control will not operate whilst LPG is the selected fuel. If the conversion does not meet Ford recommendations the rear brakes may overheat.
ABS
Electronic Brake-Force Distribution (EBD)
If a system defect is detected in the traction control only, the traction control part of the TCS will switch itself OFF. The ABS will remain functional. If some other fault occurs in the TCS the complete system (ABS and traction control) will switch itself OFF. The driver can still use the base brake system without the anti-lock feature, and can still accelerate and drive normally without the traction control feature. This change over is indicated by means of illuminating both the ABS and the traction control warning lights on the instrument panel.
The Brake-Force Distribution is controlled by omitting the currently used mechanical proportional valve(s) and controlling the pressure to the rear wheels via the current Anti-Lock Brake System (ABS). The information as to when and how much the master cylinder pressure is to be proportioned, is received from the rear and front Wheel Speed Sensors (WSS). This difference in slip between the front and rear wheel speeds, is calculated and then reacted upon by the ABS assembly. The EBD operation takes effect prior to the increased slip rate required for ABS intervention. The ABS unit has additional software that will, in the case of an EBD operation, operate the rear inlet valves of the ABS Hydraulic Modulator Assembly. These inlet valves will open and close as required, to control the amount of pressure that can be applied to the rear wheels before ABS is required. If the restriction of the pressure, by closing the rear inlet valves, does not prevent the slip from continuing to increase at the rear axle, the outlet valve will open and allow a reduction of the pressure to be transferred to the accumulator of the ABS unit. The pump motor does not operate at this stage and is therefore not in ABS mode. If then the pressure reduction is not sufficient to reduce the rear wheel slip, a normal ABS operation will take place. The EBD uses a select low logic on the rear wheels, that is, the condition of the rear wheel with the least amount of traction is duplicated on the opposing wheel.
If a system defect is detected, the ABS will switch itself OFF. The driver can still use the base brake system without the anti-lock feature. This change over is indicated by means of illuminating the ABS warning light on the instrument panel.
TCS
Modulator and ECU The ECU uses the inputs from the wheel speed sensors to determine if ABS [or traction control] operation is necessary, and if so, energises the solenoids to control hydraulic brake pressure [and communicates the desired wheel torque to the EEC]. The ECU controls all diagnostic functions and monitors all external inputs and outputs. NOTE: The ABS modulator and ECU is serviced only as a complete assembly. The ECU should not be removed from the modulator body.
Self-Monitoring When the vehicle is started, the system automatically carries out a static system analysis. Wheel speed sensors are checked for continuity, solenoid valves and the pump motor are operated, feedback signals from the valves and motor are monitored [and communication with the EEC is acknowledged]. As the vehicle is driven the system monitors itself by comparing the input and output signals of the valves with memorised limit values, in addition to monitoring the voltage supply. It also continuously compares the wheel speed signals with each other [and continuously exchanges information with the EEC].
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Sensors and Tone Wheels Each wheel is fitted with a sensor and tone wheel. The front sensors are attached to the steering spindle and the tone wheels are pressed onto the hub assembly. At the rear, sensors are attached to the differential housing for (IRS) or the parkbrake back plate (for beam axle), whilst the tone wheels are attached to the drive shafts. Each tone wheel incorporates teeth which generate pulses in the wheel sensor. These pulses are used by the ECU to calculate wheel speeds and acceleration rates.
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DESCRIPTION AND OPERATION (Continued) Sensor and Tone Wheel — Front
ABS Indicator Light
Sensor and Tone Wheel — Rear (IRS)
This light will illuminate each time the ignition is turned to the ON position and will go out after approximately 2 seconds. In the event that the ABS light remains on, or illuminates constantly while driving, this indicates that the ABS function is disabled. and should receive immediate attention to restore the benefits of the ABS features. If the fault is of a temporary nature, the ABS will reset on the next ignition cycle and the light will then return to normal operation. However, a fault code will be stored in the ECU - see Diagnosis and Testing later in this section. NOTE: Most malfunctions in the ABS system will cause the indicator light to illuminate indicating the system has been disabled. Normal braking is not affected unless the brake warning light is also illuminated.
Traction Control (TCS) Indicator Light
Sensor and Tone Wheel — Rear (Live Axle) Wagon and Ute
This light will illuminate, along with the ABS light, each time the ignition is turned to the ON position and will go out after approximately 3 seconds. If the traction control light flashes while driving this indicates that one or both of the drive wheels are spinning and that the TCS is applying brakes and/or reducing engine power. In the event that the traction control light remains on, or illuminates constantly while driving, this indicates that the function is disabled. If it cannot be enabled by pressing the traction control on/off switch it should receive immediate attention to restore the benefits of the traction control features. If the fault is of a temporary nature, the traction control will reset on the next ignition cycle and the light will then return to normal operation. However, a fault code will be stored in the ECU - see Diagnosis and Testing later in this section. NOTE: The traction control light can be illuminated by turning the traction control off with the switch on the dash. If only the traction control light is on, the ABS function is not affected.
Traction Control Switch (TCS)
Brake Pipes The hydraulic connections are by conventional steel brake tubing. Two master cylinder pipes are connected to the inlets of the hydraulic modulator. The three [four] outlets of the hydraulic modulator are connected individually to the front brake calipers and as a pair [TCS-individually] to the rear brake calipers.
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The TCS is used to toggle the traction control feature on/off depending on the driver’s preference at the time. When the traction control is turned off, the indicator light will illuminate and stay on until the system is again reactivated. The system may be reactivated by pressing the switch again. Traction control is turned on each time the ignition is cycled regardless of whether the system was on or off previously.
Operating Modes The hydraulic modulator executes ABS/TCS ECU commands using six [ten], two-position solenoid valves, [including a priming valve, and a switching valve]. The hydraulic modulator valve positions correspond to various ABS/TCS ECU control phases: 01/2003 2003.0 BA Falcon
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DESCRIPTION AND OPERATION (Continued) 1. Non ABS/TCS condition 2. Maintaining pressure (ABS) 3. Reducing pressure (ABS) 4. Increasing pressure (ABS) 5. Traction control in operation (brake intervention) For explanation of ABS operation, only one segment of the system will be described. For explanation of traction control operation, only the part of the system related to the rear wheels will be described.
ABS Braking - Standard braking no ABS assistance During this condition, both build and decay valves are not energised; that is the ABS ECU does not supply any current to the solenoid coils, and this provides for conventional non ABS braking. From the brake master cylinder, hydraulic pressure is applied to brake circuit. If the ABS ECU does not detect any rapid wheel deceleration, the ABS will remain passive at this time.
ABS Braking - Standard braking no ABS assistance
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DESCRIPTION AND OPERATION (Continued) TCS operation - No ABS or Trac control assistance This is a schematic of the Hydraulic Modulator under normal driving conditions. All the valves are in their normal rest position allowing uninterrupted flow for normal braking conditions. This is depicting no pressure within the system, therefore, no application of brakes. Status Inlet Valve Outlet Valve Prim- Swit- Motor ing ching Valve Valve Left Right Left Right Closed Open Off Open Open Closed Closed
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DESCRIPTION AND OPERATION (Continued) TCS operation - No ABS or Trac control assistance
Maintaining Pressure When the ABS ECU detects excessive wheel deceleration (based on the wheel speed sensor signals), it commands the build valve to maintain brake circuit pressure. It does this by supplying a current to the solenoid coil. This causes the armature and the valve to move downwards isolating the brake circuit from the master cylinder. NOTE: With the brake circuit isolated, brake circuit pressure between the build solenoid and the caliper remains constant despite increased master cylinder hydraulic pressure.
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DESCRIPTION AND OPERATION (Continued) Maintaining Pressure (ABS operation)
Reducing Pressure If isolation of a brake circuit between the modulator and the brake caliper does not reduce the excessive wheel deceleration, the ABS ECU commands the decay valve to reduce hydraulic brake pressure in the brake circuit. During this phase, the ABS ECU supplies a current to the decay solenoid coil, opening the valve. This opens a passage from the brake circuit to the accumulator and return pump inlet. NOTE: At this time, the brake circuit is isolated from the master cylinder by the return pump valving, and the return pump is energised. This action sends brake
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fluid from the brake circuit back to the master cylinder against brake pedal pressure. The return pump continues to operate during the rest of the anti-lock cycle. Accumulators During the “pressure reduction” phase of ABS modulation, the accumulator temporarily stores fluid from the brake circuits. Some road conditions require the relief of a large volume of fluid from the brake calipers. In such conditions, the accumulator guarantees pressure reduction. As soon as the
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DESCRIPTION AND OPERATION (Continued) solenoid valves move to the “pressure reduction” position, brake fluid from the brake circuit flows into the accumulator. Thus before the return pump starts, the accumulator allows an immediate pressure reduction in the brake circuit. Reducing Pressure (ABS operation)
Increasing (building-up) Pressure The wheel accelerates again as a result of the reduced braking pressure. Upon reaching a specific limit, the ECU registers the fact that the wheel is now not being braked sufficiently. The ECU then de-energises the build and decay valves (0 amps) and the formerly reduced pressure is then increased so that the wheel is again decelerated. The ABS control G23420 en
cycle begins again. There are approximately up to 10 cycles per second, depending on the state of the road surface. NOTE: Circuit pressure cannot increase above master cylinder pressure.
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DESCRIPTION AND OPERATION (Continued) Increasing (Building-Up) Pressure (ABS operation)
TCS in operation (brake intervention only) In this schematic, the right hand wheel speed sensor has detected that the wheel is about to enter into a situation where slippage can occur from excess engine torque for the road conditions. The priming valve is open allowing fluid to be drawn from the master cylinder by the pump assembly. The switching valve is closed ensuring the fluid is directed to the wheels and not back to the master cylinder. With the right wheel tending to slip, the inlet valve on the left side closes allowing only the brakes to be applied to the right wheel. This will transfer the engine torque to left wheel. This operation can be applied up G23420 en
to 10 times a second and can function on either of the driven wheels, or both. Status Inlet Valve Outlet Valve Prim- Swit- Motor ing ching Valve Valve Left Right Left Right Open Closed On Open Open Closed Closed
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DESCRIPTION AND OPERATION (Continued) TCS in operation
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DIAGNOSIS AND TESTING
Anti Lock Control Principles of Operation The ABS/TCS system has a self-test capability and will memorise faults for 125 key starts. Fault codes are accessed using the WDS tester. Self-test codes are held in the EPROM and can only be cleared using the WDS tester. Up to 3 “on demand” or “stored” codes can be logged by the ECU. It is essential that the system is retested after any fault is rectified until no further on-demand codes are displayed. The self test connector is located behind the fuse box panel cover (underneath the instrument panel on the right of the steering column). Follow the operating procedures provided with the test equipment.
WDS Tester The WDS tester is used to communicate serially with the ABS module for diagnostics. The WDS must be used to carry out the following functions/tests on the ABS system: Diagnostic Test Modes Trouble code clearing PIDs/Data monitoring Function test — to operate ABS modulator components NOTE: When operating the ABS pump using the WDS tester, the pump should not be allowed to run for more than 5 seconds. After confirming pump operation, switch off the pump motor by pressing the WDS button.
Inspection and Verification If a vehicle is presented with an ABS/TCS concern, indicated either by way of the ABS or traction control warning lamp or by the Owner/Driver reporting an unexpected operating characteristic (eg noise, vibration, wheel lock-up, spinning wheels, etc.) follow the Diagnosis Procedure to: determine whether or not there is a fault with the ABS/TCS system locate and isolate the fault rectify the fault confirm the repair with an ABS/TCS road test.
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It is important that all of the steps in the Procedure are followed to avoid the unnecessary replacement of parts that are not faulty and to ensure that the ABS/TCS system is returned to its designed operating condition.
Procedure 1. Complete an ABS/TCS Concern Customer Questionnaire. Determine whether or not the issues raised indicate a fault with the ABS/TCS system or are in fact normal operating characteristics of ABS/TCS systems in general. 2. If a fault is indicated, proceed to the ABS/TCS Diagnostic Procedure table. 3. Follow the table. If any hard or memory DTCs are displayed, refer to the DTC Table for a definition and reference to the appropriate pin point test flow chart for each DTC. 4. When the table directs you to return to the ABS Diagnostic Procedure table, return to the “RETURN FROM PIN POINT TEST” box and proceed to confirm the repair. NOTE: Ensure that all memory DTCs are cleared PRIOR to confirming the repair. If hard DTCs still exist then the related faults also still exist. 5. Confirm the repair by following the ABS/TCS Diagnostic Procedure table. If at any time the ABS or traction control warning lamp flashes or illuminates (other than the normal 3-second period after the ignition is switched on) then there is a fault within the ABS/TCS system. 6. In the event that the same DTC appears, continue to follow the flow chart back to the same pin point test flow chart. Conduct the same checks and if no fault is found the flow chart will direct you to replace the ABS Modulator Assembly. NOTE: The ABS/TCS Modulator Assembly is a critical safety item. It should only be installed by trained and experienced ABS Technicians. After replacing the ABS/TCS Modulator Assembly, it will still be necessary to confirm the repair by returning to the ABS/TCS Diagnostic Procedure table. 7. At the conclusion of the road test if there are no DTCs then the system can be considered to be working correctly and is ready for return to the Owner/Driver.
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DIAGNOSIS AND TESTING (Continued) ABS/TCS CONCERN CUSTOMER QUESTIONNAIRE Customer’s Name________________________ R/O Number________________________ Registration Number______________________ Date______________________________ Odometer Reading_______________________ PROBLEM DESCRIPTION 1. Do the ABS and traction control warning lamps come on when you start the car? Yes No 2. Do the ABS or traction control Lamps turn off after 3 seconds or do they stay on or flash? Turns Off Stays On Flashes 3. Do the ABS or traction control lamps flash or stay on whilst driving? No Stays On Flashes 4. If not the warning lamp, what caused you to suspect a fault with the ABS or TCS system? Was it Noise? Please describe the noise, and whether it occurred during braking, during an ABS stop, during heavy acceleration or at some other time. _______________________________________________________________________________________ _______________________________________________________________________________________ or was it Vibration/Harshness? Please describe the vibration/harshness, and whether it occurred during braking, during an ABS stop or at some other time. _______________________________________________________________________________________ _______________________________________________________________________________________ or was it the feel/travel of the brake pedal? Please describe how the brake pedal behaved, and whether it occurred during braking, during an ABS stop or at some other time. _______________________________________________________________________________________ _______________________________________________________________________________________ Other_______________________________________________________________________ _______________________________________________________________________________________ 5. How often does it happen? Frequently Infrequently Once 6. Does it usually happen only under specific circumstances? (eg. only when the vehicle is cold, only in the wet, only on rough or slippery surface roads, etc) _______________________________________________________________________________________ _______________________________________________________________________________________ VEHICLE HISTORY 1. Have you had any repairs made to your vehicle recently? Describe. _______________________________________________________________________________________ 2. Have you had new tyres fitted or have you had a flat tyre recently? Yes No 3. Have you had a flat battery recently? Yes No 4. Have you had the ABS system checked or repaired previously? If so, when and why? _______________________________________________________________________________________
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DIAGNOSIS AND TESTING (Continued) ABS/TCS DIAGNOSTIC PROCEDURE DIAGNOSTIC PROCEDURE - PART A 1. Refer to the completed ABS/TCS Concern Customer Questionnaire for information relating to when, where and how frequently the concern is noticed. NOTE: I. The ABS and TCS lamps only indicate the presence of hard faults. They will not illuminate if only a memory fault is present. II. The ECU can store no more than 3 DTC’s. The oldest DTC will be erased if more than 3 are present. III. If the ABS/TCS ECU wiring loom connector is not connected properly, the ABS & TCS lamps will remain on while the ignition is on. IV. If a hard fault is present, the ABS and TCS lamps will remain lit until the fault is corrected. 2. Turn the ignition OFF 3. Connect the WDS and turn the ignition ON Does the WDS communicate with the ABS/TCS system?
Are there any DTC’s?
Yes Refer below No Refer to COMMUNICATIONS FAULT, Pinpoint Test F. Yes Record DTC and refer to DTC table in this section for diagnosis and repair procedure. No Go to 4. Below
4. Turn the ignition OFF then disconnect the WDS 5. Confirm correct operation of the system. 6. Go to DIAGNOSTIC PROCEDURE - PART B. DIAGNOSTIC PROCEDURE - PART B 1. Turn the ignition ON Do the ABS & TCS come on and then go out after 3 seconds? Yes Go to 2. Below No One or both lamps do not come on or they stay on after 3 seconds Check bulb and wiring for open circuits and shorts to ground. Be sure to wiggle the wiring whilst testing. Repair as required. Go to DIAGNOSTIC PROCEDURE - PART A, Item 2. 2. Ensure that the vehicle is safe to drive. 3. Drive the vehicle above 30 km/h for at least 80 seconds. 4. Select a safe, clear section of road and perform an ABS stop.
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DIAGNOSIS AND TESTING (Continued) Did either of the lamps come on at all whilst driving the vehicle?
Yes Go to DIAGNOSTIC PROCEDURE - PART A, Item 2. No Go to 5. Below
5. Select a safe, clear section of road where wheel slip can occur. Perform an acceleration hard enough to cause wheel slip NOTE: Perform this test only if the vehicle is equipped with TCS. Yes Did the TCS lamp flash during the acceleration? Return the vehicle to the customer. No Go to DIAGNOSTIC PROCEDURE - PART A, Item 2.
Diagnosis of Peculiar ABS Operating Characteristics
magnetic fields) may interfere with the electric signals being provided to the ABS ECU.
Unless the ABS/TCS Technician has a thorough understanding of the principles behind the operation of ABS and TCS systems, it is possible that misdiagnosis may occur and components may be replaced unnecessarily. It is therefore recommended that only trained and experienced ABS/TCS Technicians perform the diagnosis of ABS/TCS concerns.
Noise, Vibration, Harshness ABS/TCS systems make loud noise whilst in operation during heavy braking and TCS systems make some noise during traction control operation. The level of noise experienced in one vehicle may be higher than in another, but this does not necessarily indicate a fault with the noisier vehicle. Typical sources of noise are
ABS/Traction Control Lamp If the ABS or traction control warning lamp comes on or stays illuminated whilst driving, refer to the Diagnosis Procedure for diagnosis and repair. It is likely that one or more DTCs will be present in the ABS ECU memory.
ABS Modulator - the modulator contains an electric pump and electrically operated solenoids that control brake fluid flow. These items all create noise from the front of the vehicle. If the noise is of a metallic or grinding nature, check the security of the brake fluid lines and their proximity to other tubes or vehicle bodywork (insulate where necessary). Also check the ABS Modulator rubber bushings for correct installation and contamination with small pebbles or dirt. Tyres - during ABS operation the tyres are (by definition) at the limits of their adhesion. It is normal for tyre squeal and slipping noises to be heard. The nature of ABS systems also means that a certain level of vibration and harshness will be felt during an ABS stop. The severity is very much dependent on the traction between the road surface and tyres. Typical instances are Brake Pedal Pulsation - the brake pedal will pulsate underfoot during an ABS stop. This is due to the action of the ABS modulator in increasing and decreasing brake fluid pressures in various brake circuits. Whole Vehicle Vibration - an ABS stop involves the violent application of braking forces to individual wheels in order to stop a vehicle as quickly as possible whilst maintaining directional control. It should therefore not be surprising that the vehicle occupants feel a high level of pulsating force as they are forced forward into their
NOTE: The traction control indicator will flash when the traction control system is activating traction control. If the light flashes only under certain circumstances, ensure that the potential for wheel spin is not the cause. It is possible for the ABS ECU to falsely determine a fault with the ABS/TCS as a result of completely unrelated work taking place on the vehicle. Always check the ABS/TCS Concern Customer Questionnaire for the vehicle history prior to the ABS/TCS concern. Examples include: New tyres fitted recently - under some circumstances this can induce a false wheel speed sensor fault. Perform the ABS/TCS Diagnostic Procedure to confirm correct system operation. Underinflated tyres / recent puncture - can also induce a false wheel speed sensor fault. Inflate all tyres to specification, clear DTCs and perform the road test procedure (ABS/TCS Diagnostic Procedure) to confirm correct system operation. Electrical interference - under certain circumstances some electrical or electronic accessories (or external high strength electric or G23421 en
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DIAGNOSIS AND TESTING (Continued) seatbelts. The driver may also perceive that the vehicle is moving about on the road. However, steering control is maintained to counter any sideway movement of the vehicle. The nature of traction control systems also means that a certain level of vibration and harshness will be felt during an traction control acceleration. The severity is very much dependent on the traction between the road surface and tyres. Typical instances are Engine Power Reduction - ignition and fuel injection cutout will occur during TCS operation. The driver may hear a change in engine sound as the engine runs on a reduced number of cylinders Vehicle Surging - Engine torque is being increased and decreased independently of the accelerator pedal during TCS operation, and is dependent upon drive wheel adhesion. Under some circumstances this surging may be felt by
the driver and passengers as the TCS attempts to make the best use of the traction available. Spongy Brake Pedal This symptom should be treated in exactly the same way as it is for non-ABS vehicles. Check the brake fluid condition and level and bleed the brake system (including ABS Modulator if necessary). Brake Bleeding Bleed the brake system as normal through the calliper bleed screws. Refer to section 206-00. Replacement modulators are filled with brake fluid and should normally only require a conventional bleed procedure to be conducted. However, if a spongy pedal is present and air in the modulator is suspected, a Service bleed using the WDS tester should be carried out.
Diagnostic Trouble Code (DTC) Chart WDS Display B1342 C1145 C1165 C1155 C1175 C1148 C1168 C1158 C1178 C1095 C1266 B1318
Fault Description ECU Fault. There may be an internal fault in the ECU. Right Front Wheel Speed Sensor Continuity Fault Right Rear Wheel Speed Sensor Continuity Fault Left Front Wheel Speed Sensor Continuity Fault Left Rear Wheel Speed Sensor Continuity Fault Right Front Wheel Speed SensorOutput Fault Right Rear Wheel Speed Sensor Output Fault Left Front Wheel Speed Sensor Output Fault Left Rear Wheel Speed Sensor Output Fault Pump Motor Fault Valve Relay/Valve Relay Power Supply Fault. Low Voltage Failure
Possible Cause/Action Go to Pin Point Test E. The sensor circuit may be open circuit. The fault could be in the sensor, the wiring, or the ECU. Go to Pin Point Test A.
The sensor signal is wrong for the current vehicle conditions. The fault could be in the sensor, the wiring, or the ECU; the tone wheel may be missing, damaged or the wrong one fitted; sensor may have fallen out. Go to Pin Point Test B.
The ECU recorded a possible fault in the pump motor circuit. (Pump runs all the time or does not start.) Go to Pin Point Test E. There may be a fault in the power supply, modulator or ECU. Go to Pin Point Test E. The ECU has detected a low supply voltage. The cause could be alternator or battery, wiring or the ECU. Go to Pin Point Test C. The signal from one of the sensors is wrong for the current vehicle conditions. Go to Pin Point Test B.
C1222
Wheel Speed Sensor Frequency Fault
P1571
Brake Light Switch Failure There may be a fault in the brake light switch NOTE: Does not cause the ABS to circuit. The fault could be in the switch, shut down. switchwiring, tail light wiring or bulb. Go to Pin Point Test D.
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DIAGNOSIS AND TESTING (Continued) WDS Display U2202
Fault Description Option Coding Fault
B1317
Battery Pack voltage high
P1796
CAN Communication Bus Fault
U2501
Missing token from Engine Management system
U2509
Torque Reduction Request cannot be fulfilled by PCM
Possible Cause/Action The TCS ECU does not recognize the drive train as a valid drivetrain variant. Check that all ECU’s are correct for vehicle. Supply battery voltage above 17.2 V engine. Go to Pin Point Test C. Partial of no CAN comms (short circuit to Bat/Gnd) or open circuit. Go to CAN Wiring Test No CAN message received from EngineManagement System. (Refer PCM fault diagnostics - Section 303-14) In response to torque reduction request (Refer to PCM fault diagnostics - Section 303-14)
Connector Circuit Reference ABS MODULE 31 pin connector
Pin Number(s) 1 2 3 4
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Circuit Designation/Description Right Rear 524 Right Rear + 523 not used — Right Front 516
Normal Condition/Measurement Ignition off: 1.6 k ± 0 .0.32 k to pin 2 Ignition off: 1.6 k ± 0.32k to pin 1 — Ignition off: 1.6 k ± 0.3 k to pin 5
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DIAGNOSIS AND TESTING (Continued) Pin Number(s) 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 29 30 31
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Circuit Designation/Description Right Front + 514 Left Front 522 Left Front + 521 Left Rear 519 Left Rear + 518 not used — Serial Diagnostics 70 not used — not used 901 Brake Light Input 10 Ignition Power (ECU Relay) 16 Ground Monitoring 57 Valve Relay Power 537 Valve Relay Power 537 Ground (ECU Solenoid) — ABS Light 600 EBD Light 991 CAN -L CAN -H ASR on/off switch 601
Normal Condition/Measurement Ignition off: 1.6 k ± 0.3 k to pin 4 Ignition off: 1.6 k ± 0.3 k to pin 7 Ignition off: 1.6 k ± 0.3 k to pin 6 Ignition off: 1.6 k ± 0.32k to pin 9 Ignition off: 1.6 k ± 0.32k to pin 8 — Serial Signal — — Brake on: >9.5V.Brake off: <2.0V Ignition on: >9.5V <0.5 with reference to battery negative Ignition on: >9.5V Ignition on: >9.5V <0.5 with reference to battery negative Ignition on: <2.5V. Ignition off: >9.5V Ignition on: <2.5V. Ignition off: >9.5V Serial data line (ASR only) Serial Data line (ASR only) Serial Signal (ASR only)
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DIAGNOSIS AND TESTING (Continued) Pinpoint Tests PINPOINT TEST A : WHEEL SPEED SENSOR (WSS) CONTINUITY FAULT NOTE: CODES C1145, C1155, C1165, C1175 Test Step A1
MEASURE THE RESISTANCE OF THE WSS AT THE SENSOR CONNECTOR Disconnect the WSS from the vehicle harness Measure the resistance at the WSS connector terminals Is the resistance between 1.28 & 1.92 K Ohms?
A2
Yes
Go to A2
No
Replace faulty WSS and - Clear the DTC - Go to ABS/TCS Diagnostic Procedure Table
MEASURE THE RESISTANCE OF THE WSS AT THE ABS ECU CONNECTOR Reconnect the WSS to the vehicle harness Disconnect the vehicle harness from the ABS ECU Measure the resistance at the ECU connector terminals that correspond to the WSS being checked Is the resistance very close to that measured in A1?
A3
Result / Action to Take
Yes
Go to A3
No
Locate high resistance fault in wiring and rectify - Clear the DTC - Go to ABS/TCS Diagnostic Procedure Table
CHECK THE VEHICLE WIRING Check the wiring harness and all connections between the WSS and the ABS ECU for permanent or intermittent open circuits or shorts. Be sure to wiggle the wiring whilst testing
NOTE: Never perform resistance check on ECU WSS output pins. Always disconnect ECU before testing wiring harness and/or WSS Were any permanent or intermittent open circuits or shorts located?
Yes
Repair or replace faulty wiring or connections Clear the DTC - Go to ABS/TCS Diagnostic Procedure Table
No
Clear the DTC - Go to ABS/TCS Diagnostic Procedure Table or If this is the second time that you have reached this point (i.e. the same DTC has reappeared after the first cycle of diagnostics/repair and the and no faults were found) then the ECU may be faulty. Replace the ABS/TCS modulator and return to ABS/TCS Diagnostic Procedure Table to confirm the repair.
PINPOINT TEST B : WHEEL SPEED SENSOR (WSS) OUTPUT FAULT NOTE: CODES C1148, C1158, C1168, C1178, C1222 Test Step B1
Result / Action to Take
CHECK THE AIR GAP BETWEEN THE WSS AND THE TONE WHEEL Measure the gap between the WSS and the tone wheel Is the gap to specification?
Yes
Go to B2
No
Adjust as necessary - Clear the DTC - Go to ABS/TCS Diagnostic Procedure Table
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DIAGNOSIS AND TESTING (Continued) Test Step B2
Result / Action to Take
CHECK THE CONDITION OF THE TONE WHEEL Visually inspect he tone wheel Is the tone wheel free from damage (broken, deformed or chipped) and does it have 50 teeth?
Yes
Go to B3
No
Replace the tone wheel and reset the air gap to specification - Clear the DTC - Go to ABS/TCS Diagnostic Procedure Table
B3
CHECKING WHEEL SPEED OUTPUT USING AN OSCILLOSCOPE. Viewing of Oscilloscope Patterns (WSS.) Disconnect the vehicle harness from the ABS ECU. Set the WDS to read oscilloscope wave patters. Check the oscilloscope pattern at the ECU connector terminals that correspond to the WSS being checked. Raise the vehicles wheels off the ground and rotate to achieve the below patters.
Yes
Go to A1
No
Investigate and rectify cause of fault - Clear the DTC - Go to ABS/TCS Diagnostic Procedure Table
Simulated normal oscilloscope pattern:
Simulated pattern showing possible increasing and decreasing distance between WSS and pulse wheel:
Simulated pattern showing possible chipped or damaged teeth:
NOTE: When using an oscilloscope to check the WSS output, the wheel must be rotated at a constant speed. Incorrect wheel bearing clearance can cause inaccurate readings.
Does the oscilloscope pattern look similar to the above normal pattern?
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DIAGNOSIS AND TESTING (Continued) PINPOINT TEST C : LOW/HIGH VOLTAGE FAILURE NOTE: CODES - B1317, B1318 Test Step C1
CHECK VOLTAGE AT THE BATTERY Check the battery voltage Check battery charging voltage (Refer to Alternator test procedure) Is the battery voltage to specification?
C2
Check the voltage at terminals 17 & 18 (Check voltage across each terminal to ground) Is the voltage at terminals 17 & 18 constant battery voltage regardless of ignition position?
Go to C2
No
Repair as required - Clear DTC - Go to ABS/TCS Diagnostic Procedure Table
Yes
Go to C3
No
Check corresponding fuses, wiring connections and looms for open circuits or shorts to ground. Be sure to wiggle the wiring whilst testing and repair as required - Clear the DTC - Go to ABS/TCS Diagnostic Procedure Table
CHECK VOLTAGE AT THE ECU CONNECTOR TERMINAL 15 Check the voltage at terminal 15 (Check voltage across each terminal to ground) Is the voltage at terminals 15 constant battery voltage with ignition ON?
C4
Yes
CHECK VOLTAGE AT THE ABS ECU CONNECTOR – TERMINALS 17 & 18 Disconnect the vehicle harness from the ABS ECU
C3
Result / Action to Take
Yes
Go to C4
No
Check corresponding fuses, wiring connections and looms for open circuits or shorts to ground. Be sure to wiggle the wiring whilst testing and repair as required - Clear the DTC - Go to ABS/TCS Diagnostic Procedure Table
CHECK CONTINUITY AT THE ECU CONNECTOR TERMINAL 16 & 19 Check the resistance at terminals 16 & 19 (Check resistance between Yes each terminal and ground) Repair as required - Clear the DTC - Go to ABS/TCS Diagnostic Procedure Table Is there a high resistance or open circuit between terminals 16 & 19 and ground No Clear the DTC - Go to ABS/TCS Diagnostic Procedure Table or If this is the second time that you have reached this point (i.e. the same DTC has reappeared after the first cycle of diagnostics/repair and the and no faults were found) then the ECU may be faulty. Replace the ABS/TCS modulator and return to ABS/TCS Diagnostic Procedure Table to confirm the repair.
G23421 en
01/2003 2003.0 BA Falcon
206-09-24
Anti Lock Control
206-09-24
DIAGNOSIS AND TESTING (Continued) PINPOINT TEST D : BRAKE LIGHT SWITCH FAILURE NOTE: CODES - P1571 Test Step D1
Result / Action to Take
CHECK THE BRAKE LIGHTS Check the brake lights Do the brake lights work?
Yes
Go to D2
No
Check the following. Repair as required. Clear DTC. Go to ABS/TCS Diagnostic Procedure Table. Check for voltage supply at the brake light switch Check the operation and adjustment of the brake light switch Check for blown bulbs, open circuits or shorts in the wiring from the brake light switch to the brake lights. Be sure to wiggle the wiring whilst testing.
D2
CHECK VOLTAGE AT THE ECU CONNECTOR TERMINAL 14 Disconnect the vehicle harness from the ABS ECU. Check the voltage at terminal 14 (Check voltage across each terminal to ground) Does terminal 14 have >10V when the brakes are applied?
Yes
Clear the DTC - Go to ABS/TCS Diagnostic Procedure Table or If this is the second time that you have reached this point (i.e. the same DTC has reappeared after the first cycle of diagnostics/repair and the and no faults were found) then the ECU may be faulty. Replace the ABS/TCS modulator and return to ABS/TCS Diagnostic Procedure Table to confirm the repair.
No
Check for open circuits or shorts in the wiring from the brake light switch to the ABS/TCS ECU. Be sure to wiggle the wiring whilst testing Repair as required - Clear DTC - Go to ABS/TCS Diagnostic Procedure Table
PINPOINT TEST E : ABS/TCS MODULATOR ASSEMBLY INTERNAL FAULT NOTE: CODES - C1342, C1266, C1095 Test Step E1
Result / Action to Take
CHECK VOLTAGE AT THE ABS ECU CONNECTOR – TERMINALS 17 & 18 Disconnect the vehicle harness from the ABS ECU Check the voltage at terminals 17 & 18 (Check voltage across each terminal to ground) Is the voltage at terminals 17 & 18 constant battery voltage regardless of ignition position?
G23421 en
Yes
Go to E2
No
Check corresponding fuses, wiring connections and looms for open circuits or shorts to ground. Be sure to wiggle the wiring whilst testing and repair as required - Clear the DTC - Go to ABS/TCS Diagnostic Procedure Table
01/2003 2003.0 BA Falcon
206-09-25
Anti Lock Control
206-09-25
DIAGNOSIS AND TESTING (Continued) Test Step E2
CHECK VOLTAGE AT THE ECU CONNECTOR TERMINAL 15 Check the voltage at terminal 15 (Check voltage across each terminal to ground) Is the voltage at terminals 15 constant battery voltage with ignition ON?
E3
Result / Action to Take
Yes
Go to E3
No
Check corresponding fuses, wiring connections and looms for open circuits or shorts to ground. Be sure to wiggle the wiring whilst testing and repair as required - Clear the DTC - Go to ABS/TCS Diagnostic Procedure Table
CHECK CONTINUITY AT THE ECU CONNECTOR TERMINAL 16 & 19 Check the resistance at terminals 16 & 19 (Check resistance between Yes each terminal and ground) Repair as required - Clear the DTC - Go to ABS/TCS Diagnostic Procedure Table NOTE: I. The ABS/TCS Modulator Assembly contains no No serviceable items Clear the DTC - Go to ABS/TCS Diagnostic NOTE: II. Under no circumstances is the ABS/TCS Modulator Procedure Table Assembly to be dismantled or a repair attempted. or If this is the second time that you have reached Is there a high resistance or open circuit between terminals 16 & this point (i.e. the same DTC has reappeared 19 and ground? after the first cycle of diagnostics/repair and the and no faults were found) then the ECU may be faulty. Replace the ABS/TCS modulator and return to ABS/TCS Diagnostic Procedure Table to confirm the repair.
PINPOINT TEST F : COMMUNICATIONS FAULT Test Step F1
Result / Action to Take
WDS CONNECTION Is the WDS properly plugged into the diagnostic connector? - Is the WDS properly connected to the power supply? - Is the correct vehicle selected?
Yes
Go to ABS/TCS ECU CONNECTOR - FITMENT below
No
Rectify and return to DIAGNOSTIC PROCEDURE - PART A
F2
ABS/TCS ECU CONNECTOR - FITMENT Is the ABS/TCS connector free from damage and corrosion and is it properly connected?
Yes
Go to ABS/TCS ECU CONNECTOR CIRCUITS below
No
Rectify and return to DIAGNOSTIC PROCEDURE - PART A
F3
ABS/TCS ECU CONNECTOR - CIRCUITS Remove the ABS/TCS connector. Are all the terminal voltages and resistances within specification?
Yes
Go to WDS below
No
Check corresponding fuses, wiring connections and looms for open circuits or shorts to ground. Be sure to wiggle the wiring whilst testing Rectify and return to DIAGNOSTIC PROCEDURE - PART A
G23421 en
01/2003 2003.0 BA Falcon
206-09-26
Anti Lock Control
206-09-26
DIAGNOSIS AND TESTING (Continued) Test Step F4
Result / Action to Take
WDS Can the WDS establish communications with the ABS/TCS on another vehicle?
Yes
If no other fault is found, the fault may be within the ABS/TCS ECU. Replace the ABS/TCS modulator and return to ABS/TCS Diagnostic Procedure Table to confirm the repair.
No
The WDS is faulty. Use another WDS and return to DIAGNOSTIC PROCEDURE - PART A
G23421 en
01/2003 2003.0 BA Falcon
206-09-27
Anti Lock Control
206-09-27
REMOVAL AND INSTALLATION
Rear ABS sensor — IRS
4. Remove ABS-Knuckle Screw behind the Rotor.
Removal 1. Remove lower rear seat cushion.
5. Remove ABS Sensor. 2. Disconnect the ABS wheel sensor plug and push it and the grommet through the floor plan.
3. Unclip Firtree Clip connecting ABS Sensor with Control Blade. Feed ABS Sensor Cable through hole in Control Blade.
G23422 en
Installation 1. Locate ABS Sensor to Knuckle using ABS-Knuckle Screw. 2. Torque ABS-Knuckle Screw to 8.9 - 12.1 Nm.
01/2003 2003.0 BA Falcon
206-09-28
Anti Lock Control
206-09-28
REMOVAL AND INSTALLATION (Continued) 3. Feed ABS Sensor Cable through hole in Control Blade.
6. Refit lower seat cushion.
4. Affix Firtree Clip to ABS Sensor Cable and clip to the Control Blade as shown.
ABS Wheel Speed Sensor — Rear (Beam Axle) Removal 1. Remove the rear seat cushion. Refer to section 501-10. 2. Disconnect the ABS wheel sensor. Plug and push it and the grommet through the floor plan.
5. Reconnect wiring plug and fit grommet.
Item 1 2
G23422 en
Description ABS Wheel Sensor Plug Grommet
01/2003 2003.0 BA Falcon
206-09-29
Anti Lock Control
206-09-29
REMOVAL AND INSTALLATION (Continued) 3. Unclip ABS Sensor cable clips from the leaf spring (3 off).
4. Remove ABS sensor retaining bolt and withdraw the ABS Sensor.
3. Remove ABS Sensor retaining bolt.
4. Remove ABS Sensor. Installation 1. Installation is the reverse order to removal.
Rear Tone Wheel The rear tone wheel is not separately serviceable. The tone wheel is serviced with the complete half shaft assembly.
Front Tone Wheel The front hub tone wheel is not separately serviceable. The tone wheel is serviced with the complete hub assembly.
ABS Modulator Assembly
Front ABS Wheel Sensors
Removal NOTE: The ABS Modulator Assembly is a critical safety item. It should only be installed by trained and experienced ABS Technicians.
Removal 1. Disconnect ABS Sensor cable. 2. Unclip fir tree clip 2 places.
1. Ensure ignition is in the off position. 2. Disconnect wiring from modulator by sliding the locking slide pin out and lifting the connector from the modulator.
Installation 1. Installation is the reverse order to removal.
G23427 en
01/2003 2003.0 BA Falcon
206-09-30
Anti Lock Control
206-09-30
REMOVAL AND INSTALLATION (Continued) 3. Loosen the brake lines.
3. Refit mounting nuts and torque to specifications.
4. Loosen the 2 mounting nuts and withdraw the modulator from the vehicle.
4. Torque brake lines to specifications.
Installation 1. Ensure mounting dampers are in place. 2. Position modulator ensuring fully seated in bottom pin and hand thread to brake lines.
5. Re-connect wiring by placing the connector on the locating lugs of the ABS ECU and then pushing in the locking slide to secure the connector.
6. Bleed braking system as described in section 206-00 Brake System-General Information.
G23427 en
01/2003 2003.0 BA Falcon
211-00-1
Steering System — General Information
211-00-1
SECTION : 211-00 Steering System — General Information VEHICLE APPLICATION : 2003.0 BA Falcon CONTENTS
PAGE
DESCRIPTION AND OPERATION Service Kits ............................................................................................................................211-00-2 GENERAL PROCEDURES Power Steering System Bleeding Air .....................................................................................211-00-3 Rack and Pinion Gear Rack Bearing Preload Adjustment ....................................................211-00-4 Steering Gear Lubrication ......................................................................................................211-00-4 DISASSEMBLY AND ASSEMBLY Steering System Exploded .....................................................................................................211-00-5
01/2003 2003.0 BA Falcon
211-00-2
Steering System — General Information
211-00-2
DESCRIPTION AND OPERATION
Service Kits Service Kit Contents Outer Tie Rod Assembly Service Kit 26092580 Outer Tie Rod Assembly Inner Tie Rod Assembly Service Kit 26092849 Inner Tie Rod Assembly Metric Hex Nut Seal Retaining Clamp Rack And Pinion Boot Service Kit 26092851 Rack And Pinion Boot Seal Retaining Clamp Tie Rod End Clamp Service Kit Grease (Not Shown) Seal Installation Instruction Sheet (Not Shown) Seal And Bearing Service Kit 26102901 Retaining Ring Spool Shaft Seal Needle And Bearing Assembly Valve Body Ring (4) Metric Hex Nut Dust Cover Adjuster Plug Lube Shaft And Seal Instruction Sheet (Not Shown) Service Kit Grease (Not Shown) Cylinder Line Assembly Service Kit (Right) 26102902 Cylinder Line Assembly O-Ring Seal Cylinder Line Assembly Service Kit (Left) 26102903 Cylinder Line Assembly O-Ring Seal Sleeve And Bushing Service Kit 26103515 Steering Gear Bushing Steering Gear Bushing Sleeve NOTE: Kits in bold reflect service kits supplied by Delphi Saginaw. Parts listed below service kits are included in each kit.
G27360 en
01/2003 2003.0 BA Falcon
211-00-3
Steering System — General Information
211-00-3
GENERAL PROCEDURES
Power Steering System Bleeding Air
6. While turning wheel, check fluid constantly. NOTE: No bubbles are allowed.
NOTE: For any sign of bubbles, recheck CAUTION: You should bleed after any connections. Repeat step 5. component replacement or after disconnecting fluid line in case of steering system noise. 7. Start engine. With engine idling, maintain fluid Bleeding is important to prevent pump damage, to level. Reinstall cap. ensure proper system operation and to stop 8. Return wheels to centre. Lower front wheels to steering system noise. ground. NOTE: Inspect steering system. Check, and correct 9. Keep engine running for two minutes. as needed: 10. Turn steering wheel in both directions. Hoses must not touch any other part of vehicle. 11. Verify: Hose touching frame, body, or engine could cause steering system noise. Smooth power assist All hose connections must be tight. Loose Noiseless operation connections might not leak but could allow air into Proper fluid level system. No system leaks NOTE: Use only clean, new power steering fluid. Fluid Proper fluid condition (i.e. No bubbles, no must be: foam and no discolouration) Conventional climate: 12. If all proper conditions apply, procedure is GM #1052884 - 16 ounce. complete. GM #1050017 - 32 ounce. 13. If any problem remains, check these special conditions: Cold climate: Fluid: If there is foam or bubbles in the fluid. GM #12345866 - 16 ounce. The fluid must be completely free of bubbles. GM #12345867 - 32 ounce. In step 5, be alert to periodic bubbles that 1. Switch ignition off. could indicate a loose connection or leaky O-ring seal in either the return hose or 2. Raise front wheels off ground. pressure hose. Also check for discoloured 3. Turn steering wheel full left. fluid. Follow the following steps top remedy 4. Fill fluid reservoir to “FULL COLD” level. Leave the situation: cap off. Switch ignition off.
Wait two minutes. Recheck hose connections. Repeat steps 7-10 of procedure. If condition still exists then check: return hose clamps, return hose O-ring, pressure hose O-rings and gear cylinder line O-rings Noise: If the pump whines or groans then with engine running, recheck hoses for possible contact with frame body or engine. If no contact is found, follow either of the below methods: Method one: Normal cool down Switch engine off. Wait for system to cool. 5. With assistant checking fluid level and condition, Install reservoir cap. turn steering wheel lock-to-lock at least 20 times. Method two: Partial fluid replacement Engine remains off. Switch engine off. NOTE: On systems with long return lines or fluid Use a suction device to remove fluid coolers, turn steering wheel lock-to-lock at least from reservoir. 40 times. Refill with cool, clean fluid. NOTE: Trapped air may cause fluid to overflow. Install reservoir cap. Thoroughly clean any spilled fluid to allow for leak NOTE: After either method of cooling, start engine check. and allow engine to come up to operating NOTE: Keep fluid level at “FULL COLD”. temperature. If noise persists, remove and replace
G27361 en
01/2003 2003.0 BA Falcon
211-00-4
Steering System — General Information
211-00-4
GENERAL PROCEDURES (Continued) power steering pump. Repeat bleed procedure following pump replacement.
Rack and Pinion Gear Rack Bearing Preload Adjustment 1. Remove the steering gear from the vehicle. Refer to Section 211-02. 2. Remove and discard the adjuster plug.
3. Install a new adjuster plug. 4. Turn the adjuster plug clockwise onto the rack and pinion gear assembly until the adjuster plug bottoms in the rack and pinion gear assembly. 5. Tighten the adjuster plug to 10 Nm (90 lb. in.) then turn back 35 degrees to 55 degrees. 6. Install the steering gear into the vehicle. Refer to Section 211-02.
Steering Gear Lubrication 1. The rack and pinion steering gears are lubricated by a semi-liquid grease. 2. The correct amount of grease can only be applied during steering gear rebuild and therefore check and top-up is not a maintenance service operation.
G27361 en
01/2003 2003.0 BA Falcon
211-00-5
Steering System — General Information
211-00-5
DISASSEMBLY AND ASSEMBLY
Steering System Exploded
G27365 en
01/2003 2003.0 BA Falcon
211-00-6
Steering System — General Information
211-00-6
DISASSEMBLY AND ASSEMBLY (Continued) Disassembled View Item Description 1 Outer Tie Rod Assembly 2 Metric Hex Nut 3 Tie Rod End Clamp 4 Rack and Pinion Boot 5 Seal Retaining Clamp 6 Inner Tie Rod Assembly 7 Cylinder Line Assembly (Right) 8 Cylinder Line Assembly (Left) 9 O-Ring 10 Rack and Pinion Housing Assembly 11 Spool Shaft Boot 12 Retaining Ring 13 Spool Shaft Seal 14 Needle Bearing Assembly 15 Valve Body Ring 16 Pinion and Valve Assembly 17 Metric Hex Nut 18 Dust Cover 19 Rack Bearing Assembly 20 O-Ring Seal 21 Adjuster Spring 22 Adjuster Plug 23 Steering Gear Bushing 24 Steering Gear Bushing Sleeve Parts in bold reflect service checked parts on Delphi Saginaw’s Parts List.
G27365 en
01/2003 2003.0 BA Falcon
211-02-1
Power Steering
211-02-1
SECTION : 211-02 Power Steering VEHICLE APPLICATION : 2003.0 BA Falcon CONTENTS
PAGE
SPECIFICATIONS Specifications .........................................................................................................................211-02-2 DESCRIPTION AND OPERATION Power Steering Pump — I6 ...................................................................................................211-02-3 Power Steering Pump — V8 ..................................................................................................211-02-3 Pump Identification ...............................................................................................................211-02-4 DIAGNOSIS AND TESTING Power Steering Pump — I6 ...................................................................................................211-02-5 Symptom Chart ....................................................................................................................211-02-5 GENERAL PROCEDURES Start of Procedure ................................................................................................................211-02-15 Remedying Pump Noise ......................................................................................................211-02-15 Purging Power Steering System of Air ................................................................................211-02-15 Flushing Power Steering Pump (I6) .....................................................................................211-02-15 Flushing Power Steering Gear (I6) ......................................................................................211-02-15 REMOVAL AND INSTALLATION Steering Gear Cylinder Pipe and O — Ring Seals ..............................................................211-02-17 Steering Gear Spool Shaft Seals and Bearings ..................................................................211-02-17 Power Steering Pump (I6) ....................................................................................................211-02-21 Power Steering Pump (V8) ..................................................................................................211-02-22 Power Steering Pump Pulley (V8) .......................................................................................211-02-23 Steering Gear — I6 ..............................................................................................................211-02-23 Steering Gear — V8 .............................................................................................................211-02-24 Steering Gear Bushing and Sleeve .....................................................................................211-02-24 Drive Belt (I6) .......................................................................................................................211-02-25 Quick Connect Power Steering Fitting (I6) ..........................................................................211-02-25 Power Steering Lines (I6) ....................................................................................................211-02-26 Power Steering Lines (V8) ...................................................................................................211-02-27 DISASSEMBLY AND ASSEMBLY Resorvoir Assembly (I6) .......................................................................................................211-02-29 Resorvoir Assembly (V8) .....................................................................................................211-02-29 Control Valve Assembly (I6) ................................................................................................211-02-29 Drive Shaft Seal (I6) .............................................................................................................211-02-30 Hydraulic Pump Assembly (I6) .............................................................................................211-02-31
01/2003 2003.0 BA Falcon
211-02-2
Power Steering
211-02-2
SPECIFICATIONS General Specifications Description Specification Lubrication Power Steering Hydraulic ESN M2C 134 D (Mobil System 424 or equivelant) Ford R1-424 0.95 litre approximately (total system) Power Steering Rack and ESA M1 C 75B Pinion (Shell Alvania L 50 grams PRO) Pump Capacity 0.6 litre Multi-Purpose Grease ESB-M1C93-B and DOAZ-19584-AA ESR-M1C159-A MERCON® MERCON® Multi-Purpose ATF XT-2-QDX Power Steering Gear Steering Gear Constant 47.8mm/rev Ratio Steering Ratio (on 18.9:1 centre) Turns of Steering Wheel 3.09 (Stop to Stop) Preload: Maximum 5 Nm allowable over full travel of rack Torque Specifications Description Rack Pad Locknut Tube Nuts (Feed Pipes) Tube Nuts (Pressure and Return) Tie Rod Ball Housing Pressure Switch Steering Gear to Sub-frame Pinion Lower Retaining Nut Pinion Lower Screw Plug Reservoir to Pump Pump to Mounting Brackets (V8) Pump to Mounting Brackets (I6) Mounting Brackets to Cyl. Head (I6 -m8) Mounting Brackets to Cyl. Head (I6 -m10) Mounting Brackets to Cyl. Head (V8 -7/6) Idler Pulley Locknut Idler Pulley Bracket to Block Pressure Hose Tube Nut Return Hose Clamp Screw Discharge Fitting to Pump G37358 en
Description Fitting Connector to Discharge Power steering pump (V8) lower bolt Power steering pump (V8) upper bolts
Nm 65 30 20-30 20-30
Nm 75 20 35 85 14 80 40 60 50 50 25 47 23 47 47 40 24 30 5 01/2003 2003.0 BA Falcon
211-02-3
Power Steering
211-02-3
DESCRIPTION AND OPERATION
Power Steering Pump — I6 The power steering pump is a constant displacement vane type providing hydraulic pressure for the steering system. The housing and internal parts of the pump are inside the reservoir so the pump parts operate submerged in oil. The reservoir is sealed against the pump housing, leaving the housing face and the shaft hub exposed. The drive shaft is fitted with a pulley and is belt driven from the crankshaft. The rotor is loosely splined to the drive shaft and secured with a retaining ring. Ten vanes are mounted in radial slots in the rotor. An identification label showing the pump model number is located on the outboard side of the pump reservoir.
Power Steering Pump — V8 NOTE: On early build 4.6L and 5.4L engines there are four bolts mounting the power steering pump to the engine block. The fourth bolt on earlier builds may be discarded upon the replacement of the power steering pump. The CIII power steering pump has the following features: It is a belt-driven, vane-type, power steering pump. It is mounted directly to the engine block by three bolts. The power steering pump is replaced as an assembly. An identification tag attached to the power steering pump indicates the model number and bar code. Refer to the identification tag when the pump replacement is required. The power steering pump uses a quick connect fitting for the power steering pressure hose. The power steering fluid reservoir is mounted to the front of the engine bay on top of the shroud.
G37361 en
01/2003 2003.0 BA Falcon
211-02-4
Power Steering
211-02-4
DESCRIPTION AND OPERATION (Continued) System View — I6
Item 1 2 3 4 5
Description Steering Gear Power Steering Pump Power Steering Return Hose Power Steering Fluid Cooler Press & Return Hose Assy
Pump Identification CAUTION: Always use the ID code when ordering service parts. An identification tag is attached to the valve housing. Item 1 2 3 4 5 6
G37361 en
Description Model Code For Manufacturing Purposes Only Day Shift Year Month
01/2003 2003.0 BA Falcon
211-02-5
Power Steering
211-02-5
DIAGNOSIS AND TESTING
Power Steering Pump — I6 Symptom Chart Power Steering Pump (I6) Symptom Chart Condition
Source
Action
Jerky Steering
Power Steering Fluid Level Low Leak Glazed, Loose or Broken Power Steering Pump Belt Air in Power Steering System Binding Front Suspension Ball Joints or Steering Linkage Loose, Worn, or Damaged Steering Linkage or Connections Loose Steering Gear Mountings Incorrect Steering Gear Adjustment Incorrect Brake Adjustment Incorrect Front Wheel Bearing Adjustment Wheel Out of Balance Obstruction Within Steering Gear
Remove/Repair as required
Loose Steering
Loose, Worn, or Damaged Steering Linkage or Connections Loose Steering Gear Mountings Incorrect Steering Gear Adjustment Incorrect Front Wheel Bearing Adjustment
Remove/Repair as required
Hard Steering and/ or Loss of Power Assist
Incorrect Tyre Pressure Tyre Sizes Not Uniform Power Steering Fluid Level Low Leak Glazed, Loose or Broken Power Steering Pump Belt Lack of Lubrication Air in Power Steering System Obstruction in Power Steering Lines Binding Front Suspension Ball Joints or Steering Linkage Insufficient Steering Pump Pressure Incorrect Steering Gear Adjustment Incorrect Front Wheel Alignment Excessive Wear of Steering Pump Internal Parts Steering Gear Valve Sleeve or Seals Worn Obstruction Within Steering Gear
Remove/Repair as required
Hard Turning When Stationary
Incorrect Tyre Pressure Tyre Sizes Not Uniform Power Steering Fluid Level Low Leak Glazed, Loose or Broken Power Steering Pump Belt Lack of Lubrication Obstruction in Power Steering Lines Binding Front Suspension Ball Joints or Steering Linkage Insufficient Steering Pump Pressure Incorrect Steering Gear Adjustment Steering Gear Valve Sleeve or Seals Worn Obstruction Within Steering Gear
Remove/Repair as required
G37362 en
01/2003 2003.0 BA Falcon
211-02-6
Power Steering
211-02-6
DIAGNOSIS AND TESTING (Continued) Condition
Source
Action
Steering and Suspension Noises
Power Steering Fluid Level Low Leak Sagging or Broken Spring Glazed, Loose or Broken Power Steering Pump Belt Broken Rear Spring Tie Bolts (Wagon) Lack of Lubrication Air in Power Steering System Obstruction in Power Steering Lines Loose or Weak Shock Absorber Loose or Worn Suspension Arm Bushings Binding Front Suspension Ball Joints or Steering Linkage Loose, Worn, or Damaged Steering Linkage or Connections Loose Steering Gear Mountings Incorrect Steering Gear Adjustment Incorrect Brake Adjustment Incorrect Front Wheel Bearing Adjustment Incorrect Front Wheel Alignment Bent Rear Axle Housing Excessive Wear of Steering Pump Internal Parts
Remove/Repair as required
Shimmy or Wheel Tramp
Incorrect Tyre Pressure Broken Rear Spring Tie Bolts (Wagon) Air in Power Steering System Loose or Weak Shock Absorber Loose or Worn Suspension Arm Bushings Loose, Worn, or Damaged Steering Linkage or Connections Loose Steering Gear Mountings Incorrect Steering Gear Adjustment Incorrect Front Wheel Bearing Adjustment Wheel Out of Balance Incorrect Front Wheel Alignment Out-of-Round Wheel
Remove/Repair as required
Pull to One Side
Incorrect Tyre Pressure Tyre Sizes Not Uniform Overloaded or Unevenly Loaded Vehicle Sagging or Broken Spring Rear Spring Tie Bolt Off Centre (Wagon) Broken Rear Spring Tie Bolts (Wagon) Rear Spring Front Hanger Mislocated (Wagon) Bent Spindle Arm Bent Spindle Loose or Worn Suspension Arm Bushings Incorrect Brake Adjustment Incorrect Front Wheel Bearing Adjustment Incorrect Front Wheel Alignment Frame or Underbody Out of Alignment Bent Rear Axle Housing Steering Gear Valve Sleeve or Seals Worn
Remove/Repair as required
G37362 en
01/2003 2003.0 BA Falcon
211-02-7
Power Steering
211-02-7
DIAGNOSIS AND TESTING (Continued) Condition
Source
Action
Side- to- side Wander
Incorrect Tyre Pressure Tyre Sizes Not Uniform Overloaded or Unevenly Loaded Vehicle Sagging or Broken Spring Broken Rear Spring Tie Bolts (Wagon) Bent Spindle Arm Bent Spindle Loose or Weak Shock Absorber Loose or Worn Suspension Arm Bushings Loose, Worn, or Damaged Steering Linkage or Connections Loose Steering Gear Mountings Incorrect Steering Gear Adjustment Incorrect Front Wheel Bearing Adjustment Incorrect Front Wheel Alignment
Remove/Repair as required
Body Sway or Roll
Incorrect Tyre Pressure Sagging or Broken Spring Broken Rear Spring Tie Bolts (Wagon) Loose or Weak Shock Absorber Incorrect Steering Gear Adjustment
Remove/Repair as required
Tyre Squeal on Turns
Incorrect Tyre Pressure Tyre Sizes Not Uniform Bent Spindle Arm Bent Spindle Loose, Worn, or Damaged Steering Linkage or Connections Incorrect Front Wheel Alignment
Remove/Repair as required
Binding or Poor Recovery
Incorrect Tyre Pressure Lack of Lubrication Binding Front Suspension Ball Joints or Steering Linkage Insufficient Steering Pump Pressure Incorrect Steering Gear Adjustment Incorrect Brake Adjustment Incorrect Front Wheel Alignment Steering Gear Valve Sleeve or Seals Worn Obstruction Within Steering Gear
Remove/Repair as required
Abnormal or Irregular Tyre Wear
Incorrect Tyre Pressure Tyre Sizes Not Uniform Overloaded or Unevenly Loaded Vehicle Sagging or Broken Spring Rear Spring Tie Bolt Off Centre (Wagon) Broken Rear Spring Tie Bolts (Wagon) Rear Spring Front Hanger Mislocated (Wagon) Bent Spindle Arm Bent Spindle Loose or Weak Shock Absorber Loose or Worn Suspension Arm Bushings Loose, Worn, or Damaged Steering Linkage or Connections Incorrect Steering Gear Adjustment Incorrect Brake Adjustment Incorrect Front Wheel Bearing Adjustment Wheel Out of Balance Incorrect Front Wheel Alignment Out-of-Round Wheel Frame or Underbody Out of Alignment Bent Rear Axle Housing
Remove/Repair as required
G37362 en
01/2003 2003.0 BA Falcon
211-02-8
Power Steering
211-02-8
DIAGNOSIS AND TESTING (Continued) Condition
Source
Action
Sag at One Wheel
Incorrect Tyre Pressure Tyre Sizes Not Uniform Overloaded or Unevenly Loaded Vehicle Sagging or Broken Spring Loose or Worn Suspension Arm Bushings
Remove/Repair as required
Hard or Rough Ride
Incorrect Tyre Pressure Overloaded or Unevenly Loaded Vehicle Sagging or Broken Spring Lack of Lubrication Loose or Weak Shock Absorber Loose or Worn Suspension Arm Bushings Binding Front Suspension Ball Joints or Steering Linkage Wheel Out of Balance Out-of-Round Wheel
Remove/Repair as required
Rear Suspension Misalignment (DogTracking)
Rear Spring Tie Bolt Off Centre (Wagon) Broken Rear Spring Tie Bolts (Wagon) Rear Spring Front Hanger Mislocated (Wagon) Loose or Worn Suspension Arm Bushings Frame or Underbody Out of Alignment Bent Rear Axle Housing
Remove/Repair as required
WARNING: Whenever a repair to the power steering system is carried out, which may permit air to enter the fluid lines or the pump, the system must be purged of air on completion of the repair. CAUTION: Do not hold the steering gear against the lock stops for more than 5 seconds. Several of these symptoms are also common to suspension, frame, and wheel and tyre troubles. For this reason, be sure that the cause of the trouble is in the power steering pump before adjusting, repairing, or replacing any of the pump parts. General Diagnosis Condition
Source
Action
Chirp noise in steering pump
Loose belt
Remove/Repair as required
Belt squeal (particularly noticeable at full wheel travel and standstill parking).
Loose belt
Remove/Repair as required
Growl noise in steering pump
Excessive back-pressure in hoses or steering gear caused by restriction
Remove/Repair as required
Growl noise in steering pump (particularly noticeable at full wheel travel and standstill parking).
Scored pressure plate, thrust plate or rotor. Extreme wear of pump ring and vanes.
Remove/Repair as required
Groan noise in steering pump
Low oil level. Air in the oil. Poor pressure hose connection
Remove/Repair as required
Rattle noise in steering pump
Vanes not installed properly.
Remove/Repair as required
G37362 en
01/2003 2003.0 BA Falcon
211-02-9
Power Steering
211-02-9
DIAGNOSIS AND TESTING (Continued) Condition
Source
Action
Momentary increase in effort when turning wheel fast to right or left.
Low oil level in pump Pump belt slipping High internal leakage. Valve or gear cylinder
Remove/Repair as required
Steering wheel surges or jerks when turning with engine running, especially during parking
Low oil level Loose pump belt Insufficient pump pressure Sticky flow control valve
Remove/Repair as required
Hard steering or lack of assist, especially in parking
Loose pump belt Low oil level in reservoir. Steering gear to column misalignment Tires not properly inflated NOTE: If checks 1 through 4 do not reveal cause of hard steering, follow the Power Steering Test Procedure.
Remove/Repair as required
Further possible causes could be: Sticky flow control valve Insufficient pump pressure output Excessive internal pump leakage Excessive internal system leakage Foaming milky power steering fluid, low fluid level and possible low pressure
Air in the fluid, and loss of fluid due to internal pump leakage causing overflow.
Remove/Repair as required
Low pressure from steering pump
Flow-control valve stuck or inoperative Pressure plate not flat against pump ring Extreme wear of pump ring and vanes Scored pressure plate, thrust plate or rotor Vanes not installed properly Vanes sticking in rotor slots Cracked or broken thrust or pressure plate
Remove/Repair as required
Power Steering Pump (V8) Symptom Chart Condition
Source
Action
Jerky Steering
Power Steering Fluid Level Low Leak Glazed, Loose or Broken Power Steering Pump Belt Air in Power Steering System Binding Front Suspension Ball Joints or Steering Linkage Loose, Worn, or Damaged Steering Linkage or Connections Loose Steering Gear Mountings Incorrect Steering Gear Adjustment Incorrect Brake Adjustment Incorrect Front Wheel Bearing Adjustment Wheel Out of Balance Obstruction Within Steering Gear
Remove/Repair as required
Loose Steering
Loose, Worn, or Damaged Steering Linkage or Connections Loose Steering Gear Mountings Incorrect Steering Gear Adjustment Incorrect Front Wheel Bearing Adjustment
Remove/Repair as required
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01/2003 2003.0 BA Falcon
211-02-10
Power Steering
211-02-10
DIAGNOSIS AND TESTING (Continued) Condition
Source
Action
Hard Steering and/ or Loss of Power Assist
Incorrect Tyre Pressure Tyre Sizes Not Uniform Power Steering Fluid Level Low Leak Glazed, Loose or Broken Power Steering Pump Belt Lack of Lubrication Air in Power Steering System Obstruction in Power Steering Lines Binding Front Suspension Ball Joints or Steering Linkage Insufficient Steering Pump Pressure Incorrect Steering Gear Adjustment Incorrect Front Wheel Alignment Excessive Wear of Steering Pump Internal Parts Steering Gear Valve Sleeve or Seals Worn Obstruction Within Steering Gear
Remove/Repair as required
Hard Turning When Stationary
Incorrect Tyre Pressure Tyre Sizes Not Uniform Power Steering Fluid Level Low Leak Glazed, Loose or Broken Power Steering Pump Belt Lack of Lubrication Obstruction in Power Steering Lines Binding Front Suspension Ball Joints or Steering Linkage Insufficient Steering Pump Pressure Incorrect Steering Gear Adjustment Steering Gear Valve Sleeve or Seals Worn Obstruction Within Steering Gear
Remove/Repair as required
Steering and Suspension Noises
Power Steering Fluid Level Low Leak Sagging or Broken Spring Glazed, Loose or Broken Power Steering Pump Belt Broken Rear Spring Tie Bolts (Wagon) Lack of Lubrication Air in Power Steering System Obstruction in Power Steering Lines Loose or Weak Shock Absorber Loose or Worn Suspension Arm Bushings Binding Front Suspension Ball Joints or Steering Linkage Loose, Worn, or Damaged Steering Linkage or Connections Loose Steering Gear Mountings Incorrect Steering Gear Adjustment Incorrect Brake Adjustment Incorrect Front Wheel Bearing Adjustment Incorrect Front Wheel Alignment Bent Rear Axle Housing Excessive Wear of Steering Pump Internal Parts
Remove/Repair as required
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01/2003 2003.0 BA Falcon
211-02-11
Power Steering
211-02-11
DIAGNOSIS AND TESTING (Continued) Condition
Source
Action
Shimmy or Wheel Tramp
Incorrect Tyre Pressure Broken Rear Spring Tie Bolts (Wagon) Air in Power Steering System Loose or Weak Shock Absorber Loose or Worn Suspension Arm Bushings Loose, Worn, or Damaged Steering Linkage or Connections Loose Steering Gear Mountings Incorrect Steering Gear Adjustment Incorrect Front Wheel Bearing Adjustment Wheel Out of Balance Incorrect Front Wheel Alignment Out-of-Round Wheel
Remove/Repair as required
Pull to One Side
Incorrect Tyre Pressure Tyre Sizes Not Uniform Overloaded or Unevenly Loaded Vehicle Sagging or Broken Spring Rear Spring Tie Bolt Off Centre (Wagon) Broken Rear Spring Tie Bolts (Wagon) Rear Spring Front Hanger Mislocated (Wagon) Bent Spindle Arm Bent Spindle Loose or Worn Suspension Arm Bushings Incorrect Brake Adjustment Incorrect Front Wheel Bearing Adjustment Incorrect Front Wheel Alignment Frame or Underbody Out of Alignment Bent Rear Axle Housing Steering Gear Valve Sleeve or Seals Worn
Remove/Repair as required
Side- to- side Wander
Incorrect Tyre Pressure Tyre Sizes Not Uniform Overloaded or Unevenly Loaded Vehicle Sagging or Broken Spring Broken Rear Spring Tie Bolts (Wagon) Bent Spindle Arm Bent Spindle Loose or Weak Shock Absorber Loose or Worn Suspension Arm Bushings Loose, Worn, or Damaged Steering Linkage or Connections Loose Steering Gear Mountings Incorrect Steering Gear Adjustment Incorrect Front Wheel Bearing Adjustment Incorrect Front Wheel Alignment
Remove/Repair as required
Body Sway or Roll
Incorrect Tyre Pressure Sagging or Broken Spring Broken Rear Spring Tie Bolts (Wagon) Loose or Weak Shock Absorber Incorrect Steering Gear Adjustment
Remove/Repair as required
Tyre Squeal on Turns
Incorrect Tyre Pressure Tyre Sizes Not Uniform Bent Spindle Arm Bent Spindle Loose, Worn, or Damaged Steering Linkage or Connections Incorrect Front Wheel Alignment
Remove/Repair as required
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01/2003 2003.0 BA Falcon
211-02-12
Power Steering
211-02-12
DIAGNOSIS AND TESTING (Continued) Condition
Source
Action
Binding or Poor Recovery
Incorrect Tyre Pressure Lack of Lubrication Binding Front Suspension Ball Joints or Steering Linkage Insufficient Steering Pump Pressure Incorrect Steering Gear Adjustment Incorrect Brake Adjustment Incorrect Front Wheel Alignment Steering Gear Valve Sleeve or Seals Worn Obstruction Within Steering Gear
Remove/Repair as required
Abnormal or Irregular Tyre Wear
Incorrect Tyre Pressure Tyre Sizes Not Uniform Overloaded or Unevenly Loaded Vehicle Sagging or Broken Spring Rear Spring Tie Bolt Off Centre (Wagon) Broken Rear Spring Tie Bolts (Wagon) Rear Spring Front Hanger Mislocated (Wagon) Bent Spindle Arm Bent Spindle Loose or Weak Shock Absorber Loose or Worn Suspension Arm Bushings Loose, Worn, or Damaged Steering Linkage or Connections Incorrect Steering Gear Adjustment Incorrect Brake Adjustment Incorrect Front Wheel Bearing Adjustment Wheel Out of Balance Incorrect Front Wheel Alignment Out-of-Round Wheel Frame or Underbody Out of Alignment Bent Rear Axle Housing
Remove/Repair as required
Sag at One Wheel
Incorrect Tyre Pressure Tyre Sizes Not Uniform Overloaded or Unevenly Loaded Vehicle Sagging or Broken Spring Loose or Worn Suspension Arm Bushings
Remove/Repair as required
Hard or Rough Ride
Incorrect Tyre Pressure Overloaded or Unevenly Loaded Vehicle Sagging or Broken Spring Lack of Lubrication Loose or Weak Shock Absorber Loose or Worn Suspension Arm Bushings Binding Front Suspension Ball Joints or Steering Linkage Wheel Out of Balance Out-of-Round Wheel
Remove/Repair as required
Rear Suspension Misalignment (DogTracking)
Rear Spring Tie Bolt Off Centre (Wagon) Broken Rear Spring Tie Bolts (Wagon) Rear Spring Front Hanger Mislocated (Wagon) Loose or Worn Suspension Arm Bushings Frame or Underbody Out of Alignment Bent Rear Axle Housing
Remove/Repair as required
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01/2003 2003.0 BA Falcon
211-02-13
Power Steering
211-02-13
DIAGNOSIS AND TESTING (Continued) WARNING: Whenever a repair to the power steering system is carried out, which may permit air to enter the fluid lines or the pump, the system must be purged of air on completion of the repair. CAUTION: Do not hold the steering gear against the lock stops for more than 5 seconds. Several of these symptoms are also common to suspension, frame, and wheel and tyre troubles. For this reason, be sure that the cause of the trouble is in the power steering pump before adjusting, repairing, or replacing any of the pump parts. General Diagnosis Condition
Source
Action
Chirp noise in steering pump
Loose belt
Remove/Repair as required
Belt squeal (particularly noticeable at full wheel travel and standstill parking).
Loose belt
Remove/Repair as required
Growl noise in steering pump
Excessive back-pressure in hoses or steering gear caused by restriction
Remove/Repair as required
Growl noise in steering pump (particularly noticeable at full wheel travel and standstill parking).
Scored pressure plate, thrust plate or rotor. Extreme wear of pump ring and vanes.
Remove/Repair as required
Groan noise in steering pump
Low oil level. Air in the oil. Poor pressure hose connection
Remove/Repair as required
Rattle noise in steering pump
Vanes not installed properly.
Remove/Repair as required
Momentary increase in effort when turning wheel fast to right or left.
Low oil level in pump Pump belt slipping High internal leakage. Valve or gear cylinder
Remove/Repair as required
Steering wheel surges or jerks when turning with engine running, especially during parking
Low oil level Loose pump belt Insufficient pump pressure Sticky flow control valve
Remove/Repair as required
Hard steering or lack of assist, especially in parking.
Loose pump belt Low oil level in reservoir. Steering gear to column misalignment Tires not properly inflated NOTE: If checks 1 through 4 do not reveal cause of hard steering, follow the Power Steering Test Procedure.
Remove/Repair as required
Further possible causes could be: Sticky flow control valve Insufficient pump pressure output Excessive internal pump leakage Excessive internal system leakage Foaming milky power steering fluid, low fluid level and possible low pressure
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Air in the fluid, and loss of fluid due to internal pump leakage causing overflow.
Remove/Repair as required
01/2003 2003.0 BA Falcon
211-02-14
Power Steering
211-02-14
DIAGNOSIS AND TESTING (Continued) Condition Low pressure from steering pump
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Source Flow-control valve stuck or inoperative Pressure plate not flat against pump ring Extreme wear of pump ring and vanes Scored pressure plate, thrust plate or rotor Vanes not installed properly Vanes sticking in rotor slots Cracked or broken thrust or pressure plate
Action Remove/Repair as required
01/2003 2003.0 BA Falcon
211-02-15
Power Steering
211-02-15
GENERAL PROCEDURES 4. Fill pump reservoir to COLD FULL mark on dipstick. Using auxiliary starter switch, crank After Power Steering Pump or Gear Overhaul engine, while cycling steering wheel from lock-to-lock. Check fluid level. After engine start up, follow these steps to eliminate 5. Tightly insert the rubber stopper of the air excessive steering system noise due to air trapped in evacuator assembly into pump reservoir fill neck. the system during service: 6. Apply 51 kPa (15 in-Hg) maximum vacuum on 1. Disconnect the starter solenoid activation wire. pump reservoir for a minimum of three minutes 2. Connect the remote starter switch wiring the with the engine idling. As air purges from system, starter solenoid and the battery positive terminal. the vacuum will fall off. Maintain adequate 3. Ensure the Power Steering Pump Reservoir is full. vacuum with vacuum source. 4. Crank the engine, using the remote starter switch, 7. Release vacuum and remove vacuum source. Fill and add fluid until the level remains constant. reservoir to COLD FULL mark. 5. While cranking the engine, rotate the steering 8. With engine idling, apply 51 kPa (15 in-Hg.) wheel from lock-to-lock. vacuum to pump reservoir. Slowly cycle the NOTE: Front wheels must either be off the floor or steering wheel from lock-to-lock every 30 seconds on free running turntables during lock-to-lock for approximately five minutes. Do not hold rotation of the steering wheel. steering wheel on stops while cycling. Maintain adequate vacuum with vacuum source as the air 6. Check the fluid level and add fluid if necessary. purges. 7. Disconnect the remote starter switch, reconnect 9. Release vacuum and remove vacuum equipment. the starter solenoid activation wire and start Add additional fluid if necessary. Install dipstick. engine, allow it to run for several minutes. 10. Start engine and cycle steering wheel. Check for 8. Rotate the steering wheel from lock-to-lock. oil leaks at all connections. In severe cases of 9. Switch engine off and check the fluid level. Add aeration, it may be necessary to repeat Steps 5 fluid if required. through 9. 10. If air is still present in the steering system, purge, Flushing Power Steering Pump (I6) as described in diagnosis section.
Start of Procedure
If dirt is found in power steering gear, flush pump as follows: The most common noise complaint is a moan or 1. Making sure all other hoses are connected, whine noise (refer Symptom Chart) which in most disconnect pressure hose at gear. cases is caused by air trapped in the system. 2. Place end of hose in a container. The system must be purged of air promptly to prevent 3. Fill reservoir with Power Steering Fluid Mobil 424 permanent damage to the pump. or equivalent that meets spec. ESN-M2C-134D. If the air purging operation only temporarily 4. Disconnect the starter solenoid activation wire. overcomes the noise, check for faults that could 5. Connect a remote starter switch to the starter cause entry of air into the system. solenoid. Purging Power Steering System of Air 6. While adding approximately 2 litres of fluid, crank the engine using the remote starter switch. When Air trapped in the power steering system, which all fluid has been added cease cranking engine. causes a whine or moan-type noise, can be removed by using a power steering pump air evacuator 7. Re-attach pressure hose at gear. assembly (devac tool). 8. Check fluid level, add as required. 9. Remove remote starter switch and reconnect CAUTION: Under no circumstances should starter solenoid wire. engine vacuum be utilised.
Remedying Pump Noise
1. Check and fill the pump reservoir with Power Steering Fluid Mobil 424 (or equivalent that meets spec. ESN-M2C- 134D) to the COLD FULL mark on pump dipstick. 2. Raise vehicle front wheels from floor. 3. Install an auxiliary starter switch in starting circuit. With ignition switch in the OFF position, and using auxiliary starter switch, crank engine.
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Flushing Power Steering Gear (I6) NOTE: Always flush power steering gear when replacing pump due to fluid contamination. 1. Disconnect fluid return hose at pump and place end in a container. Plug return hose nipple on reservoir. 2. Fill reservoir with Power Steering Fluid Mobil 424 or equivalent that meets spec. ESN-M2C-134D. 3. Disconnect the starter solenoid activation wire. 01/2003 2003.0 BA Falcon
211-02-16
Power Steering
211-02-16
GENERAL PROCEDURES (Continued) 4. Connect a remote starter switch to the starter solenoid. 5. Raise the vehicle front wheels off floor. 6. While adding approximately 2 litres of fluid, crank the engine using the remote starter switch, whilst turning steering wheel from lock-to-lock. When all fluid has been added cease cranking engine. 7. Lower vehicle. 8. Remove remote starter switch and reconnect starter solenoid wire. 9. Remove plug from the reservoir return hose nipple. Attach return hose to nipple. 10. Check fluid level. Add fluid if necessary. Do not overfill reservoir. 11. Start engine and turn steering wheel slowly from lock-to-lock several times. Check fluid level and adjust as required. 12. Check for air in system. If so purge system as explained in this chapter.
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01/2003 2003.0 BA Falcon
211-02-17
Power Steering
211-02-17
REMOVAL AND INSTALLATION
Steering Gear Cylinder Pipe and O — Ring Seals Removal 1. Remove the steering gear from the vehicle. Refer to your dealership service manual. 2. Loosen both cylinder line fittings on the cylinder end of the gear assembly. 3. Loosen both cylinder line fittings on the valve end of the gear assembly. 4. Remove both cylinder line assemblies from the rack and pinion gear assembly. 5. Remove the O-ring seals from the valve end of the cylinder line.
4. Install the cylinder line assemblies to the gear assembly. NOTE: Tighten the valve end fittings to 16.9 Nm (12.6 lb. ft.) Tighten the cylinder end fittings to 27 Nm (20 lb. ft.)
Steering Gear Spool Shaft Seals and Bearings Special Tool(s) Valve Body Seal Protector/ Sizer Kit J 46192
Bearing and Seal Installer J 46193 6. Discard the O-ring seals. Installation 1. Inspect the cylinder lines for the following items: Cracks Dents Damage to the threads 2. Replace the parts as needed. 3. Install the new O-ring seals to the valve end of the cylinder lines.
Spool Shaft Seal Protector J 46221
Removal 1. Remove the steering gear from the vehicle. Refer to your dealership service manual.
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01/2003 2003.0 BA Falcon
211-02-18
Power Steering
211-02-18
REMOVAL AND INSTALLATION (Continued) 2. Remove the following from the steering gear: Adjuster plug Adjuster spring Rack bearing assembly with o-ring
8. Remove and discard the metric hex nut from the lower end of the pinion and valve assembly while holding the spool shaft.
NOTE: When performing the following procedure, do not remove the valve assembly from the rack and pinion gear assembly. Press the pinion end of the valve assembly only far enough to allow removal of the spool shaft seal and the needle bearing assembly. 9. Gently tap a pointed center punch into the threaded end of the pinion to remove only the following items: Spool shaft seal Needle bearing assembly
3. Discard the adjuster plug. NOTE: The rack assembly must be marked inside the rack and pinion housing to show correct alignment. Lubrication on the rack may cause the alignment marks to smear if the rack is moved. 4. Hold the rack firmly and mark the rack assembly inside of the rack and pinion housing. 5. Remove the spool shaft boot. 6. Remove and discard the retaining ring from the top of the valve housing. 7. Remove and discard the dust cover from the bottom of the rack and pinion gear assembly. NOTE: The spool shaft must be held in place during the following step.
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01/2003 2003.0 BA Falcon
211-02-19
Power Steering
211-02-19
REMOVAL AND INSTALLATION (Continued) 10. Discard the spool shaft seal and the needle bearing assembly. NOTE: Handle the valve assembly with caution. Failure to do so may result in replacement of the steering gear.
1. Install the new valve body rings onto the valve assembly using J 46192-1. Remove J 46192-1.
11. Pull the valve assembly out of the rack and pinion housing. 12. Remove and discard the valve body rings (4) from the valve assembly.
2. Lubricate the valve assembly with power steering fluid. 3. Compress the valve body rings onto the valve assembly using J 46192-2.
NOTE: The rack assembly must be aligned before installing the valve assembly. Failure to do so will cause the steering wheel to be out of position. Installation NOTE: Handle the pinion and valve assembly with caution. Failure to do so may result in replacement of the steering gear.
4. Align the rack assembly using the marks inside the rack and pinion housing. NOTE: The orientation of the pinch bolt notch on the valve assembly must be aligned as shown. Failure to do so will cause the steering wheel to be out of position. 5. With J 46192-2 still on the valve assembly, install the valve assembly into the rack and pinion housing.
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01/2003 2003.0 BA Falcon
211-02-20
Power Steering
211-02-20
REMOVAL AND INSTALLATION (Continued) 6. Remove J 46192-2 from the rack and pinion housing.
9. Remove J 46193 from the rack and pinion housing.
NOTE: The bearings in the needle bearing assembly must be facing down when installing into gear.
10. Install J 46221 onto the valve spool shaft. 11. Lubricate the new spool shaft seal with grease. 12. Install the spool shaft seal onto the spool shaft of the valve assembly. 13. Using the larger end of J 46193 and a rubber mallet, gently tap the spool shaft seal into the rack and pinion housing. 14. Remove J 46193 from the rack and pinion housing.
7. Install the new needle bearing assembly onto the spool shaft of the valve assembly. 8. Using the smaller end of J 46193 and a rubber mallet, gently tap the needle bearing assembly into the rack and pinion housing.
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01/2003 2003.0 BA Falcon
211-02-21
Power Steering
211-02-21
REMOVAL AND INSTALLATION (Continued) 15. Remove J 46221 from the valve spool shaft. NOTE: The spool shaft must be held in place during the following step.
20. Lubricate the rack bearing assembly with o-ring with lithium base grease. 21. Install the following items into the gear assembly: Rack bearing assembly with o-ring Adjuster spring New adjuster plug
16. Install the new metric hex nut onto the pinion while holding the valve spool shaft. NOTE: Tighten the metric hex nut to 30 Nm (22 lb. ft.).
22. Turn the adjuster plug clockwise onto the rack 17. Install the new dust cover to the rack and pinion and pinion gear assembly until the adjuster plug gear assembly. bottoms in the rack and pinion gear assembly. NOTE: Tighten the adjuster plug to 10 Nm (90 lb. 18. Install the new retaining ring into the groove in the in.) then turn back 35 degrees to 55 degrees. top of the valve assembly of the rack and pinion gear assembly. 23. Flush and bleed power steering system. Refer to 19. Install the spool shaft boot. Bleeding the Power Steering System procedure. NOTE: Flush and bleed power steering system (hoses, reservoir and cooler lines) with power steering fluid. 24. Install the steering gear into the vehicle. Refer to your dealership service manual.
Power Steering Pump (I6) Removal 1. Using a 15mm socket, rotate the drive belt tensioner clockwise to reduce belt tension and remove belt.
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01/2003 2003.0 BA Falcon
211-02-22
Power Steering
211-02-22
REMOVAL AND INSTALLATION (Continued) 2. Remove pump and pulley as a whole unit by accessing pump attaching hardware through holes in pulley OR 3. Remove pump pulley using special tool #E9240 B.
Removal and Installation 1. Remove the power steering pump pulley. For additional information, refer to Power Steering Pump Pulley (V8) in this section. 2. Disconnect the power steering reservoir pump hose and pressure line from the power steering pump. Drain the power steering oil reservoir.
4. Remove fluid from pump reservoir using a syringe or syphon hose. 5. Loosen the pump pressure line connector and detach pressure line. Detach return line. 3. Remove the three bolts and the pump. CAUTION: Take care to prevent power steering pump fluid loss by plugging connections. 6. Remove pump retaining hardware and withdraw pump from mount. Installation 1. Position pump in front cylinder cover. 2. Install return line and torque hose clamp. 3. Install pump mounting hardware and torque to specification. 4. Install pressure hose connector. 5. Install pump pulley using special tool No. E9239-A. 4. To install, reverse the removal procedure. 6. Install the drive belt. Refer Figure 10 for routing. NOTE: Install a new power steering seal on the power steering pressure fitting by stretching the NOTE: Ensure belt is correctly engaged on pulley seal over the seal replacer until it is large enough ribs. to slip over the threads of the fitting. 7. Fill power steering pump reservoir with specified 5. Install the power steering pump pulley. For fluid. additional information, refer to Power Steering 8. Attach a remote starter switch and carry out start Pump Pulley (V8) in this section. up procedure. 6. Fill, purge and leak check the system as outlined Power Steering Pump (V8) in the relevant chapter. Special Tool(s) Teflon® Seal Replacer Set 211-D027 (D90P-3517-A) or equivalent
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01/2003 2003.0 BA Falcon
211-02-23
Power Steering
211-02-23
REMOVAL AND INSTALLATION (Continued)
Power Steering Pump Pulley (V8) Special Tool(s) Steering Pump Pulley Remover 211-016 (T69L-10300-B)
5. Loosen the tie rod end stud nuts and free the tie rod end stud tapers in the wheel spindles. Remove the nuts and detach the tie rod ends from the spindles.
Steering Pump Pulley Replacer 211-185 (T91P-3A733-A)
Removal 1. Remove the drive belt as outlined in chapter Section 303-05. 2. Using the special tool, remove the power steering pump pulley (3A733). Installation 1. Using the special tool, install the power steering pump pulley (3A733). 2. Install the drive belt as outlined in chapter Section 303-05.
6. Remove the catalytic converter assembly as outlined in the relevant section. 7. Remove the two nuts securing the steering gear to the cross-member and remove the gear from the vehicle. Installation 1. Position the steering gear assembly on the cross-member, install and tighten the securing nuts. 2. Connect the tie rod ends to the wheel spindles, install and tighten the nuts.
Steering Gear — I6 Removal 1. Raise the hood and raise the vehicle supporting it under the body side rails. 2. Place a drain pan under the steering gear. 3. Disconnect the pump to steering gear hydraulic lines at the gear using a six point tube nut wrench. 4. Remove the bolt from the clamp at the lower end of the intermediate shaft. Slide the intermediate shaft upwards until it is clear of the steering gear valve splines. 3. Refit the catalytic convertor assembly. 4. Centralise the steering gear and align the intermediate shaft with the steering gear valve and slide the shaft yoke onto the valve. Install and tighten the lower clamp bolt. 5. Connect the hydraulic lines to the steering gear and tighten the unions with a six point tube nut wrench. 6. Remove drain pan and lower the vehicle. 7. Top up the pump reservoir with the specified fluid and bleed the system as per manual.
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01/2003 2003.0 BA Falcon
211-02-24
Power Steering
211-02-24
REMOVAL AND INSTALLATION (Continued)
Steering Gear — V8 Removal 1. Raise the hood and raise the vehicle supporting it under the body side rails. 2. Place a drain pan under the steering gear. 3. Disconnect the pump to steering gear hydraulic lines at the gear using a standard 12 point ring spanner (double hex). 4. Remove the bolt from the clamp at the lower end of the intermediate shaft. Slide the intermediate shaft upwards until it is clear of the steering gear valve splines. 5. Loosen the tie rod end stud nuts and free the tie rod end stud tapers in the wheel spindles. Remove the nuts and detach the tie rod ends from the spindles. 6. Remove both catalytic converter assemblies as outlined in the relevant section. 7. AUTOMATIC ONLY - Remove the torque convertor inspection cover as outlined in the relevant section. 8. Loosen the two nuts securing the steering gear to the cross-member . 9. Draw the steering gear back away from the cross-member to access both the steering gears left and right transfer tubes. 10. Remove the left and right transfer tubes from the steering gear. 11. Remove the two nuts securing the steering gear to the cross-member and remove the gear from the vehicle. Installation 1. Position the steering gear assembly on the cross-member. 2. Install but only tighten the securing nuts slightly allowing the steering gear to rest safely away from the cross-member. 3. Install both left and right transfer tubes into the steering gear, tighten the securing nuts. 4. AUTOMATIC ONLY - Install the torque convertor inspection cover as outlined in the relevant section. 5. Connect the tie rod ends to the wheel spindles, install and tighten the nuts. 6. Refit the catalytic convertor assemblies. 7. Centralise the steering gear and align the intermediate shaft with the steering gear valve and slide the shaft yoke onto the valve. Install and tighten the lower clamp bolt. 8. Connect the hydraulic lines to the steering gear and tighten the unions with a 12 point ring spanner (double hex). 9. Remove drain pan and lower the vehicle.
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10. Top up the pump reservoir with the specified fluid and bleed the system as per manual.
Steering Gear Bushing and Sleeve Removal 1. Remove the steering gear from the vehicle. Refer to your dealership service manual. 2. Remove the steering gear bushing sleeve from the steering gear bushings. 3. Remove the steering gear bushings from the rack and pinion housing.
Installation 1. Install the steering gear bushings into the rack and pinion housing. NOTE: Do not apply any type of lubricant or grease to the steering gear bushings or the steering gear bushing sleeve. 2. Align the steering gear bushing sleeve and install into the steering gear bushings. The steering gear bushings must be flush with the steering gear bushing sleeve. NOTE: The steering gear bushing sleeve must be properly aligned.
3. Install the steering gear into the vehicle. Refer to your dealership service manual.
01/2003 2003.0 BA Falcon
211-02-25
Power Steering
211-02-25
REMOVAL AND INSTALLATION (Continued)
Drive Belt (I6) NOTE: Vehicles are equipped with a V-ribbed serpentine accessory drive belt and automatic tensioner. Replacement belts should be of the same type as originally installed.
3. Install new belt over pulleys. Ensure that all V-grooves make proper contact with the pulley as shown in figure.
NOTE: Automatic belt tensioners are spring loaded devices which set and maintain the drive belt tension. The drive belt should not require tension adjustment for the life of the belt. Automatic tensioners have belt wear indicator marks. If the indicator mark is not between the indicator lines, the belt is worn or an incorrect belt has been installed.
Item 1 2 3 4 5 6 7 Item 1 2 3 4
Description Worn belt mark 15mm bolt New belt mark Belt wear reference mark
NOTE: Conditions requiring belt replacement are rib chunkout, severe glazing, frayed cords, etc. Replace any belt exhibiting one of these conditions.
Description Power steering pump pulley Idle pulley Tensioner pulley A/C Compressor pulley Harmonic Balancer Alternator pulley Water pump pulley
Quick Connect Power Steering Fitting (I6) Seal Replacement If a leak occurs between the tubing and tube nut, replace the hose assembly. If a leak occurs between the tube nut and the pump outlet, replace the teflon seal.
NOTE: Cracks on the ribbed side of the belt are considered acceptable. If the belt has chunks missing from the ribs it should be replaced if two or more adjacent ribs have lost sections 13 mm (1/2inch) or longer, or if the missing chunks are creating a noise or vibration. Removal and Installation 1. Rotate automatic tensioner clockwise. 2. Remove old belt.
Item 1 2 3 4 5
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Description Tube nut Snap ring Pump outlet Rubber O-Ring Rubber O-Ring
01/2003 2003.0 BA Falcon
211-02-26
Power Steering
211-02-26
REMOVAL AND INSTALLATION (Continued) 1. Check fitting to determine whether leak is between tube and tube nut or between tube nut and pump outlet. 2. If leak is between tube nut and pump outlet, check to ensure nut is tightened to 30 Nm. CAUTION: DO NOT over-tighten. 3. If leak continues or if leak is between tube and connector, remove line. 4. Unscrew connector, and inspect and replace rubber O-ring seal. 5. The rubber O-ring inside the connector (quick connect fitting) cannot be serviced with this design. If leak is due to the O-ring, replace the hose assembly.
6. Connect quick connector and tighten to 30 Nm. The quick connect fitting may disengage if not fully assembled, if the snap ring is missing, or if the tube nut or the hose end is not machined properly. If the fitting disengages, replace the hose assembly. The fitting is fully engaged only when the hose will not pull out. To test for positive engagement, the system should be properly filled, the engine started, and the steering wheel cycled from lock-to-lock. When replacing pressure hose assembly the following parts will be required. Pressure hose assy. – Qty 1. Quick Connect Fitting – Qty 1.
Power Steering Lines (I6)
Removal 6. Loosen both clamps on return hoses at the cooler ends & disconnect hoses. 1. Disconnect pressure & return lines from the steering gear 7 drain the fluid into a suitable 7. Loosen clamp on return hose at reservoir & container. remove hose. 2. Remove the bolt from the securing clamp from the 8. Remove the nuts securing the cooler to the RH side of the 2B crossmember. subframe cooler brackets. 3. Remove the bolt from the cooler line securing 9. Remove press & rtn line assy & cooler assy from clamp from the RH side of 2A crossmember. vehicle. 4. Remove front bumper lower valance. 5. Disconnect the pressure line from pump. G37378 en
01/2003 2003.0 BA Falcon
211-02-27
Power Steering
211-02-27
REMOVAL AND INSTALLATION (Continued) Installation 1. Refit press & rtn line assy & cooler assy to vehicle. 2. Secure the cooler to the cooler mounting brackets on the subframe (check that the clearances from the cooler & side chassis rail are adequate) & tighten nuts. 3. Secure the bolt from the cooler line securing clamp to the RH side of the 2A crossmember. 4. Secure the bolt from the press & rtn line assy clamp to the RH side of the 2B crossmember. 5. Connect pressure & return lines to steering gear end. 6. Connect both return hoses to cooler ends & secure both clamps. 7. Connect return hose to resorvoir inlet & secure clamp. 8. Refit a new quick connect fitting to pump & connect the pressure line. 9. Refit the front bumper lower valance. 10. Fill with specified Mobil 424 oil or equivalent & conduct specified bleed procedure. 11. Start vehicle, check for leaks, rectify if necessary.
Power Steering Lines (V8)
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01/2003 2003.0 BA Falcon
211-02-28
Power Steering
211-02-28
REMOVAL AND INSTALLATION (Continued) Removal 1. Disconnect pressure & return lines from the steering gear & drain the fluid into a suitable container. 2. Remove the bolt from the securing clamp from the RH side of the 2B crossmember. 3. Remove the bolt from the cooler line securing clamp from the RH & LH side of a 2A crossmember. 4. Remove front bumper lower valance. 5. Disconnect the pressure line from pump. 6. Loosen clamp on return hose at pump & disconnect hoses. 7. Loosen both clamps on return hoses at the cooler ends & disconnect hoses. 8. Loosen both clamps on return hoses at resorvoir & remove hoses. 9. Remove the nuts securing the cooler to the subframe cooler brackets. 10. Remove press & return line assembly & cooler assembly from vehicle. Installation NOTE: When connecting a fitting with a seal ring, the ring must be replaced, using the seal replacer special tool. 1. Refit press & return line assembly & cooler assembly to vehicle. 2. Secure the cooler to the cooler mounting brackets on the subframe (check that the clearances from the cooler side chassis rail condenser are adequate) & tighten nuts. 3. Secure the bolts from the cooler line securing clamp to the LH & RH side of the 2A crossmember. 4. Secure the bolt from the press & return line assy clamp to the RH side of the 2B crossmember. 5. Connect pressure & return lines to steering gear end. 6. Connect return hose to pump & secure clamp. 7. Connect both return hoses to cooler ends & secure both clamps. 8. Connect return hoses to reservoir & secure clamps. 9. Refit a new quick connect fitting to pump & connect the pressure line. 10. Refit the front bumper lower valance. 11. Fill with specified Mobil 424 or equivelant & conduct specified bleed preocedure. 12. Start vehicle, check for leaks, rectify if necessary
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01/2003 2003.0 BA Falcon
211-02-29
Power Steering
211-02-29
DISASSEMBLY AND ASSEMBLY
Resorvoir Assembly (I6)
3. Remove the power steering fluid reservoir from its support bracket.
NOTE: Take the following precautions when servicing the power steering pump reservoir: Use a clean work bench and tools. Plug the inlet and outlet openings of the pump with plugs or masking tape. Thoroughly clean the exterior of the pump with solvent. Disassembly 1. Remove pump assembly from vehicle, if necessary for access (Refer to Power Steering Pump Removal in this section). 2. Disconnect retaining clips from reservoir assembly and housing.
Assembly 1. To install, reverse the removal procedure. 2. Fill and leak check the system.
Control Valve Assembly (I6) Disassembly
3. Remove reservoir from housing. 4. Remove O-ring seal from reservoir. Assembly 1. Lubricate new O-ring with power steering fluid. Install O-ring seal to reservoir. 2. Connect reservoir assembly to housing. 3. Install retaining clips to reservoir and housing. 4. Install pump assembly to vehicle, if removed.
Resorvoir Assembly (V8) Disassembly 1. Drain the power steering fluid reservoir. 2. Disconnect the power steering warm drive hoses. 1. Loseen and move the power steering hose clamps. 2. Disconnect the power steering return hose and the power steering reservoir pump hose.
Item 1 2 3 4 5
Description Housing ASM, HYD Pump Spring, Flow Control Valve ASM, Control Seal, O-Ring Fitting, O-Ring Union
1. Remove pump assembly from vehicle, if necessary for access (Refer to Power Steering Pump Removal in this section). 2. Remove O-ring union fitting and O-ring. 3. Remove control valve assembly. 4. Remove flow control spring. Assembly 1. Install flow control spring. 2. Install control valve assembly. 3. Install O-ring on fitting.
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01/2003 2003.0 BA Falcon
211-02-30
Power Steering
211-02-30
DISASSEMBLY AND ASSEMBLY (Continued) 4. Install fitting into hydraulic pump housing assembly and tighten to 75Nm. 5. Install pump assembly to vehicle, if removed.
Drive Shaft Seal (I6) Special Tool(s) Shaft Oil Seal Installer J 7728
Disassembly 1. Remove P/S Pump pulley using tool 7185. 2. Remove pump assembly from vehicle, if necessary for access (Refer to Power Steering Pump Removal in this section).
Item 1 2 3 4 5 6
Description Pin, Pump Ring Dowel Shaft, Drive Housing ASM, HYD Pump Seal, Drive Shaft Plate, Thrust Ring, Pump
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Item 7 8 9 10 11 12
Description Vane Rotor, Pump Ring, Shaft Retaining Plate, Pressure Seal, O-Ring Spring, Pressure Plate 01/2003 2003.0 BA Falcon
211-02-31
Power Steering
211-02-31
DISASSEMBLY AND ASSEMBLY (Continued) Item 13 14 15
Description Seal, O-Ring Cover, End Ring, Retaining
Hydraulic Pump Assembly (I6) Special Tool(s) Shaft Oil Seal Installer J7728
3. Protect drive shaft with shim stock.
NOTE: The following precautions must be observed when servicing the power steering pump:
Item 1 2 3 4 5
Description Chisel Shaft Drive Shim Stock Housing ASM, HYD Pump Seal Drive Shaft
Use a clean work bench and tools. Thoroughly clean the exterior of the unit with solvent. Drain as much fluid from the pump as possible. If only the reservoir is to be removed, clean as outlined. Do not use cleaning solvents on the seal. Disassembly 1. Disassemble retaining ring using punch in access hole.
4. Remove seal and discard (Use small chisel to cut drive shaft seal). Assembly 1. Install new drive shaft seal (lubricated with power steering fluid, using tool J 7728).
Item 1 2 3
2. Install pump assembly to vehicle, if removed.
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Description Punch Access Hole Ring Retaining
2. Disassemble internal components of pump from pump housing by gentle pushing on drive shaft. Components should include pressure plate subassembly consisting of: End cover O-ring seal Pressure plate spring Pressure plate Drive shaft subassembly consisting of: Pump rotor Thrust plate Drive shaft 01/2003 2003.0 BA Falcon
211-02-32
Power Steering
211-02-32
DISASSEMBLY AND ASSEMBLY (Continued)
3. 4. 5. 6. 7. 8. 9.
Shaft retaining ring and pump ring and vanes. Remove O-ring from pump housing. Remove dowel pins. Remove drive shaft seal. Remove end cover (pressure plate spring) and O-ring from pressure plate. Remove pump ring (and vanes) from drive shaft subassembly. Remove shaft retaining ring (from drive shaft). Remove pump rotor (and thrust plate) from drive shaft.
3. Install thrust plate and pump rotor to drive shaft.
Assembly NOTE: Clean all parts in power steering fluid, then dry Item Description parts. 1 Shaft Drive Inspect the following parts 2 Plate, Thrust Pressure plate 3 Rotor, Pump Pump ring 4 Ring, Shaft Retaining Vanes 4. Install new shaft retaining ring onto drive shaft. Thrust plate 5. Install drive shaft subassembly into pump Drive shaft housing. For scoring, pitting or chatter marks. If noted replace 6. Install vanes into pump rotor. appropriate parts. 7. Install pump ring (with holes positioned correctly 1. Lubricate new drive shaft seal with power steering onto dowel pins in pump housing. fluid and assemble drive shaft seal (into pump housing) with tool J 7728.
2. Install pump ring dowel pins into pump housing.
Item 1 2
Description Rotor, Pump Ring, Pump
8. Lubricate new O-ring with power steering fluid. Install O-ring into groove in pump housing. 9. Assemble pressure plate. 10. Assemble pressure plate spring. 11. Lubricate new O-ring (with power steering fluid). Assemble O-ring into end cover. 12. Lubricate outer edge of end cover with power steering fluid. 13. Press end cover into pump housing.
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01/2003 2003.0 BA Falcon
211-02-33
Power Steering
211-02-33
DISASSEMBLY AND ASSEMBLY (Continued) 14. Assemble retaining ring into groove in pump housing (with ring opening near access hole in pump housing.
Item 1 2 3 4 5
Description Press Retaining Ring Opening Bolt Hole Access Hole Ring Retaining
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01/2003 2003.0 BA Falcon
211-03-1
Steering Linkage
211-03-1
SECTION : 211-03 Steering Linkage VEHICLE APPLICATION : 2003.0 BA Falcon CONTENTS
PAGE
SPECIFICATIONS Specifications .........................................................................................................................211-03-2 DIAGNOSIS AND TESTING Steering Linkage ....................................................................................................................211-03-3 REMOVAL AND INSTALLATION Outer Tie — Rod ....................................................................................................................211-03-4 Inner Tie — Rod .....................................................................................................................211-03-5 Steering Gear Boot ................................................................................................................211-03-7
01/2003 2003.0 BA Falcon
211-03-2
Steering Linkage
211-03-2
SPECIFICATIONS Tighten Specifications Description Metric Hex Nut (inner tie rod) Metric Hex Nut (outer tie rod)
Inner Tie Rod Valve End Fittings Cylinder End Fittings Metric Hex Nut (rack and pinion assembly) Adjuster Plug
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Nm 30 Nm (22 lb. ft.) 46.7–63.3 Nm (34–47 lb. ft.) + 120 degrees (2 flats) 100 Nm (74 lb. ft.) 16.9 Nm (12.6 lb. ft.) 27 Nm (20 lb. ft.) 30 Nm (22 lb. ft.) 10 Nm (90 lb. in.) then turn back 35 degrees to 55 degrees
01/2003 2003.0 BA Falcon
211-03-3
Steering Linkage
211-03-3
DIAGNOSIS AND TESTING
Steering Linkage Refer to Section 211-00.
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211-03-4
Steering Linkage
211-03-4
REMOVAL AND INSTALLATION
Outer Tie — Rod
4. Loosen the metric hex nut.
Special Tool(s) Universal Steering Linkage Puller J 24319-B
Removal 1. Remove the steering gear from the vehicle. Refer to your dealership service manual. 2. Remove the tie rod ball stud and metric hex nut.
3. Use J 24319-B in order to separate the outer tie rod from the steering knuckle. NOTE: Do not attempt to free the ball stud by using a pickle fork or wedge type tool; seal or bushing damage could result. Use the proper tool to separate all ball joints.
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5. Remove the outer tie rod from the inner tie rod.
Installation 1. Install the outer tie rod to the inner tie rod. NOTE: Tighten the metric hex nut to 30 Nm (22 lb. ft.).
01/2003 2003.0 BA Falcon
211-03-5
Steering Linkage
211-03-5
REMOVAL AND INSTALLATION (Continued) 2. Install the outer tie rod to the steering knuckle.
Inner Tie — Rod Special Tool(s) Inner Tie Rod Wrench J 34028
3. If the fastener does not meet these criteria, REPLACE the fastener. NOTE: This is a prevailing torque type fastener. This fastener may be reused ONLY if: • The fastener and its counterpart are clean and free from rust. • The fastener develops 2 Nm (18 lb. in.) of torque (drag) against its counterpart prior to the fastener seating. 4. Install the metric hex nut. Tighten the metric hex nut to 46.7–63.3 Nm (34–47 lb. ft.) + 120 degrees (2 flats).
5. Inspect and adjust the toe as necessary. Refer to Front Toe Adjustment in your dealership service manual. NOTE: Ensure that 2.5–4.5 tie rod end threads are visible beyond the tie rod nut nylon. 6. Install the steering gear into the vehicle. Refer to your dealership service manual.
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Removal 1. Remove the rack and pinion gear boot. Refer to Boot Replacement procedure. 2. Place the gear in a vise. Clamp gear at solid mount only. NOTE: Do not change the steering gear preload adjustment before moving the inner tie rod from the steering gear. Changing the steering gear preload adjustment before removing the inner tie rod could result in damage to the pinion and the steering gear. NOTE: The pipe wrench must be placed at the valve end of the steering gear and positioned up against the inner tie rod housing. Placing the pipe wrench in any other location will cause damage to the steering gear.
3. Place a pipe wrench on the rack next to the inner tie rod housing. 4. Place a wrench on the flats of the inner tie rod housing. 5. Rotate the inner tie rod housing counterclockwise, while holding the rack stationary, until the inner tie rod separates from the rack.
01/2003 2003.0 BA Falcon
211-03-6
Steering Linkage
211-03-6
REMOVAL AND INSTALLATION (Continued) 6. Remove the old LOCTITE® from the threads of the inner tie rod and rack.
2. Attach the inner tie rod onto the rack. NOTE: The pipe wrench must be placed at the valve end of the steering gear and positioned up against the inner tie rod housing. Placing the pipe wrench in any other location will cause damage to the steering gear.
NOTE: Do not change the steering gear preload adjustment before moving the inner tie rod from the steering gear. Changing the steering gear preload adjustment before removing the inner tie rod could result in damage to the pinion and the steering gear.
3. Place a pipe wrench on the rack next to the inner tie rod housing. NOTE: The pipe wrench must be placed at the valve end of the steering gear and positioned up against the 4. Place a torque wrench and J 34028 on the flats of inner tie rod housing. Placing the pipe wrench in any the inner tie rod housing. Tighten the inner tie rod other location will cause damage to the steering gear. to 100 Nm (74 lb. ft.). NOTE: Threads must be clean prior to LOCTITE® 7. Place a pipe wrench on the rack next to the inner application. tie rod housing. Check LOCTITE®, or equivalent, container for 8. Place a wrench on the flats of the inner tie rod expiration date. Use only enough LOCTITE® to housing. evenly coat threads. 9. Rotate the inner tie rod housing counterclockwise, while holding the rack stationary, until the inner tie 5. Apply LOCTITE® 262, or equivalent, to the inner rod separates from the rack. tie rod threads. Installation 6. Attach the inner tie rod onto the rack. NOTE: The pipe wrench must be placed at the NOTE: Threads must be clean prior to LOCTITE® valve end of the steering gear and positioned up application. against the inner tie rod housing. Placing the pipe Check LOCTITE®, or equivalent, container for wrench in any other location will cause damage to expiration date. Use only enough LOCTITE® to the steering gear. evenly coat threads. 1. Apply LOCTITE® 262, or equivalent, to the inner tie rod threads.
7. Place a pipe wrench on the rack next to the inner tie rod housing. 8. Place a torque wrench and J 34028 on the flats of the inner tie rod housing. Tighten the inner tie rod to 100 Nm (74 lb. ft.). G47381 en
01/2003 2003.0 BA Falcon
211-03-7
Steering Linkage
211-03-7
REMOVAL AND INSTALLATION (Continued) 9. Install the rack and pinion gear boot. Refer to Boot Replacement procedure.
4. Remove the seal retaining clamp from the boot with side cutters.
Steering Gear Boot Special Tool(s) Service Boot Clamp Installer J 22610
Removal 1. Remove the outer tie rod. Refer to Outer Tie Rod Replacement procedure. 2. Remove the metric hex nut from the inner tie rod assembly.
3. Remove the tie rod end clamp from the rack and pinion gear boot.
5. Discard the seal retaining clamp. 6. Remove the boot from the gear assembly. Installation 1. Install the new seal retaining clamp onto the boot.
2. Prior to the boot installation, apply grease to the inner tie rod assembly and the rack and pinion gear assembly.
3. Install the boot onto the inner tie rod assembly. NOTE: The rack and pinion boot must not be twisted, puckered or out of shape in any way. If the rack and pinion boot is not shaped properly, adjust the rack and pinion boot by hand before installing the boot clamp. G47383 en
01/2003 2003.0 BA Falcon
211-03-8
Steering Linkage
211-03-8
REMOVAL AND INSTALLATION (Continued) 4. Install the boot onto the gear assembly until the boot is seated in the gear assembly groove. 5. Install the boot clamp on the rack and pinion boot with J 22610. 6. Crimp the seal retaining clamp. 7. Pinch the pliers together on the boot in order to install the tie rod end clamp.
8. Install the tie rod end clamp onto the boot.
9. Install the metric hex nut to the inner tie rod assembly. Do not tighten the metric hex nut. 10. Install the outer tie rod assembly. Refer to Outer Tie Rod Replacement procedure.
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01/2003 2003.0 BA Falcon
211-04-1
Steering Column
211-04-1
SECTION : 211-04 Steering Column VEHICLE APPLICATION : 2003.0 BA Falcon CONTENTS
PAGE
SPECIFICATIONS Specifications .........................................................................................................................211-04-2 DESCRIPTION AND OPERATION Steering Column ....................................................................................................................211-04-3 Steering Column ..................................................................................................................211-04-3 Floor Plate & Intermediate Shaft ..........................................................................................211-04-4 Steering Column Air Bag .....................................................................................................211-04-4 Steering Column Lock ..........................................................................................................211-04-4 Adjustable Steering Column ................................................................................................211-04-4 Fixed Steering Column (Column Shift Automatic) ...............................................................211-04-5 Steering Column - Accident Damage and Replacement .....................................................211-04-5 REMOVAL AND INSTALLATION Steering Column Shrouds ......................................................................................................211-04-6 Ignition Key Barrel .................................................................................................................211-04-6 Passive-Anti-Theft-System (PATS) Unit, and key illumination ..............................................211-04-7 Adjustable Steering Column ..................................................................................................211-04-7 Fixed Steering Column (Column Shift automatic) .................................................................211-04-9 Floor Plate & Intermediate Shaft ...........................................................................................211-04-9 Driver Air Bag .......................................................................................................................211-04-10 Steering Wheel ...................................................................................................................211-04-11 DISASSEMBLY AND ASSEMBLY Setting the Steering Column Adjustment Clamp .................................................................211-04-12 Adjustable Steering Column ...............................................................................................211-04-12 Fixed Steering Column .......................................................................................................211-04-13 Gear Shift Module ................................................................................................................211-04-14 Centralizing the Clockspring ................................................................................................211-04-14 Floor Plate and Intermediate Shaft .....................................................................................211-04-15
01/2003 2003.0 BA Falcon
211-04-2
Steering Column
211-04-2
SPECIFICATIONS Torque Specifications Description Steering column to Instrument panel Steering shaft to connector tube Adjustment lever bolt Serrated nut on clamp mechanism Multifunction switch to lock housing PATS Unit to lock housing Lower shroud Driver Air Bag to steering wheel Steering wheel to steering column Floor plate to dash panel Intermediate shaft to steering rack input shaft M12 nut for shift lever on fixed column Shift gate on fixed column
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Nm 18 25 11 11 1.3 1.3 1.3 5 38 7 22 18 2
01/2003 2003.0 BA Falcon
211-04-3
Steering Column
211-04-3
DESCRIPTION AND OPERATION Multi-function switch, incorporating the turn indicator, headlight on/off and dip switch, and wash/ wipe (including rear wash/ wipe for Steering Column wagons). There are two types of steering column assembly Shroud covers, which incorporate a switch for used, depending on the vehicle model. These column adjustment of the pedals (where fitted).The lower types are Rake/Reach (adjustable) & Column Shift shroud has impact absorbing foam for knee Automatic (fixed). protection. Steering wheel and Driver Air Bag assembly. The steering column is designed to work in conjunction with the restraint system, and may collapse upon inflation of the airbag and subsequent impact of the driver.
Steering Column
Item 1 2 3
Description Key barrel illumination light Switch for adjustable pedal option Column adjustment lever The columns are fixed to the vehicle in two places. The upper mounting point is via four bolts that fix the column to the instrument panel, and the lower mounting point is via a connector tube on the floor plate.
Item Description 1 Automatic Transmission Shift Lever Both of these columns are fitted with: Fully integrated steering lock. Fully integrated ignition switch. Ignition key lock barrel. Passive Anti Theft System (PATS) transceiver unit with fully integrated key barrel illumination light ring. Alloy mounting bracket with 4 plastic break-away capsules, to allow the column to move forward in a severe impact. Clockspring, which contains a ribbon of wire that electrically connects the steering wheel and Driver Air Bag to the steering column. A12341 en
The fixed steering column incorporates a column mounted gear shift lever for automatic vehicles, which are fitted with an optional centre front seat. The gear shift lever operates a cable, which is linked to the automatic transmission. The fixed steering column is identical to an adjustable column, but has the adjustment mechanism locked in one position. The gear shift mechanism is a separate module welded on to the left hand side of the column. The column is fixed so that the correct alignment is maintained between the gear shift mechanism, the gearshift cable and its abutment bracket. 01/2003 2003.0 BA Falcon
211-04-4
Steering Column
211-04-4
DESCRIPTION AND OPERATION (Continued) Floor Plate & Intermediate Shaft One intermediate shaft and floor plate assembly exists for all engines and transmissions. NOTE: FPV will be introducing a unique shaft for some XR vehicles. The floor plate consists of: a connector tube roller bearing in a rubber diaphragm rubber torsional isolator universal joint floor closing plate which attaches to the dash panel.
used during assembly of the universal joint to the steering rack input shaft. The sliding joint top end is sealed with a plastic cap and ’O’ ring, and the lower end is sealed by a bung. The universal joint is fully sealed, and not serviceable. The pinch bolt yoke assembles onto the steering rack pinion, and is keyed to fit together in only one orientation.
Steering Column Air Bag The steering wheel is bolted to the top of the column and is fitted with a supplemental restraint system (SRS) Driver Side Air Bag module. Before carrying out work on or around any SRS component, observe all SRS conditions and warnings to avoid unnecessary air bag deployment and possible injury. See Section 211-04-9 & Section 501-20.
Steering Column Lock The steering column lock is integral to the key barrel housing. When the ignition key is turned to the "0" position and removed, a tongue inside the steering column lock can engage with the steering column tube, locking it into position. When the ignition key is turned to the "I", "II", or "III" position, the steering column lock tongue withdraws, unlocking the steering column tube and allowing it to rotate. For information on the key barrel. See Section 501-14.
Item Description 1 Upper universal joint and rubber isolator 2 Floor Plate & Rubber Diaphragm 3 Sliding Joint 4 Heat Shield 5 Lower universal joint and pinch bolt yoke 6 Dash Panel The connector tube has a plastic over-moulding which incorporates a safety clip and captive M8 nut. A slot in the connector tube aligns with a pip on the steering column, and can only be assembled in one orientation. The safety clip prevents the joint disengaging should the 8mm bolt work loose. A bung is inserted into the connector tube to prevent noise, water and dust from engine bay entering the passenger compartment. The roller bearing allows the column to rotate, and the rubber diaphragm acts as a pivot, allowing the column to tilt. The floor closing plate is attached to the outside of the dash panel by three nuts. The torsional isolator has a pin through it, to maintain steering control in the event of the rubber failing. The universal joint is fully sealed, and not serviceable. The intermediate shaft incorporates: a sliding collapse joint a universal joint and pinch bolt yoke The sliding collapse joint helps to prevent intrusion of the steering column during a heavy impact. It is also A12341 en
Adjustable Steering Column Floor shift vehicles (manual & automatic) are equipped with an adjustable steering column. The adjustments are for both rake (up and down) and reach (in and out). Adjustment of the column is achieved by loosening the adjustment lever located underneath the column shroud. Swing the lever down and away from the column, adjust the steering wheel to the desired position, then swing the lever fully upwards to lock the column in position. The adjustable column is fitted with a counter balance spring, so that column does not drop down to the lowest position when the adjustment lever is loosened. 01/2003 2003.0 BA Falcon
211-04-5
Steering Column
211-04-5
DESCRIPTION AND OPERATION (Continued) The key barrel is lit via an illuminated ring around the barrel. This ring is illuminated whenever the interior lights are on. When adjustable pedals are fitted, they are operated via a rocker switch on the right hand side of the lower steering column shroud covers, just forward of the ignition barrel.
Fixed Steering Column (Column Shift Automatic) Column Shift vehicles are equipped with a fixed column. It is not possible to adjust the column, as this will interfere with the alignment between the gear shift mechanism, and the gearshift cable and its abutment bracket. To select a gear, the gear shift lever must be pulled towards the driver to disengage it from the gear shift gate. The lever can then be rotated clockwise or anti-clock wise to select gears. The gear selected is indicated by an illuminated number or letter in the instrument cluster.
Steering Column - Accident Damage and Replacement
In a severe impact the steering column is designed to decouple from the instrument panel attachment points, and slide forward in the vehicle. The steering column is bolted to the instrument panel with four bolts. These bolts pass through white plastic break away capsules. If these capsules have moved, then the steering column assembly needs to be replaced.
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211-04-6
Steering Column
211-04-6
REMOVAL AND INSTALLATION
Steering Column Shrouds Removal and Installation Upper Shroud 1. Unclip the upper shroud by grabbing it at the openings where the switch levers pass through the shroud. Pull the rear of the shroud directly upwards to disengage the two rear clips. The shroud can then be moved rearwards to disengage the two forward clips.
Lower Shroud 1. Undo the three screws underneath the lower shroud. Move the steering column adjustment lever (adjustable columns only) about half way through its travel. Gently spread the lower shroud to clear the key illumination ring.
Item 1 2
Description Screw x 3 Move adjustment down
2. The rubber flap on the upper shroud is attached 2. Slide the shroud down and rearwards, ensuring to the instrument panel via 4 arrow head clips. the adjustment lever passes through the aperture Gently pull the rubber flap rearwards to disengage in the lower shroud. Unclip the wire harness for the 4 clips. the adjustable pedal switch (where fitted).
3. To install the upper shroud, guide the 2 forward clips into the mating parts in the lower shroud. Push the shroud forward, and then down, to secure the 2 rear clips. Ensure the tongue-in-groove between the upper and lower shrouds are aligned. Clip the rubber flap to the instrument panel.
3. The pedal adjust switch can be removed from the shroud by deflecting the steel retaining clips, and pushing the switch outwards. 4. NOTE: Ensure the steering column adjustment lever passes under the pedal switch wire harness, when installing the lower shroud. To install the lower shroud, reverse the removal procedure.
Ignition Key Barrel Removal and Installation 1. Remove the upper steering column shroud. See Section 211-04-5.
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211-04-7
Steering Column
211-04-7
REMOVAL AND INSTALLATION (Continued) 2. Remove the ignition key barrel by installing the ignition key, turning it to position "I" and then depressing the pin in the side of the ignition lock housing.
Item 1 2
Description Depress Pin behind illumination ring to remove key barrel Align key head with "I"
3. To install the ignition key barrel, reverse the removal procedure. For information on the key barrel, see Section 501-14.
Passive-Anti-Theft-System (PATS) Unit, and key illumination Removal and Installation 1. Remove the upper steering column shroud. See Section 211-04-5. 2. Remove the lower steering column shroud. See Section 211-04-5. 3. Remove the electrical connector from the PATS unit.
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4. Remove the screw that attaches the PATS unit to the ignition lock housing. Slide the PATS unit off the ignition lock housing. NOTE: The ignition illumination globe is not serviceable as a separate item. Replacement of the PATS unit is required.
5. To install the PATS unit, reverse the removal procedure. 6. If a new PATS unit is fitted, it will be necessary to re-program the Body Electronics Module. For more information on the PATS unit see Section 419-01 & Section 419-10.
Adjustable Steering Column Removal 1. Ensure that the front wheels and steering wheel are in the straight ahead position. This will ensure that the clockspring is centralized when it is removed. 2. Disarm and remove the Driver Air Bag module in accordance with the procedure given in Section 211-04-09 of this manual. 3. Remove the steering wheel in accordance with the procedure given in Section 211-04-10 ensuring that the front wheels are still in the straight ahead position. 4. Remove the M8 flanged head bolt that joins the steering column shaft to the floor plate connector tube. Carefully lift the plastic safety clip and pull the steering shaft rearwards out of the connector tube. 5. Remove the upper and lower steering column shrouds. See Section 211-04-6 & Section 211-04-5
01/2003 2003.0 BA Falcon
211-04-8
Steering Column
211-04-8
REMOVAL AND INSTALLATION (Continued) 6. Disconnect the 2 wire harnesses from the clockspring.
Item 1 2 3 4 5 6
Description Four mounting bolts. Torque to 18 Nm. Two clockspring connectors One release tab for lever lock connector Pull back safety clip before removing the aluminum shaft Torque bolt to 25 Nm Two release tabs for ignition wiring lever lock connector
7. Disconnect the ignition wire harness lever-lock connector. The lever has two retaining tabs that keep the lever locked in place. These must be disengaged before the lever can be rotated. 8. Disconnect the multi-function switch wire harness lever-lock connector. The lever has a single retaining tab that keeps the lever locked in place. This must be disengaged before the lever can be rotated.
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9. Remove the four bolts retaining the alloy steering column mounting bracket onto the instrument panel, and completely remove the column from the vehicle. NOTE: The four bolts are retained in the alloy mounting bracket using special fibre retaining washers. Make sure all these washers are in place before re-installing the steering column. If one or more of the washers are missing, the alloy mounting bracket may become distorted, adversely affecting the column adjustment mechanism and column break-away mechanism . Delete all the washers from the installation if one or more of the fibre washers are missing. Installation 1. Before re-installing the steering column, check that the front wheels are in the straight ahead position. 2. Check that the clockspring has been centralized on the steering column. See Section 211-04-13. 3. Fit the lower steering column shaft into the connector tube on the floor plate. Loosely fit the M8 flanged head bolt. 4. To align the alloy mounting bracket to the steering column, close the adjustment lever so that the clamping mechanism is just nipped up. The alloy bracket should still be able to rotate by hand so that it can align to the instrument panel. Secure the four M8 mounting bracket bolts to the instrument panel and torque to 18Nm. NOTE: The four bolts are retained in the alloy mounting bracket using special fibre retaining washers. Make sure all these washers are in place before re-installing the steering column. If one or more of the washers are missing, the alloy mounting bracket may become distorted, adversely affecting the column adjustment mechanism and column break-away mechanism . Delete all the washers from the installation if one or more of the fibre washers are missing. 5. Torque the M8 flanged head bolt in the lower steering column shaft to 25Nm. 6. Connect the lever lock connectors for the multi function switch, and ignition wiring. 7. Connect the two clockspring connectors. 8. Refit the shrouds. See Section 211-04-5. 9. Refit the steering wheel and Driver Air Bag. See Section 211-04-09 & Section 211-04-10. 10. Adjust the steering column through its full range to ensure the movement is smooth. 11. Re-connect the battery.
01/2003 2003.0 BA Falcon
211-04-9
Steering Column
211-04-9
REMOVAL AND INSTALLATION (Continued)
Fixed Steering Column (Column Shift automatic) Removal and Installation 1. The removal and installation of the Column Shift Automatic steering column is identical to the adjustable steering, but requires one additional operation. 2. Put the gear shift lever into "Park". Underneath the instrument panel on the LHS of the steering column, is the cable that operates the automatic transmission. Remove the cable end (ball socket) from the steering column by levering it off with a screwdriver.
2. In the driver’s foot well, remove the M8 flanged head bolt that joins the steering column shaft to the floor plate connector tube. Carefully lift the plastic safety clip and pull the steering shaft rearwards out of the connector tube. 3. In the engine bay remove the three nuts securing the floor plate to the dash panel.
Item 1 2
3. To assemble the cable end ball socket, pull it rearwards onto the ball stud, which is fitted to the steering column shift mechanism.
Floor Plate & Intermediate Shaft NOTE: The apperance of the intermediate shaft in XR6 Turbo and XR8 will vary from that shown in that the shaft will be fitted with a reflective sheath and in that no ’bell’ will be fitted over the lower universal joint. Removal of this type of intermediate shaft is as described below with the exception that the body mounted intermediate shaft heat shield may need to be removed to obtain adequate access to the intermediate shaft. Removal 1. Ensure that the front wheels and steering wheel are in the straight ahead position. Tape the steering wheel to the upper and lower shrouds so that the steering wheel cannot be inadvertently rotated during this procedure. This protects the clockspring from being over-wound at full left hand or right hand steering wheel lock.
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Description Floor plate securing nut Intermediate nut to steering rack nut
4. Remove the bolt that secures the lower end of the intermediate shaft to the steering rack. Slide the intermediate shaft rearwards to collapse it, removing the universal joint from the steering rack input shaft. 5. The intermediate shaft and floor plate assembly can now be removed from the vehicle. CAUTION: Be carefull collapsing steering shaft . Installation 1. Ensure that the front wheels and steering wheel are in the straight ahead position. 2. Before installation of the floor plate assembly, check that the rubber gasket face on the floor plate, and the mating sealing surface on the dash panel are clean and dry. Ensure that the threads of the three studs on the dash panel are clean, and that the nuts are free running. 3. Position the floor plate over the three studs of the dash panel, and loosely attach the three nuts. 4. From the driver’s foot well, extend the steering shaft by hand and guide it into the floor plate connector tube. Install the M8 flanged head bolt shaft and torque to 25Nm.
01/2003 2003.0 BA Falcon
211-04-10
Steering Column
211-04-10
REMOVAL AND INSTALLATION (Continued) 5. Torque the three M6 nuts on the floor plate to 7Nm. WARNING: Over torquing could result in the stud snapping off.
Item 1 2
Description Floor plate securing nut Intermediate nut to steering rack nut
6. Slide the intermediate shaft lower universal joint yoke onto the steering rack input shaft. Note that the spline is keyed so that it can only be assembled in one orientation. 7. Insert the M8 bolt into the yoke and torque to 22Nm.
Driver Air Bag NOTE: Also refer to Section 501-20B.
deformation. Install and correctly position the new sensor or any other damaged supplemental restraint system (SRS) components whether or not the air bag is deployed. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or installing a new front or side supplemental restraint system (SRS) components and before repairing, installing new, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hoodlatches. Please refer to the appropriate workshop manual to determine the location of the front air bag sensors. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). WARNING: The restraint system diagnostic tool is for restraint system repair only. Remove from vehicle prior to road use. Failure to remove could result in injury and possible violation of vehicle safety standards. 1. Disconnect the battery. Wait at least one minute to deplete the backup power supply energy. 2. Rotate the steering wheel 90° from straight ahead, to access one of the Driver Air Bag retaining screws on the front face of the steering wheel.
Removal WARNING: Always wear safety glasses when repairing an air bag supplemental restraint system (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. WARNING: Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. WARNING: Vehicle sensor orientation is critical for correct system operation. If a vehicle equipped with an air bag supplemental restraint 3. Rotate the steering wheel 180° to access the system (SRS) is involved in a collision, inspect other screw. the sensor mounting bracket and wiring pigtail for
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01/2003 2003.0 BA Falcon
211-04-11
Steering Column
211-04-11
REMOVAL AND INSTALLATION (Continued) 4. Gently pull the Driver Air Bag away from the steering wheel.
Item 1 2
2. Unscrew the retaining bolt using a Torx T50 driver. To stop the steering wheel rotating, remove the key from ignition barrel, and rotate the steering wheel to the left until the steering column lock engages.
Description Horn/Cruise/Audio Connector Inflator Connectors
3. Install the steering wheel puller, Ford service tool No. J-1859-A (09561-11002). 5. Disconnect the wiring to the Driver Air Bag inflator Ensure that the pusher block is used so that the by depressing the retaining clips on either side of thread in the end of the steering column is not the connector. damaged. Loosen the wheel from the column. 6. Remove the horn/audio wiring connector. 4. Carefully feed the clockspring wire harnesses 7. Remove the Driver Air Bag from the vehicle. through the hub of the steering wheel, and remove the steering wheel from the vehicle. Installation 5. Installation of the steering wheel is a reverse of 1. Disconnect the battery. Wait at least one minute the above procedure. Torque the M10 steering to deplete the backup power supply energy. wheel attachment bolt to 38Nm. 2. Connect the wiring to the Driver Air Bag inflators. The connectors are mechanically keyed to fit in only one orientation. 3. Ensure the inflator wire harness is clipped into position. 4. Connect the horn/audio wiring. Ensure the wire harness is clipped into position. 5. Gently push the Driver Air Bag into the steering wheel. Ensure all wiring is clear of the Driver Air Bag attachment screws. 6. Rotate the steering wheel 90° from straight ahead, to access the one of the Driver Air Bag retaining screws on the front face of the steering wheel. Torque the screw with a Torx T30 bit, to 5Nm. 7. Rotate the steering wheel 180° to access the other screw. 8. Reconnect the battery.
Steering Wheel Removal and Installation 1. Remove the Driver Air Bag. See Section 211-04-09.
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01/2003 2003.0 BA Falcon
211-04-12
Steering Column
211-04-12
DISASSEMBLY AND ASSEMBLY
Setting the Steering Column Adjustment Clamp Assembly 1. Remove the bolt and washer securing the black plastic adjustment lever to the serrated clamping nut. 2. Remove the lever from the clamp nut.
1. The clockspring is clipped into the multi-function switch, and can be removed by deflecting and releasing the three retaining clips. Remove the two electrical connectors from the wire harness bracket.
2. Remove the three screws which secure the multi-function wash/wipe/indicator/headlight switch. Slide the lever-lock connector off the tag of the wire harness bracket. Item 1 2 3
Description Serrated Clamping Nut Bolt Adjustment Lever
3. Slacken off and re-tighten the clamp nut to 11Nm torque. 4. Reposition the lever on the clamp-nut ensuring the serrations mesh correctly, and the lever is in the fully closed position. i.e. the main arm of the lever is parallel to the centreline of the steering column 5. Hold the lever and replace the washer and bolt. Tighten the bolt to 11Nm torque.
Adjustable Steering Column Disassembly NOTE: The degree of disassembly required will depend on the nature of the repair or the component which is to be replaced. Disassembly instructions are given below, but it may not be necessary to carry out all steps to effect the required repairs. These instructions refer to a steering column that has been completely removed from the vehicle.
3. Remove the electrical connector from the PATS unit. 4. Remove the screw that attaches the PATS unit to the ignition lock housing. Slide the PATS unit off the ignition lock housing. NOTE: The ignition illumination globe in the PATS unit is not serviceable as a separate item. 5. Remove the bolt and washer securing the adjustment lever, and remove the lever. Undo serrated clamping nut and remove the plastic thrust washer. NOTE: The bolt, serrated clamp nut, and clamp bolt use a special double start thread, and cannot be replaced with conventional metric fasteners. 6. Remove the counter balance spring, clamp bolt and clamping spacer. 7. Remove the alloy mounting bracket.The column is now completely disassembled. NOTE: The upper and lower steering shafts and bearings are not serviceable. The upper shaft and
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01/2003 2003.0 BA Falcon
211-04-13
Steering Column
211-04-13
DISASSEMBLY AND ASSEMBLY (Continued) bearing is staked into position. It has to sustain the impact of the driver in a severe accident, and must not be disassembled.
5. Fit the lever, washer and bolt.
NOTE: The upper & lower sections of the telescoping steering shafts are made as an assembly, and can only be assembled in one orientation. Carefully mark the lower bearing carrier (white plastic) and alloy shaft before disassembly, to ensure correct alignment. The two flats on the lower alloy shaft are aligned to the two LONG flats on the upper steering shaft. NOTE: The locking mechanism for the steering column is not serviceable. It is fully secured to provide maximum anti-theft protection. NOTE: The ignition switch for the steering column is fully integrated into the lock housing, and is not serviceable. It is integrated to provide maximum anti-theft protection.
6. Fit the multi-function switch, ensuring that centre drive hub is aligned to the two flats of the steering shaft. Fit the three screws. Torque to 1.3Nm. NOTE: If a new steering column is fitted, the Assembly screws used to attach the multi-function switch 1. Assemble the alloy mounting bracket over the and lower shroud will cut their own thread into the column. Lightly smear the working surfaces with a lock housing. A torque higher than 1.3Nm may be general purpose grease. experienced while cutting these threads. 7. Ensure the wiring is correctly routed, then secure the lever-lock connector to the wire harness bracket.
Fixed Steering Column Disassembly 1. The degree of disassembly required will depend on the nature of the repair or the component which is to be replaced. Complete disassembly instructions are given below, but it may not be necessary to carry out all steps to effect the required repairs. 2. These instructions refer to a steering column that has been completely removed from the vehicle. 3. Disassembly of the fixed steering column is identical to the adjustable steering column, except for gear shift module.
2. Fit the clamping spacer, bolt and counterbalance spring. 3. Fit the plastic thrust washer, ensuring that the protruding face of the washer is fitted into the vertical slot in the alloy bracket. 4. Fit the serrated clamping nut, and tighten to finger Assembly 1. Assembly of the fixed steering column is the same tight. as adjustable column, expect for the clamping NOTE: DO NOT tighten the clamp nut at this mechanism. stage, this will be done after the column is fitted to the vehicle, and the lever will be set at the same 2. Install the column as described in Section time. 211-04-9.
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01/2003 2003.0 BA Falcon
211-04-14
Steering Column
211-04-14
DISASSEMBLY AND ASSEMBLY (Continued) 3. To set the steering column correct height, slacken 2. New Clockspring the serrated nut on the clamping bolt, and drop Remove the grenade pin. the column 12mm from its top position. Torque Rotate the centre hub clockwise 1/4 of a turn, the clamp nut to 11Nm. relative to the body of the clockspring.
Gear Shift Module Disassembly and Assembly 1. Remove the M12 nut on the shift shaft.
Item 1
Description Remove grenade pin before installing onto column
3. Existing Clockspring Rotate the centre hub fully anticlockwise relative to the body of the clockspring. The green and yellow wire harnesses should be almost aligned to the "TOP" marking on the body. Rotate the centre hub clockwise 3 1/2 turns clockwise.
Item 1 2
Description Selectorgate screw Shift lever retaining nut - M12
2. Remove the shift lever and ball stud assembly. 3. Remove the three screws which secure the gear shift selector gate. The column is now completely disassembled.Further disassembly is not recommended. 4. Assembly is the reverse of the above procedure 5. Torque the selector gate screws to 2Nm. 6. Torque the shift lever retaining nut to 18Nm.
Centralizing the Clockspring Assembly 1. Before fitting the clockspring it must be centralized.
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4. The clockspring is now suitable for installation on a column that is installed into a vehicle with the road wheels in a straight ahead position. 5. Ensure that the two flats on the lower alloy steering shaft are vertical, with the pip at the bottom. 6. Slide the clockspring over the upper steering shaft, and clip it to the multifunction switch. NOTE: This clockspring is used in another vehicle application. When installed in a Falcon it is rotated 180 degrees, and the "TOP" mark should be located at the bottom. 01/2003 2003.0 BA Falcon
211-04-15
Steering Column
211-04-15
DISASSEMBLY AND ASSEMBLY (Continued) 7. Route the wiring and attach the two connectors to the wire harness bracket. 8. Fit the PATS unit. See Section 211-04-6. 9. Install the column. See Section 211-04-7. 10. Re-set the steering column adjustment clamp load. See Section 211-04-11. 11. Refit the shrouds. See Section 211-04-5 & Section 211-04-6
Floor Plate and Intermediate Shaft Disassembly 1. It is recommended the floor plate and intermediate shaft should not be disassembled. 2. If it is deemed necessary to separate the upper and lower sliding halves of the intermediate shaft, then it is vital that an alignment mark is made on the shafts, to ensure correct orientation on reassembly. It is recommended that this sliding joint is NOT disassembled.
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01/2003 2003.0 BA Falcon
211-05-1
Steering Column Switches
211-05-1
SECTION : 211-05 Steering Column Switches VEHICLE APPLICATION : 2003.0 BA Falcon CONTENTS
PAGE
DESCRIPTION AND OPERATION Steering Column Switches .....................................................................................................211-05-2 Steering Column Switches ...................................................................................................211-05-2 DIAGNOSIS AND TESTING Steering Column Switches .....................................................................................................211-05-3 Inspection and Verification ...................................................................................................211-05-3 Symptom Chart ....................................................................................................................211-05-3 Connector Circuit Reference ................................................................................................211-05-3 Pinpoint Tests ......................................................................................................................211-05-5 REMOVAL AND INSTALLATION Steering Column Multifunction Switch ...................................................................................211-05-7 Ignition Key Barrel ..................................................................................................................211-05-7 Pedal Adjust Switch................................................................................................................211-05-7
01/2003 2003.0 BA Falcon
211-05-2
Steering Column Switches
211-05-2
DESCRIPTION AND OPERATION
Steering Column Switches Steering Column Switches The steering column switches consist of the following: Multifunction switch Ignition switch Pedal adjustment switch (if fitted)
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01/2003 2003.0 BA Falcon
211-05-3
Steering Column Switches
211-05-3
DIAGNOSIS AND TESTING 2. Visually inspect the ignition switch and the steering column multifunction switch for damage; refer to the following chart: Refer to Wiring Diagram Section 700-02 for schematic and connector information. Visual Inspection Chart Mechanical Special Tool(s) Ignition switch Multimeter Turn signal switch (component of steering WDS column multifunction switch) Wiper/washer switch (component of steering column multifunction switch) Pedal Adjust switch
Steering Column Switches
3. If cause of the switch concern is not visually apparent, proceed to Symptom Chart.
Inspection and Verification 1. Verify the customer concern by operating ignition switch and the multifunction switch.
Symptom Chart Condition
Source
Action
Ignition switch is inoperative (No power in ACC/ON or START)
Ignition switch Circuitry Battery
Go to PinPoint Test A.
Wiper/washer, turn signal switch or headlamp switch does not operate correctly
Steering column multifunction switch Circuitry Battery
Go to PinPoint Test B
Adjustable pedals do not operate correctly
Pedal adjustment switch Pedal box Circuitry Battery
Go to PinPoint Test C
Connector Circuit Reference C167 - View of Multifunction connector - Harness side
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01/2003 2003.0 BA Falcon
211-05-4
Steering Column Switches
211-05-4
DIAGNOSIS AND TESTING (Continued) Pinout Pin Number(s) 1 2 3 5 6 7 8 9 10 11 12 13 14 16 17 20 22 23 24
Circuit Designation/Description 175 Park Red 57 Earth (H/Lamps) Yellow 293 BEM (Auto H/Lamp) Grey 590A Rear Wipe Orange / Brown 20 Dipper (High Beam) Green / Orange 942 Rear Wash Blue 56 Wiper (High) Blue / Yellow 58Wiper (Low) White / Blue 589 Var Wiper Earth Orange 993 Var Wipe (to BEM) Brown / White 18 Dipper (Low Beam) Red / Yellow 2 Turn RH Brown / White 2 Turn RH Brown / White 57 Wiper, Dipper, rear wiper earth Black, violet, pink 8 Turn Ign Green / Red 3 Turn LH Green 941 Wash (to BEM) Grey / Black 28 Wiper (Park) Blue / Pink 59C Wiper (Int) Green / White
Normal Condition/Measurement
S/C to GND when high wipe on S/C to GND when low wipe on
See “Intermittent Wipe” table below
S/C to pin17 when RH Ind activated S/C to pin17 when RH Ind activated
S/C to pin17 when LH Ind activated S/C to GND when activated
Intermittent Wipe Resistance values Detent Resistance 1 400 - 600Ω 2 1,372 - 1,678Ω 3 2300 - 2800Ω 4 3,218 - 3,933Ω 5 4,140 - 5,060Ω
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01/2003 2003.0 BA Falcon
211-05-5
Steering Column Switches
211-05-5
DIAGNOSIS AND TESTING (Continued) Pedal Adjust Switch Connector and Pinout
Pin Number(s) 1 3 6 8
Circuit Designation/Description Pedal Circuits Batery +VEYellow Pedal Circuits Ground Black Pedal Circuits Motor -VE- (Back) Light Blue / Orange Stripe Pedal Circuits Motor +VE(Forward) Light Blue / Black Stripe
Normal Condition/Measurement
Pinpoint Tests PINPOINT TEST A : IGNITION SWITCH IS INOPERATIVE (NO POWER IN ACC/ON OR START) Test Step A1
Result / Action to Take
CHECK CONTINUITY OF IGNITION SWITCH AND LOCK HOUSING Remove steering column shrouds from vehicle. Refer to Section 211-04. Disconnect ignition switch connector. With car keys inserted, use a multimeter to check the continuity of the ignition switch for the various positions (ACC, ON) at the ignition switch connector.
Yes
Check wiring for ignition switch circuit. Please refer to wiring diagrams for details of circuits.
No
Go to A2.
Is continuity of ignition switch accurate for each position?
A2
CHECK FUNCTIONALITY OF LOCK BARREL Remove lock barrel from steering column. Check functionality of lock barrel: rotate key in barrel and confirm that the shaft in barrel is turned when key is turned. Is lock barrel functional?
Yes
Install a new ignition switch. Refer to ignition switch installation and removal section. Repeat test A1 to confirm operation of system. NOTE: Ignition switch is integral with column. Need to replace column assembly. See Section 211-04.
No
Install a new lock barrel. Repeat test A1 to confirm operation of ignition switch.
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01/2003 2003.0 BA Falcon
211-05-6
Steering Column Switches
211-05-6
DIAGNOSIS AND TESTING (Continued) PINPOINT TEST B : WIPER/WASHER OR TURN SIGNAL SWITCH DOES NOT OPERATE CORRECTLY Test Step B1
Result / Action to Take
CHECK CONTINUITY OF MULTIFUNCTION SWITCH Remove steering column shrouds from vehicle. Refer to Section 211-04.
Yes
Disconnect multifunction switch connector.
Check wiring for multifunction switch circuit. Please refer to wiring diagrams for details of circuits.
Use a multimeter to check the continuity of the multifunction switch for the various positions at the multifunction switch connector.
No
Is continuity of multifunction switch accurate for each position?
Install a new multifunction switch. Refer to multifunction switch installation and removal section. Repeat tests to confirm correct operation of system.
PINPOINT TEST C : ADJUSTABLE PEDALS DO NOT OPERATE CORRECTLY Test Step C1
Result / Action to Take
CHECK CONTINUITY OF PEDAL ADJUST SWITCH Remove steering column shrouds from vehicle. Refer to Section 211-04 Disconnect Pedal Adjust switch connector. Use a multimeter to check the continuity of the Pedal Adjust switch Is continuity of Pedal Adjust switch accurate?
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Yes
Check wiring for Adjustable pedals circuit. Please refer to wiring diagrams for details of circuits.
No
Install a new Pedal Adjust switch. Repeat tests to confirm correct operation of system.
01/2003 2003.0 BA Falcon
211-05-7
Steering Column Switches
211-05-7
REMOVAL AND INSTALLATION
Steering Column Multifunction Switch Removal and Installation 1. Disconnect the battery ground cable. For additional information, refer to Section 414-01. 2. Remove upper and lower steering column shrouds. For additional information refer to Section 211-04. 3. Remove the driver air bag and steering wheel. For additional information refer to Section 211-04 and Section 501-20b. 4. Remove clockspring from steering column. For additional information refer to section Section 501-20b.
6. Remove the three screws that secure the multifunction switch to the steering column and then pull of multifunction switch.
7. To install, reverse the removal procedure. Refer to Section 211-04 for instructions for centralizing the clockspring.
Ignition Key Barrel Removal and Installation 1. Please refer to Section 211-04 for instructions for removing and installing the ignition key barrel.
Pedal Adjust Switch 5. Remove the electrical connector from the PATS unit. For additional information refer to Section 211-04.
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Removal and Installation 1. Disconnect the battery ground cable. For additional information refer to Section 414-01. 2. Remove upper and lower steering column shrouds. For additional information refer to Section 211-04. 3. Disconnect Pedal Adjust switch connector from wiring harness. Remove Pedal Adjust switch from Lower Shroud.
01/2003 2003.0 BA Falcon
303-00-1
Engine System — General Information
303-00-1
SECTION : 303-00 Engine System — General Information VEHICLE APPLICATION : 2003.0 BA Falcon CONTENTS
PAGE
DESCRIPTION AND OPERATION Engine ....................................................................................................................................303-00-3 DIAGNOSIS AND TESTING Engine ....................................................................................................................................303-00-4 Inspection and Verification ...................................................................................................303-00-4 Symptom Chart ....................................................................................................................303-00-4 Components Tests ...............................................................................................................303-00-6 GENERAL PROCEDURES Camshaft Journal — Diameter ...............................................................................................303-00-8 Camshaft Journal — Clearance, Plastigage Method .............................................................303-00-8 Camshaft —8 End Play, OHC Engines .................................................................................303-00-8 Camshaft — Lobe Surface .....................................................................................................303-00-8 Camshaft — Runout .............................................................................................................303-00-9 Crankshaft Main Bearing Journal — Diameter ......................................................................303-00-9 Crankshaft Main Bearing Journal — Taper ...........................................................................303-00-9 Crankshaft Main Bearing Journal — Clearance ....................................................................303-00-9 Crankshaft — End Play ........................................................................................................303-00-10 Crankshaft — Runout ..........................................................................................................303-00-10 Crankshaft — Connecting Rod Journal Taper, Out of Round .............................................303-00-10 Cylinder Bore — Taper .......................................................................................................303-00-11 Cylinder Bore — Out-of-Round ............................................................................................303-00-11 Piston — Inspection ............................................................................................................303-00-11 Piston — Pin to Bore Diameter ............................................................................................303-00-11 Piston — Diameter ...............................................................................................................303-00-12 Piston — to Cylinder Bore Clearance ..................................................................................303-00-12 Piston — Ring End Gap .......................................................................................................303-00-12 Piston — Ring-to-Groove Clearance ...................................................................................303-00-12 Piston — Pin Diameter .........................................................................................................303-00-13 Connecting Rod — Cleaning ...............................................................................................303-00-13 Connecting Rod — Large End Bore ....................................................................................303-00-13 Connecting Rod — Bushing Diameter .................................................................................303-00-13 Connecting Rod — Bend .....................................................................................................303-00-13 Connecting Rod — Twist .....................................................................................................303-00-14 Connecting Rod — Bearing Journal Clearance ...................................................................303-00-14 Roller Follower — Inspection ...............................................................................................303-00-14 Valve Rocker Arm/Lash Adjuster Assembly — Inspection ..................................................303-00-14 Hydraulic Lash Adjuster Diagnosis ......................................................................................303-00-14 Valve — Stem Diameter ......................................................................................................303-00-15 Valve — Stem to Valve Guide Clearance ............................................................................303-00-15 Valve — Inspection ..............................................................................................................303-00-15 Valve — Guide Inner Diameter ............................................................................................303-00-15 Valve — Guide Reaming .....................................................................................................303-00-16 Valve — Spring Installed Length .........................................................................................303-00-16 Valve — Spring Free Length ...............................................................................................303-00-16 01/2003 2003.0 BA Falcon
303-00-2
Engine System — General Information
303-00-2
(Continued) Valve — Spring Squareness ................................................................................................303-00-16 Valve — Spring Strength ....................................................................................................303-00-17 Valve — Seat Inspection ......................................................................................................303-00-17 Valve — Seat Width ............................................................................................................303-00-17 Valve — Seat Runout .........................................................................................................303-00-18 Cylinder Bore — Cleaning ...................................................................................................303-00-18 Cylinder Block — Core Plug Replacement ..........................................................................303-00-18 Exhaust Manifold — Inspection ...........................................................................................303-00-19 Bearing -Inspection ..............................................................................................................303-00-19
01/2003 2003.0 BA Falcon
303-00-3
Engine System — General Information
303-00-3
DESCRIPTION AND OPERATION
Engine NOTE: This section contains information, steps and procedures that may not be specific to your engine. This section covers general procedures and diagnosis and testing of the engine system, except for exhaust emission control devices, which are covered in the Chapter 303-14, Powertrain Control Module. The engine incorporates the following features: a closed positive crankcase ventilation (PCV) system. For additional information, refer to Section 303-08. an exhaust emission control system. For additional information, refer to Section 303-08. an evaporative emission control system. For additional information, refer to Section 303-13. Some engines incorporate a fail-safe cooling system. Refer to the appropriate section in Group 303 for the procedure. The engine, fuel system, ignition system, emissions system and exhaust system all affect exhaust emission levels and must be maintained according to the maintenance schedule. Refer to the scheduled Maintenance Guide. For engine identification, refer to Section 100-01. For engine number location, refer to figure. Engine Number Locations (I6)
Engine Number Locations (V8)
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01/2003 2003.0 BA Falcon
303-00-4
Engine System — General Information
303-00-4
DIAGNOSIS AND TESTING
Engine Inspection and Verification Since diagnosis and testing actually begins when repairs are taken on, the following procedure is recommended. 1. Verify the customer concern by operating the system. 2. Visually inspect for obvious signs of mechanical damage or electrical damage. If the concern cannot be reproduced, carry out a road test and/or visual check with the aid of the following table.
Visual Inspection Chart Mechanical Coolant leaks Oil leakso Leaks in the fuel system Visibly damaged or worn parts Loose or missing nuts or bolts 3. If an obvious cause for an observed or reported concern is found, correct the cause (if possible) before proceeding to the next step. 4. If the concern is not visually evident, verify the symptom and refer to the Symptom Chart.
Symptom Chart Condition Engine will not crank
Engine cranks but will not start
Engine slow/difficult to start
Engine misfires
Insufficient Power
G37831 en
Source
Action
Faulty Starter System
Refer to Section 303-05.
Transmission lever not in P or N.
Place in P.
Seized engine
Replace engine
Coolant in cylinders
Replace engine
Ignition system inoperative
Refer to appropriate Section in group 303.
Fuel system inoperative
Refer Section 310-00.
LPG engine requires "key-off" to regain starting enrichment after initial failed start.
Key-off LPG engine if 1st starting attempt failed.
Variable Cam Timing (VCT) unit lock pin not engaged at start.
Refer to appropriate Section in group 303.
VCT unit Oil Control Valve jammed.
Clean Oil Control Valve. Refer to appropriate Section in group 303.
Fail Safe Cooling in operation
Repair coolant system
Ignition system faulty
Refer to appropriate Section in group 303.
Fuel system faulty
Refer Section 310-00.
Restricted exhaust system
Inspect Exhaust system
Intake vacuum leak
Carry out Intake Manifold Vacuum test in this section
Burned valve/poor seating
Perform a compression check
Broken valve spring
Inspect valve springs
Head gasket leakage
Inspect head gasket
Piston damage
Perform cylinder compression check
Broadband Intake Manifold not operative
Check switching occurs at 3800 rpm Refer to appropriate Section in group 303.
VCT unit(s) not operative
Refer to appropriate Section in group 303.
01/2003 2003.0 BA Falcon
303-00-5
Engine System — General Information
303-00-5
DIAGNOSIS AND TESTING (Continued) Condition
Excessive Fuel Consumption
Excessive Oil Consumption
Engine leaks oil
Engine Noise.
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Source
Action
Electronic Throttle Control Unit faulty
Refer to appropriate Section in group 303.
Green(low mileage) engine/vehicle City/stop-start driving
Establish accurate fuel consumption using full to full method.
Faulty Fuel System
Refer to appropriate Section in group 303.
Green engine
Recheck at 15,000 km
Valve stem seal damaged or missing.
Inspect the seals. Refer to appropriate Section in group 303.
Oil leakage
Repair oil leakage
Incorrect Oil viscosity
Drain and fill with correct oil
Piston/rings/cylinder worn or damaged
Repair. Refer to appropriate Section in group 303.
Diluted oil
Determine cause. Correct. Drain and refill oil.
Crankcase overfilled
Adjust oil level.
Faulty PCV Valve
Check and replace. Refer to appropriate Section in group 303.
Joint fasteners loose
Tighten to specification.
Out of position or damaged seal/RTV sealant omitted/inadequate.
Pressurise crankcase to 35kPa. Apply soapy water, check for leak. Inspect and replace. Refer to appropriate Section in group 303.
Worn/out of position crank rotary seal
Inspect and replace. Refer to appropriate Section in group 303.
Porous casting
Clean suspect area, Perform pressurized crankcase check. Run engine, check for leak. Replace casting.
Sealant in Crank Damper keyway omitted or inadequate
Replace sealant. Refer to appropriate Section in group 303.
Sealant between Rear Main Cap and block omitted or inadequate
Perform pressurized crankcase leak check. Repair.
Excessive Crankshaft Main bearing or big end clearance. Excessive Crankshaft end play Excessive camshaft end play Excessive piston to bore clearance/damaged piston/bent connecting rod. Excessive hydraulic valve adjuster clearance
Inspect and repair. Refer relevant Section.
Soft or spongy lash adjusters Worn cam lobe or roller finger follower Excessive valve guide clearance Broken valve spring Loose timing chain Loose crank damper Worn/noisy Front End Accessory Drive Belt Worn/noisy FEAD tensioner/idler pulley Exhaust gas leakage
Check for excessively low or high oil level. Air leak in suction side of oil pump.
Carbon in combustion chamber/top land of piston
Remove carbon using proprietary carbon removal treatment
01/2003 2003.0 BA Falcon
303-00-6
Engine System — General Information
303-00-6
DIAGNOSIS AND TESTING (Continued) Components Tests Engine Oil Leaks
7. Install the components in reverse order, observing the specified tightening torques. 8. Reset the PCM fault memory.
NOTE: Before installing new gaskets or oil seals, make sure that the fault is clearly established. If the oil leak cannot be identified clearly by a visual inspection, carry out a pressurized crankcase leak check:
Interpretation of the Results The indicated compression pressures are considered within specification if the lowest reading cylinder is within 75% of the highest reading.
Pressurised leak check 1. Clean the engine with a suitable cleaning fluid to remove all traces of oil. 2. Block off the line to the PCV valve. 3. Apply a regulated air supply line to the fresh air makeup point on the rocker cover. 4. Pressurise the crankcase to 35 kPa. 5. Check for air leaks by washing the suspect area with a solution of soapy water and watching for bubbles. 6. Repair all leaks as necessary.
Compression Test General Remarks NOTE: Removing fuses and disconnecting electrical components causes the powertrain control module (PCM) to log an error message. After the measurements have been carried out this error message should be cleared from memory by connecting to PDU. The compression pressure should be checked with the engine at operating temperature. Check The Compression Pressure WARNING: On manual transmissions, shift the transmission into neutral. On automatic transmission vehicles, select ’’P’’. Failure to follow these instructions may result in personal injury. 1. Remove the fuel pump relay. 2. Start the engine - the engine will start, run for a few seconds then stall. 3. Remove the spark plugs. 4. Install the compression tester. 5. Install an auxiliary starter switch in the starting circuit. With the ignition switch OFF, using the auxiliary starter switch, crank the engine a minimum of five compression strokes and record the highest reading. NOTE: The approximate number of compression strokes required to obtain the highest reading. 6. Repeat the test on each cylinder, cranking the engine approximately the same number of compression strokes.
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CAUTION: If engine oil is sprayed into the combustion chamber, after carrying out the measurement run the engine at 2000 rpm for about 15 minutes, in order to burn the oil and prevent damage to the catalytic converter. If the measurement on one or more cylinders is much lower than the specified value, spray some engine oil into the combustion chamber and repeat the compression measurement. If the reading greatly improves, the piston rings are damaged. If the reading stays the same, the cause is either damaged valve seats or valve stem seals. If the measurements for two cylinders next to each other are both too low then it is very likely that the cylinder head gasket between them is burnt through. This can also be recognized by traces of engine oil in the coolant and/or coolant in the engine oil.
Excessive Engine Oil Consumption The amount of oil an engine uses will vary with the way the vehicle is driven in addition to normal engine-to-engine variation. This is especially true during the first 15,000 km when a new engine is being broken in or until certain internal components become conditioned. Vehicles used in heavy-duty operation may use more oil. The following are examples of heavy-duty operation: trailer towing applications severe loading applications sustained high speed operation Engines need oil to lubricate the following internal components: cylinder block cylinder walls pistons and piston rings intake and exhaust valve stems intake and exhaust valve guides all internal engine components When the pistons move downward, a thin film of oil is left on the cylinder walls. As the vehicle is operated, some oil is also drawn into the combustion chambers past the intake and exhaust valve stem seals and burned. The following is a partial list of conditions that can affect oil consumption rates: engine size operator driving habits 01/2003 2003.0 BA Falcon
303-00-7
Engine System — General Information
303-00-7
DIAGNOSIS AND TESTING (Continued) ambient temperatures quality and viscosity of oil Operation under varying conditions can frequently be misleading. A vehicle that has been run for several thousand kilometers on short trips or in cold ambient temperatures may have consumed a ’’normal’’ amount of oil. However, when checking the engine oil level, it may measure up to the full mark on the oil level indicator due to dilution (condensation and fuel) in the engine crankcase. The vehicle then might be driven at high speeds on the highway where the condensation and fuel boil off. The next time the engine oil is checked it may appear that a litre of oil was used in a relatively short distance. Make sure the selected engine oil meets the Ford specification and the recommended API performance category ’’SJ/CF’’ and SAE viscosity grade as shown in the vehicle Owner Literature. It is also important that the engine oil is changed at the intervals specified for the typical operating conditions.
4. Add 1 litre of oil. Start the engine and allow to idle for at least two minutes. Shut off the engine and allow the engine oil to drain back for at least five minutes. Mark the new oil level on the dipstick using the procedure above. 5. Record the vehicle’s odometer reading. 6. Instruct the customer to drive the vehicle as usual and: Check the oil level regularly at intervals of 250 km. Return to the service point when the oil level drops below the ADD mark on the oil dipstick. Add only full litres of the same oil in an emergency. NOTE: The mileage at which the oil is added.
Oil consumption Test. The following diagnostic procedure is used to determine the source of excessive oil consumption. NOTE: Oil use is normally greater during the first 15,000 km of service. As mileage increases, oil use decreases. High speed driving, towing, high ambient temperature and other factors may result in greater oil use. 1. Define excessive consumption, such as the number of kilometers driven per liter of oil used. Also determine customer’s driving habits, such as sustained high speed operation, towing, extended idle and other considerations. 2. Verify that the engine has no external oil leaks as described under Engine Oil Leaks. 3. Verify that the engine has the correct oil level. 4. Verify that the engine is not being run in an overfilled condition. Check the oil level at least five minutes after a hot shutdown with the vehicle parked on a level surface. 5. Carry out an oil consumption test: 1. Drain the engine oil and fill with one litre less than the recommended amount. 2. Run the engine for three minutes (10 minutes if cold), and allow oil to drain back for at least five minutes with vehicle parked on level surface. 3. Remove the oil dipstick and wipe clean. (Do not wipe with anything contaminated with silicone compounds.) Install the oil dipstick, making sure to seat the oil dipstick level firmly in the oil dipstick tube. Remove the oil dipstick and scribe a mark on the back (unmarked) surface at the indicated oil level. (This level should be about the same as the ADD mark on the face of the oil dipstick.) G37831 en
6. 7. 8. 9.
10. 11.
7. Check the oil level under the same conditions and at the same location as in steps 3-4. Measure the distance from the oil level to the UPPER mark on the oil dipstick and record. Measure the distance between the two scribe marks and record. Divide the first measurement by the second. Divide the distance driven during the oil test by the result. This quantity is the approximate oil consumption rate in kilometers per litre. If the oil consumption rate is unacceptable go to Step 6. Check the positive crankcase ventilation (PCV) system. Make sure the system is not plugged. Check for plugged oil drain-back holes in the cylinder head and cylinder block. If the condition still exists after carrying out the above tests go to Step 9. Carry out a cylinder compression test. Refer to the procedure in this section: Compression Test. This can help determine the source of oil consumption such as valves, piston rings or other areas. Check valve guides for excessive guide clearance. Install new valve stem seals after verifying valve guide clearance. Worn or damaged internal engine components can cause excessive oil consumption. Small deposits of oil on the tips of the spark plugs can be a clue to internal oil consumption.
01/2003 2003.0 BA Falcon
303-00-8
Engine System — General Information
303-00-8
GENERAL PROCEDURES
Camshaft Journal — Diameter
Camshaft — End Play, OHC Engines
1. Measure each camshaft journal diameter in two directions. If it is out of specification, install new components as necessary. Refer to the appropriate section in Group 303 for the procedure.
1. Remove the roller followers. Refer to the appropriate section in Group 303 for the procedure. 2. Use a Dial Indicator with Bracketry to measure camshaft end play. 3. Position the camshaft to the rear of the cylinder head. 4. Zero the indicator. 5. Move the camshaft to the front of the cylinder head. Note and record the camshaft end play. If camshaft end play exceeds specifications, install new camshaft and recheck end play. Refer to the appropriate section in Group 303 for the procedure. If camshaft end play exceeds specification after camshaft installation, install a new cylinder head. Refer to the appropriate section in Group 303 for the procedure.
Camshaft Journal — Clearance, Plastigage Method NOTE: The camshaft journals must meet specifications before checking camshaft journal clearance. 1. Remove the camshaft bearing cap and lay Plastigage across the surface. Refer to the appropriate section in Group 303 for the procedure. 2. Position the camshaft bearing cap and install the bolts. Refer to the appropriate section in Group 303 for the procedure. NOTE: Do not turn the camshaft while carrying out this procedure.
Camshaft — Lobe Surface 1. Inspect camshaft lobes for pitting or damage in the active area. Minor pitting is acceptable outside the active area. If excessive pitting or damage is present, install new components as necessary. Refer to the appropriate section in Group 303 for the procedure.
3. Use Plastigage to verify the camshaft journal clearance. If it is out of specification, install new components as necessary. Refer to the appropriate section in Group 303 for the procedure. G37832 en
01/2003 2003.0 BA Falcon
303-00-9
Engine System — General Information
303-00-9
GENERAL PROCEDURES (Continued)
Camshaft — Runout NOTE: Camshaft journals must be within specifications before checking runout.
Crankshaft Main Bearing Journal — Taper
1. Measure each of the crankshaft main bearing journal diameters in at least two directions at each 1. Use a Dial Indicator with Bracketry to measure the end of the main bearing journal. camshaft runout. For additional information, refer to Rotate the camshaft and subtract the lowest Specifications in the appropriate section in indicator reading from the highest indicator Group 303. reading. If it out of specification, install new For additional information, refer to the components as necessary. Refer to the specification chart in the appropriate engine appropriate section in Group 303 for the section. procedure. If it is out of specification, install new components as necessary. Refer to the appropriate section in Group 303 for the procedure.
Crankshaft Main Bearing Journal — Clearance Crankshaft Main Bearing Journal — Diameter 1. Measure each of the crankshaft main bearing journal diameters in at least two directions. For additional information, refer to Specifications in the appropriate section in Group 303. If it is out of specification, install new components as necessary. Refer to the appropriate section in Group 303 for the procedure.
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NOTE: Crankshaft main bearing journals must be within specifications before checking journal clearance. 1. Remove the crankshaft main bearing caps and crankshaft main bearing. 2. Lay a piece of Plastigage across the face of each crankshaft main bearing surface. NOTE: Do not turn the crankshaft while carrying out this procedure. Install and remove the crankshaft main bearing cap.
01/2003 2003.0 BA Falcon
303-00-10
Engine System — General Information
303-00-10
GENERAL PROCEDURES (Continued) 3. Verify the crankshaft journal clearance. For additional information, refer to Specifications in the appropriate section in Group 303. If it is out of specification, install new components as necessary. Refer to the appropriate section in Group 303 for the procedure.
Crankshaft — Runout NOTE: Crankshaft main bearing journals must be within specifications before checking runout. 1. Use the Dial Indicator with Bracketry to measure the crankshaft runout. For additional information, refer to Specifications in the appropriate section in Group 303. Rotate the crankshaft and subtract the lowest dial indicator reading from the highest dial indicator reading to figure the crankshaft runout. If it is out of specification, install new components as necessary. Refer to the appropriate section in Group 303 for the procedure.
Crankshaft — End Play 1. Measure the crankshaft end play. Use a Dial Indicator with Bracketry to measure crankshaft end play. 2. Position the crankshaft to the rear of the cylinder block. 3. Zero the indicator. Crankshaft — Connecting Rod Journal 4. Move the crankshaft to the front of the cylinder Taper, Out of Round block. Note and record the crankshaft end play. If crankshaft end play exceeds specifications, 1. Measure the crankshaft connecting rod journal diameters in two directions perpendicular to one install a new crankshaft thrust washer (6334) another at each end of the connecting rod journal. or crankshaft thrust main bearing (6337). The difference in the measurements from one end Refer to the appropriate section in Group 303 to the other is the taper. Verify measurement is for the procedure. within the wear limit. For additional information, refer to Specifications in the appropriate section in Group 303. If it is out of specification, install new components as necessary. Refer to the appropriate section in Group 303 for the procedure.
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01/2003 2003.0 BA Falcon
303-00-11
Engine System — General Information
303-00-11
GENERAL PROCEDURES (Continued)
Cylinder Bore — Out-of-Round 1. Measure the cylinder bore in two directions. The difference is the out-of-round. Verify the out-of-round is within the wear limit and bore the cylinder to the next oversize limit. For additional information, refer to Specifications in the appropriate section in Group 303.
Cylinder Bore — Taper 1. Measure the cylinder bore at the top and bottom. Verify the cylinder bore is within the wear limit. The difference indicates the cylinder bore taper. Bore the cylinder to the next oversize. For additional information, refer to Specifications in the appropriate section in Group 303.
Piston — Inspection CAUTION: Do not use a caustic cleaning solution or a wire brush to clean the pistons or damage can occur. 1. Clean and inspect the (2) ring lands, (4) skirts, (3) pin bosses, and the (1) tops of the pistons. If wear marks, scores or glazing is found on the piston skirt, check for a bent or twisted connecting rod.
2. Use the Piston Ring Groove Cleaner to clean the piston ring grooves. Make sure the oil ring holes are clean.
Piston — Pin to Bore Diameter WARNING: Cover the end of the pin bore with a hand or shop rag when removing the retainer ring, since it has a tendency to spring out. Wear eye protection.
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01/2003 2003.0 BA Falcon
303-00-12
Engine System — General Information
303-00-12
GENERAL PROCEDURES (Continued) NOTE: Piston and piston pins are a matched set and should not be interchanged. Measure the piston pin bore diameter in two directions on each side. Verify the diameter is within specification. 1. If it is out of specification, install new components as necessary. Refer to the appropriate section in Group 303 for the procedure.
Piston — Ring End Gap 1. Use a piston without rings to push a piston ring in a cylinder to the bottom of ring travel. CAUTION: Use care when fitting piston rings to avoid possible damage to the piston ring or the cylinder bore. CAUTION: Piston rings should not be transferred from one piston to another. NOTE: Cylinder bore must be within specification for taper and out-of-round.
Piston — Diameter 1. Measure the piston skirt diameter 90 degrees from the piston pin at the points indicated. For additional information, refer to Specifications in the appropriate section in Group 303. If it is out of specification, install new components as necessary. Refer to the appropriate section in Group 303 for the procedure.
2. Use a feeler gauge to measure the top piston ring end gap and the second piston ring end gap. For additional information, refer to Specifications in the appropriate section in Group 303.
Piston — Ring-to-Groove Clearance 1. Inspect for a step in the grooves. 2. Measure the piston ring-to-groove clearance. For additional information, refer to Specifications in the appropriate section in Group 303. If out of specification, install new components as necessary. Refer to the appropriate section in Group 303 for the procedure.
Piston — to Cylinder Bore Clearance 1. Subtract the piston diameter from the cylinder bore diameter to find the piston-to-cylinder bore clearance. If the measurement is outside specification, replace the piston, or machine the cylinder block oversize and fit oversize pistons.
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01/2003 2003.0 BA Falcon
303-00-13
Engine System — General Information
303-00-13
GENERAL PROCEDURES (Continued)
Piston — Pin Diameter
Connecting Rod — Bushing Diameter
1. Measure the piston pin diameter in two directions 1. Measure the inner diameter of the connecting rod at the points shown. Verify the diameter is within bushing, if equipped. Verify the diameter is within specification. specification. For additional information, refer to For additional information, refer to Specifications in the appropriate section in Specifications in the appropriate section in Group 303. Group 303. If out of specification, install new components If out of specification, install new components as necessary. Refer to the appropriate section as necessary. Refer to the appropriate section in Group 303 for the procedure. in Group 303 for the procedure.
Connecting Rod — Cleaning
Connecting Rod — Bend
1. Measure the connecting rod bend on a suitable alignment fixture. Follow the instructions of the fixture manufacturer. Verify the bend measurement is within specification. Connecting Rod — Large End Bore For additional information, refer to 1. Measure the bore in two directions. The difference Specifications in the appropriate section in is the connecting rod bore out-of-round. Verify the Group 303. out-of-round is within specification. If out of specification, install new components For additional information, refer to as necessary. Refer to the appropriate section Specifications in the appropriate section in in Group 303 for the procedure. Group 303. If out of specification, install new components as necessary. Refer to the appropriate section in Group 303 for the procedure.
CAUTION: Do not use a caustic cleaning solution or damage to connecting rods can occur.
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01/2003 2003.0 BA Falcon
303-00-14
Engine System — General Information
303-00-14
GENERAL PROCEDURES (Continued) 4. Measure the Plastigage to get the connecting rod bearing journal clearance. The Plastigage should be smooth and flat. A changing width indicates a 1. Measure the connecting rod twist on a suitable tapered or damaged connecting rod or connecting alignment fixture. Follow the instructions of the rod bearing. fixture manufacturer. Verify the measurement is within specification. For additional information, refer to Specifications in the appropriate section in For additional information, refer to Group 303. Specifications in the appropriate section in Group 303. If out of specification, install new components as necessary. Refer to the appropriate section If out of specification, install new components in Group 303 for the procedure. as necessary. Refer to the appropriate section in Group 303 for the procedure.
Connecting Rod — Twist
Roller Follower — Inspection
1. Inspect the roller for flat spots or scoring. If any damage is found, inspect the camshaft lobes and valve tappet for damage.
Valve Rocker Arm/Lash Adjuster Assembly — Inspection
Connecting Rod — Bearing Journal Clearance
1. Inspect the roller for flat spots or scoring, the valve pad for wear or pitting, and the ball socket for smooth motion. Do not disassemble the clip unless replacing a part of the assembly. The clip must be a firm fit on the rocker arm, and replaced if removed. Replace any parts that show significant wear or damage.
NOTE: The crankshaft connecting rod journals must be within specifications to check the connecting rod bearing journal clearance. 1. Remove the connecting rod bearing cap. 2. Position a piece of Plastigage across the bearing surface.
Item 1 2 3
Description Valve rocker arm Retaining clip Lash adjuster
Hydraulic Lash Adjuster Diagnosis 3. Install and tighten to specifications, then remove A suspected faulty lash adjuster can be located by the connecting rod bearing cap. removing the cam cover. Check all the rockers for NOTE: Do not turn the crankshaft during this step. signs of vertical play, or sponginess in the lash adjuster. Rotate the crankshaft so that all rockers are checked with the valve closed. If necessary, operate the engine at idle and try to locate the noise by ear, or use a piece of thin dowel to feel the motion of the valve spring retainer. An indent G37876 en
01/2003 2003.0 BA Falcon
303-00-15
Engine System — General Information
303-00-15
GENERAL PROCEDURES (Continued) will be felt on the valve with the faulty adjuster. Valve — Inspection Air bubbles in the lubricating oil, caused by 1. Inspect the following valve areas: excessively high or low oil level may result in spongy 1. the keeper grooves for burns and wear. lash adjusters. A leak in the oil pick-up tube, or its joint to the oil pump may allow air to be drawn into the 2. the valve face and the edge for pits, grooves lubricating system. or scores. 3. the valve head for signs of burning, erosion, Valve — Stem Diameter warpage and cracking. 1. Measure the diameter of each intake and exhaust 4. the valve head thickness for wear. valve stem at the points shown. Verify the diameter is within specification. For additional information, refer to Specifications in the appropriate section in Group 303. If out of specification, install new components as necessary. Refer to the appropriate section in Group 303 for the procedure.
Item 1 2 3 4
Valve — Stem to Valve Guide Clearance Check the valve stem to valve guide clearance of each valve. With the cylinder head gasket face uppermost, slide a new inlet or exhaust valve as appropriate into the guide to be checked until the end of the stem is flush with the top of the valve guide. Mount a dial indicator on the cylinder head gasket face so that the plunger can be positioned on the edge of the valve head at 90º to the camshaft axis. With the dial indicator in this position and the end of the valve stem flush with the top of the guide, move the valve head from side to side at right angles to the camshaft axis as far as the clearance will allow and note the indicator reading. If the valve head deflection exceeds the specification for inlet or exhaust valves the guide in question is worn excessively and should be replaced.
Description End of stem Keeper grooves Valve head Valve head thickness
Valve — Guide Inner Diameter 1. Measure the inner diameter of the valve guides in two directions where indicated. For additional information, refer to Specifications in the appropriate section in Group 303.
2. If the valve guide is not within specifications, remove the valve guide and install a new valve guide.
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01/2003 2003.0 BA Falcon
303-00-16
Engine System — General Information
303-00-16
GENERAL PROCEDURES (Continued)
Valve — Guide Reaming
Valve — Spring Free Length
1. Use a hand-reaming kit to ream the valve guide.
1. Measure the free length of each valve spring. For additional information, refer to Specifications in the appropriate section in Group 303. If out of specification, install new components as necessary. Refer to the appropriate section in Group 303 for the procedure.
2. Reface the valve seat. 3. Clean the sharp edges left by reaming.
Valve — Spring Installed Length 1. Measure the installed length of each valve spring. For additional information, refer to Specifications in the appropriate section in Valve — Spring Squareness Group 303. 1. Measure the out-of-square on each valve spring. If out of specification, install new components. Turn the valve spring and observe the space Refer to the appropriate section in Group 303 between the top of the valve spring and the for the procedure. square. Install a new valve spring if out of square. Refer to the appropriate section in Group 303 for the procedure.
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01/2003 2003.0 BA Falcon
303-00-17
Engine System — General Information
303-00-17
GENERAL PROCEDURES (Continued)
Valve — Spring Strength Special Tool(s) Valve/Clutch Spring Tester 303-006 (TOOL-6513-DD) or equivalent
1. Check the valve head and seat. Check valve angles. Check margin width. For additional information, refer to Specifications in the appropriate section in Group 303. Be sure margin width is within specification.
1. Use a Valve/Clutch Spring Tester to check the valve spring for correct strength at the specified valve spring length. For additional information, refer to Specifications in the appropriate section in Group 303. If out of specification, install new components as necessary. Refer to the appropriate section in Group 303 for the procedure.
2. Inspect for abnormalities on the valve face and seat.
Valve — Seat Width
Valve — Seat Inspection Valve and Seat Refacing Measurements
1. Measure the valve seat width. If necessary, grind the valve seat to specification. Measure the intake valve seat width. Measure the exhaust valve seat width. Recheck the valve spring installed length after the seats have been ground. For additional information, refer to Specifications in the appropriate section in Group 303.
CAUTION: After grinding valves or valve seats, check valve clearance.
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01/2003 2003.0 BA Falcon
303-00-18
Engine System — General Information
303-00-18
GENERAL PROCEDURES (Continued)
Valve — Seat Runout
1. Use a slide hammer or tools suitable to remove the cylinder block core plug.
1. Use the Valve Seat Runout Gauge to check valve seat runout.
Cylinder Bore — Cleaning CAUTION: If these procedures are not followed, rusting of the cylinder bores may occur. 1. Clean the cylinder bores with soap or detergent and water. 2. Thoroughly rinse with clean water and wipe dry with a clean, lint-free cloth. 3. Use a clean, lint-free cloth and lubricate the cylinder bores. Use Super Premium SAE Motor Oil meeting Ford specification.
2. Inspect the cylinder block plug bore for any damage that would interfere with the correct sealing of the plug. Cup-Type CAUTION: Use care during this procedure so as not to disturb or distort the cup sealing surface. CAUTION: When installed, the flanged edge must be below the chamfered edge of the bore to effectively seal the bore. 1. Use a tool suitable to seat the cup-type cylinder block core plug.
Cylinder Block — Core Plug Replacement Special Tool(s) Impact Slide Hammer 100-001 (T50T-100-A)
Expansion-Type CAUTION: Do not contact the crown when installing an expansion-type cylinder block core plug. This could expand the plug before seating and result in leakage.
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01/2003 2003.0 BA Falcon
303-00-19
Engine System — General Information
303-00-19
GENERAL PROCEDURES (Continued) 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.
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
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Item 1 2 3 4 5 6
Description cratering-fatigue failure spot glazing-improper seating scratching-dirty base exposed-poor lubrication both edges worn-journal damaged one edge worn-journal tapered or bearing not seated
01/2003 2003.0 BA Falcon
303-01a-1
Engine — I6
303-01a-1
SECTION : 303-01a Engine — I6 VEHICLE APPLICATION : 2003.0 BA Falcon CONTENTS
PAGE
SPECIFICATIONS Specifications .......................................................................................................................303-01a-3 DESCRIPTION AND OPERATION Engine — I6 .........................................................................................................................303-01a-7 DIAGNOSIS AND TESTING Engine ................................................................................................................................303-01a-12 Inspection and Verification ..............................................................................................303-01a-12 Symptom Chart ................................................................................................................303-01a-12 Component Tests .............................................................................................................303-01a-13 GENERAL PROCEDURES Cylinder Head Inspection ...................................................................................................303-01a-16 Valve Inspection .................................................................................................................303-01a-16 Valve Measurement ..........................................................................................................303-01a-17 Valve Guide Inspection .....................................................................................................303-01a-17 Valve Guide Replacement ................................................................................................303-01a-17 Valve Seat Inspection/Repair .............................................................................................303-01a-18 Valve Spring Inspection .....................................................................................................303-01a-18 Camshaft End Play Inspection ...........................................................................................303-01a-19 Camshaft Inspection ..........................................................................................................303-01a-19 Camshaft Journal Clearance - Plastigauge Method ..........................................................303-01a-20 Roller Follower Inspection ..................................................................................................303-01a-20 Lash Adjuster Bore Inspection ...........................................................................................303-01a-20 Cylinder Block Inspection/Repair .......................................................................................303-01a-20 Cylinder Bore - Taper .........................................................................................................303-01a-21 Cylinder Bore — Out-of-Round ..........................................................................................303-01a-21 Piston Inspection ................................................................................................................303-01a-21 Piston Clearance Inspection/ Repair ..................................................................................303-01a-21 Piston Ring Clearance Inspection ......................................................................................303-01a-22 Piston Pin Clearance Inspection ........................................................................................303-01a-22 Crankshaft Inspection ........................................................................................................303-01a-23 Crankshaft Main Bearing Clearance ..................................................................................303-01a-23 Crankshaft End Play Inspection/Repair .............................................................................303-01a-24 Connecting Rod Inspection ................................................................................................303-01a-24 Connecting Rod Big End Bearing Clearance .....................................................................303-01a-24 Connecting Rod Side Clearance Inspection ......................................................................303-01a-25 Piston and Connecting Rod Inspection ..............................................................................303-01a-25 Timing Chain Elongation ....................................................................................................303-01a-25 IN-VEHICLE REPAIRS Oil Filter ..............................................................................................................................303-01a-26 Oil Level Indicator & Tube .................................................................................................303-01a-26 Cylinder Head Temperature Sensor .................................................................................303-01a-26 Cam Position Sensor .........................................................................................................303-01a-26 Crankshaft Position Sensor ...............................................................................................303-01a-27 01/2003 2003.0 BA Falcon
303-01a-2
Engine — I6
303-01a-2
(Continued) Oil Pressure & Oil Temperature Sensor ............................................................................303-01a-27 Combustion Knock Sensor ................................................................................................303-01a-27 Exhaust Gas Oxygen Sensor .............................................................................................303-01a-27 Temperature - Manifold Air Pressure Sensor ....................................................................303-01a-27 Crankshaft Vibration Damper .............................................................................................303-01a-28 Crankshaft Front Oil Seal ...................................................................................................303-01a-28 Crankshaft Rear Oil Seal ...................................................................................................303-01a-28 Flywheel/Drive Plate/Clutch Pilot Bearing ..........................................................................303-01a-29 Clutch Pilot Bearing ...........................................................................................................303-01a-29 Water Pump .......................................................................................................................303-01a-29 Electronic Throttle Body and Intake Manifold ....................................................................303-01a-30 Broadband Throttle Plate ...................................................................................................303-01a-32 Broadband Throttle Shaft Vacuum Motor ..........................................................................303-01a-32 Exhaust Manifold Assembly ...............................................................................................303-01a-32 Exhaust Manifold - Front and Rear ....................................................................................303-01a-33 Oil Control Valve Seal ........................................................................................................303-01a-33 Valve Cover .......................................................................................................................303-01a-34 Ignition Coils/Wiring Loom .................................................................................................303-01a-36 Camshafts, VCT Phaser, Oil Control Valves, & OCV Filters .............................................303-01a-37 Camshaft Removal ............................................................................................................303-01a-38 Camshaft and VCT Phasers ..............................................................................................303-01a-38 Camshaft Installation .........................................................................................................303-01a-40 Timing Chain Tensioner .....................................................................................................303-01a-41 VCT Phaser ......................................................................................................................303-01a-41 Rocker Arm, Lash Adjuster, Valve Spring and Valve Stem Seal ......................................303-01a-42 Rocker Arm and Lash Adjuster ..........................................................................................303-01a-43 Valve spring and Valve Stem Seal ....................................................................................303-01a-43 Front Cover ........................................................................................................................303-01a-44 Camshaft Drive ..................................................................................................................303-01a-46 Timing Chain Tensioner Release .......................................................................................303-01a-46 Cylinder Head ....................................................................................................................303-01a-47 Engine ................................................................................................................................303-01a-48 Engine Mounting ................................................................................................................303-01a-50 Engine Oil Pan ...................................................................................................................303-01a-50 Oil Pump Pickup Tube .......................................................................................................303-01a-51 Oil pump .............................................................................................................................303-01a-52 Piston and Rod Assembly ..................................................................................................303-01a-52 Main bearings/Crankshaft ..................................................................................................303-01a-53 Rear Main Bearing Cap Assembly .....................................................................................303-01a-54 Piston Ring .........................................................................................................................303-01a-54 DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES Key Retainer — Valve Spring ............................................................................................303-01a-55 Valve Stem Seal ................................................................................................................303-01a-55 Piston and Connecting Rod Assembly ..............................................................................303-01a-56 Piston and Connecting Rod Disassembly and Assembly ..................................................303-01a-56 Connecting Rod Bolt .........................................................................................................303-01a-56
01/2003 2003.0 BA Falcon
303-01a-3
Engine — I6
303-01a-3
SPECIFICATIONS Lubricants and Sealants Description Engine Oil 10W-30 ILSAC - GF2 Engine Oil 15W-40 API SG/CE Silicone Sealant (Loctite 5900 or similar) Anti Seize compound (Loctite 767 or similar) Rubber Grease Synthetic Grease (Dupont Krytox) General Specifications Description Displacement Number of cylinders Compression Ratio DOHC VCT LPG Power at specified rpm(DIN) DOHC VCT LPG Torque at specified rpm (DIN) DOHC VCT LPG Bore/Stroke Firing Order Oil Pressure - Hot @ 2000 rpm Spark Plug - I6 DOHC VCT LPG Compression Pressure at Maximum cranking speed DOHC VCT LPG Idle Speed Manual Trans (A/C off) DOHC VCT LPG Auto trans in Neutral DOHC VCT LPG Auto Trans in Drive DOHC VCT LPG
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Specification WSS M2C910 2 (I6 DOHC VCT) WSE M2C905 A (I6 LPG) WSS M4G323 A7 ESE FM99C100 A ESZ M1C223 A ESF M1C229 A
Specification 3984cc In line 6 9.7:1 10.7:1
182 kW @ 5000 156 kW @ 4750
380 Nm @ 3250 372 Nm @ 3000 92.26mm / 99.31mm 1-5-3-6-2-4 230kPa min
K16SR14 K20SR11
1010 Kpa 1110 Kpa
700 ± 50 rpm 700 ± 50 rpm 660 ± 50 rpm 700 ± 50 rpm 580 ± 50 rpm 700 ± 50 rpm
Description Specification Intake Manifold Vacuum @ Idle rpm DOHC VCT 60 kPa @ Idle in Neutral LPG 60 kPa @ Idle in Neutral Cylinder Head/Valve Train Combustion Chamber 65.5 - 66.5cc Volume Joint face flatness 0.08mm in 150mm or 0.18mm overall Cylinder head joint face 2.5 RZ (Din) @2.5 surface finish cut-off, Wt <10.0, Mr 68% min @ 2.0 um Minimum Cylinder head Std - 0.3 mm deck height Valve seat width- Intake 1.0mm - 1.4mm Valve seat width-Exhaust 1.25mm - 1.75mm Valve seat angle 44.75º Valve seat runout 0.04mm Valve stem to guide 0.020mm - 0.069mm clearance Valve guide parent bore 9.975mm - 10.025mm diameter Valve guide outside 10.028mm - 10.039mm diameter Valve guide inside 6.015mm - 6.044mm diameter Valve head diameter35mm intake Valve head diameter 32mm exhaust Gauge Diameters Valve face runout 0.05mm Valve face angle 45.5º Valve stem diameter (In 5.975mm - 5.995mm & Ex) Valve seat insert recess 35.07mm - 35.12mm diameter (In) Valve seat insert recess 32.37mm - 32.42mm diameter (Ex) Valve seat insert outer 35.192mm - 35.208mm diameter (In) Valve seat insert outer 32.492mm - 32.508 mm diameter (Ex) Valve spring free length 50.0 mm Valve spring installed 280N / 37.8 mm load/length Valve spring compressed 550N / 26.8mm load/length Valve spring allowable 50N @ 26.8mm load loss
01/2003 2003.0 BA Falcon
303-01a-4
Engine — I6
303-01a-4
SPECIFICATIONS (Continued) Description Valve spring - out of square Rocker arm ratio Hydraulic Lash Adjuster diameter Lash adjuster bore in cylinder head Collapsed Lash adjuster clearance at cam Camshaft Lobe lift (In & Ex) Valve lift(In & Ex) Camshaft end play Camshaft journal diameter Camshaft Journal max out of round Cylinder head bearing diameter Journal to bearing clearance Service Limit Valve Timing
Specification 2º 2.04 13.972mm - 13.984mm 13.990mm - 14.007mm 0.5mm - 1.1mm (desired)
5.39mm 11.00mm 0.1mm - 0.3mm 34.928mm - 34.968mm Front 29.928mm - 29.968mm Remainder 0.015mm 34.987mm - 35.012mm Front 29.987mm - 30.012mm Remainder 0.019mm - 0.084mm 0.120mm Engine Stopped, VCT Phasers Fully Advanced & VCT Locking Pins Engaged 27.5º BTDC 43.5º ABDC 68.5º BBDC 2.5º BTDC 97.5º ATDC
Intake Opens Intake Closes Exhaust Opens Exhaust Closes Intake Cam Centre-line (Maximum Lift) Exhaust Cam Centre-line 126.5º BTDC (Maximum Lift) Timing Chain Maximum 0.35 % Elongation Cylinder Block Head gasket thickness 0.25mm at body, 0.3mm at cylinder bore Main bearing bore 71.517mm - 71.541mm diameter Cylinder bore diameter 92.25mm - 92.31mm Std 92.75mm - 92.77 0.5mm O/S 93.25mm - 93.27 1.0mm O/S Out of round limit 0.025mm Out of round service limit 0.125mm G99770 en
Description Taper service limit Crankshaft Main bearing journal diameter Connecting rod journal diameter Crankshaft free end play Service Limit Connecting rod bearingsclearance to crankshaftdesired Connecting rod bearingsclearance to crankshaftservice limit Main bearings- clearance to crankshaft-desired Main bearings- clearance to crankshaft- service limit Connecting Rod Small end bore diameter DOHC VCT & LPG Big end bore diameter Length (centre to centre) Alignment ( bore to boremax difference)Twist Bend Side clearance (assembled to crank) Standard Side clearanceService limit Piston Piston diameter Piston to bore clearance (new) Piston to bore clearanceservice limit Intake Manifold Vacuum @ Idle rpm DOHC VCT LPG Pin bore diameter (piston) DOHC, VCT & LPG Ring groove width - Top Compression Ring groove width Lower Compression Ring groove width - Oil Ring
Specification 0.25mm 67.481mm - 67.505mm 53.93mm - 53.95mm 0.10mm - 0.20mm 0.30mm 0.02mm - 0.04mm 0.06mm 0.02mm - 0.04mm 0.06mm
23.132mm - 23.144mm 56.871mm - 56.891mm 153.78mm - 153.92mm 0.20mm 0.10mm 0.09mm - 0.27mm 0.36mm
92.24mm - 92.31mm 0.020mm interference to 0.030mm clearance 0.09mm
60 kPa @ Idle in Neutral 60 kPa @ Idle in Neutral
23.173mm - 23.178mm 1.22mm - 1.24mm 1.52mm - 1.54mm 3.01mm - 3.03mm
01/2003 2003.0 BA Falcon
303-01a-5
Engine — I6
303-01a-5
SPECIFICATIONS (Continued) Description Specification Piston pin length 64.50mm - 65.00mm Piston pin diameter DOHC VCT, LPG 23.157mm - 23.162mm Pin to piston clearance DOHC VCT & LPG 0.014mm - 0.019mm Ring groove clearance0.03mm - 0.075mm Top Compression New Ring groove clearance0.15mm Top Compression Service limit Ring groove clearance0.03mm - 0.075mm 2nd Ring New Ring groove clearance - 0.15mm 2nd Ring Service limit Oil ring groove clearance Nil - new Oil ring groove clearance 0.20mm - service limit Installed piston ring gap - 0.21mm - 0.36mm Top Compression - New Installed piston ring gap - 0.45mm Top CompressionService limit Installed piston ring gap- 0.35mm - 0.51mm 2nd Ring - New Installed piston ring 0.60mm gap-2nd Ring - service limit Oil ring (rail) gap- new 0.3mm - 0.9mm Oil ring (rail) gap-service 1.0mm limit Lubrication system Oil capacity - Initial Fill 7.0L (Dry engine) Oil Change without Filter 5.8L Oil Change with Filter 6.8L Torque Specifications Oil threads with engine oil. Do not oil threads that require thread sealant or thread locker. Description Main Bearing Cap bolts Cylinder Head Bolts
Oil Pan to Cylinder block/front cover Oil Pan to main bearing cross bolts
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Nm 85 Step 1: 40 Nm Step 2: Rotate 90º clockwise 9 58 (Apply thread sealant)
Description Oil Pan Rear Face
Oil Pan Drain Plug Intake manifold- Upper to Lower
Intake Manifold- Lower to Cylinder head
Nm Flush or 0.25mm forward of rear face of block 26 16 (Apply thread locker) 20 (Apply thread locker)
Intake Manifold Strut (Upper) To Upper Manifold
16 (Delete thread lock) To Cylinder Head 16 Intake Manifold Strut (Lower) To Lower Manifold 20 (Apply thread locker) To Cylinder Block 20 To Engine Mt. Support 50 Fuel Rail to Intake Manifold 20 Intake Manifold Butterfly Shaft Actuator 20 Assembly Intake Manifold Vacuum Connectors 4 (Apply thread sealant) Intake Manifold Pressure/Temperature 3 Sensor Electronic Throttle Body to Upper 10 Intake Manifold (Apply thread locker) Exhaust Manifold to Cylinder Head 27 Exhaust Manifold Heat Shield - Lower 20 Exhaust Manifold Slip Joint Stud 15 Nut 23 Flywheel/Flex Plate to Crankshaft 75 Clutch Pressure Plate to Flywheel 25 Manual Flywheel Housing to Block 50 Oil Pump to Cylinder Block 10 Oil Pump Pickup Tube to Oil Pump 10 Oil Pump Pickup Tube to Main Bearing 20 Bolt Oil Filter Adaptor to Cylinder Block 17 01/2003 2003.0 BA Falcon
303-01a-6
Engine — I6
303-01a-6
SPECIFICATIONS (Continued) Description Oil Filter to Cylinder block
Oil Pressure Sensor
Oil Temperature Sensor
Knock Sensor to Cylinder Block
Timing Cover to Cylinder Block Crankshaft Position Sensor to Timing Cover Thermostat Housing to Cylinder Head
Water Outlet to Thermostat Housing Heater Tube to Thermostat Housing Heater Tube to Block (Exhaust side) Water Pump to Cylinder Block Engine Mount Bracket to Cylinder Block Engine Mount to Engine Mount Bracket Power Steering Brackets to Cyl. Head and Cylinder Block Alternator Bracket(rear) to Cylinder Block Spark Plugs Variable Cam Timing Unit to Camshaft
Spark Plug Cover to Rocker Cover Brake Hose Clip to Spark Plug Cover Cam Cover to Cylinder Head - Front two long bolts
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Nm With oiled gasket, hand tighten until gasket contacts block face, tighten a further ¾ turn 20 (Apply thread sealant) 20 (Apply thread sealant) 20 (Apply thread locker) 20 9 20 (Apply thread locker) 20 20 27 20 50 (Apply thread locker) 102 43
Description Cam Cover to Cylinder Head - Six short bolts Oil Control Valve Seals to Cam Cover Cam Caps to Cylinder Head VCT Oil Control Valves to Cam Caps Camshaft position sensor to cylinder head Cylinder Head Temperature sensor to Cylinder Head Timing Chain Fixed Chain Guide to Cylinder Block and Cylinder Head Timing Chain Tensioner to Cylinder Head Timing Chain Guide Pivot Bolt to Oil Pump Timing Chain Guide Pivot Nut Crankshaft Vibration Damper/Front Pulley to Crankshaft Connecting Rod Cap to Connecting rod
Nm 10 (Apply thread locker) 7 10 9 9 15 20 9 27 9 125 Step 1: 25 Nm Step 2: 90º clockwise.
25 17 Step 1: 20 Nm Step 2: Rotate 40º clockwise 8 3 13
01/2003 2003.0 BA Falcon
303-01a-7
Engine — I6
303-01a-7
DESCRIPTION AND OPERATION
Engine — I6 The 4.0L I6 is a four valve per cylinder, dual overhead camshaft engine with individual intake and exhaust variable cam timing units. A distributorless ignition system with individual coils mounted above the spark plugs is used. The cylinder block is cast iron, and is attached to an aluminium oil pan with cross-bolted main bearing caps to increase rigidity. The oil pump is mounted on the nose of the crankshaft, and a single stage roller chain drives the hollow camshafts. Hydraulic lash adjusters and roller finger followers activate the valves. An electronic throttle body is employed together with a variable length intake manifold. Petrol, LPG and Turbocharged versions are also available.
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01/2003 2003.0 BA Falcon
303-01a-8
Engine — I6
303-01a-8
DESCRIPTION AND OPERATION (Continued) Upper Engine Components
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01/2003 2003.0 BA Falcon
303-01a-9
Engine — I6
303-01a-9
DESCRIPTION AND OPERATION (Continued) Upper Engine Components Item Description 1 Coil and Boot Assembly 2 Spark Plug 3 Cap - Camshaft intake bridge - Rear 4 Camshaft - Intake 5 Cylinder head temperature sensor 6 Engine lifting eye, LH, FRT 7 Sensor Assembly camshaft timing 8 Head gasket 9 Sensor Assembly camshaft timing 10 Cylinder head 11 Lash adjuster assembly 12 Clip 13 Engine lifting eye, RH, RR 14 Valve - Inlet 15 Valve - Exhaust 16 Insert - Cylinder Head 17 Bushing - Valve guide 18 Seal - Valve stem 19 Spring - Valve 20 Retentioner - Valve spring 21 Key - Valve spring retention 22 Rocker arm 23 Cam timing assembly - Engine variable 24 Filter - Engine oil 25 Top timing chain guide 26 Cap - Camshaft exhaust bridge, FRT 27 Housing and Valve assembly camshaft variable timing 28 Gasket - Valve rocker arm cover 29 Plate - Gasket valve rocker arm cover 30 Gasket - Rocker arm cover 31 Gasket - Spark plug 32 Cover - Valve rocker arm 33 Gasket - Spark plug cover 34 Spark plug cover assembly 35 Oil filler cap gasket 36 Oil filler cap
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01/2003 2003.0 BA Falcon
303-01a-10
Engine — I6
303-01a-10
DESCRIPTION AND OPERATION (Continued) Lower Engine Components
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01/2003 2003.0 BA Falcon
303-01a-11
Engine — I6
303-01a-11
DESCRIPTION AND OPERATION (Continued) Lower Engine Components Item Description 1 Gasket - Front Cover RH 2 Timing Chain Tensioner 3 Lever arm assembly - Timing chain tensioner 4 Timing chain 5 Guide assembly - Timing chain 6 Oil pump 7 Oil pump pick-up/ Screen 8 Sensor Assembly Engine Spark intensity (knock sensor) 9 Flywheel assembly 10 Cover - Flywheel housing 11 Filter assembly - Oil 12 Piston compression ring, Upper 13 Piston compression ring, Lower 14 Piston Oil control, Ring 15 Piston 16 Connecting rod 17 Bearing upper - Connecting rod (Big End) 18 Bearing lower - Connecting Rod (Big End) 19 Cap - Connecting rod 20 Pin - Piston 21 Cover - Flywheel 22 Plug - Oil pan drain 23 Pan - Oil 24 Baffle - Oil pan 25 Seal - Oil pan 26 Crank windage oil baffle 27 Brace - Main bearing cap support 28 Crankshaft main bearing caps 29 Crankshaft main bearing - Lower 30 Crankshaft 31 Crankshaft main bearings - Upper 32 Cylinder block 33 Tube - Oil lever indicator 34 Oil lever indicator 35 Damper assembly - Crankshaft 36 Crank sensor 37 Crankshaft sprocket / Tone wheel 38 Switch assembly - Oil pressure 39 Seal - Oil, Cylinder front cover 40 Cover - Cylinder front
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01/2003 2003.0 BA Falcon
303-01a-12
Engine — I6
303-01a-12
DIAGNOSIS AND TESTING
Engine Inspection and Verification Since diagnosis and testing actually begins when repairs are taken on, the following procedure is recommended. 1. Verify the customer concern by operating the system. 2. Visually inspect for obvious signs of mechanical damage or electrical damage. If the concern cannot be reproduced, carry out a road test and/or visual check with the aid of the following table.
Visual Inspection Chart Mechanical Coolant leaks Oil leaks Leaks in the fuel system Visibly damaged or worn parts Loose or missing nuts or bolts 3. If an obvious cause for an observed or reported concern is found, correct the cause (if possible) before proceeding to the next step. 4. If the concern is not visually evident, verify the symptom and refer to the Symptom Chart.
Symptom Chart Condition Engine will not crank
Engine cranks but will not start
Engine slow/difficult to start
Engine misfires
Insufficient Power
Excessive Fuel Consumption
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Source
Action
Faulty Starter System
Refer Section 303-06 Starting System.
Transmission lever not in P or N.
Place in P.
Seized engine
Replace engine.
Coolant in cylinders
Replace engine.
Ignition system inoperative
Refer section 303-06 Starting System
Fuel system inoperative
Refer section 303-04
LPG engine requires "key-off" to regain starting enrichment after initial failed start. Variable Cam Timing (VCT) unit lock pin not engaged at start.
Key-off LPG engine if 1st starting attempt failed.
VCT unit Oil Control Valve jammed.
Clean Oil Control Valve. Refer to Valve Cover Section.
Fail Safe Cooling in operation
Repair coolant system
Ignition system faulty
Refer Section 303-06
Fuel system faulty
Refer Section 303-04
Restricted exhaust system
Inspect Exhaust system
Intake vacuum leak
Carry out Intake Manifold Vacuum test in this section
Burned valve/poor seating
Perform a compression check
Broken valve spring
Inspect valve springs
Head gasket leakage
Inspect head gasket
Piston damage
Perform cylinder compression check
Broadband Intake Manifold not operative
Check switching occurs at 3800 rpmrefer Section 303-14.
VCT unit(s) not operative
Refer Section 303-14.
Electronic Throttle Control Unit faulty
Refer Section 303-14.
Green(low mileage) engine/vehicle City/stop-start driving
Establish accurate fuel consumption using full-to-full method.
Faulty Fuel System
Refer Section 303-04
01/2003 2003.0 BA Falcon
303-01a-13
Engine — I6
303-01a-13
DIAGNOSIS AND TESTING (Continued) Condition Excessive Oil Consumption
Engine leaks oil
Engine Noise
Source
Action
Green engine
Recheck at 15,000 km
Valve stem seal damaged or missing.
Inspect the seals.
Oil leakage
Repair oil leakage
Incorrect Oil viscosity
Drain and fill with correct oil
Piston/rings/cylinder worn or damaged
Repair. Refer Section 303-00.
Diluted oil
Determine cause. Correct. Drain and refill oil.
Crankcase overfilled
Adjust oil level.
Faulty PCV Valve
Check and replace.
Joint fasteners loose
Tighten to specification.
Out of position or damaged seal/RTV sealant omitted/inadequate.
Pressurise crankcase to 35kPa. Apply soapy water, check for leak. Inspect and replace.
Worn/out of position crank rotary seal
Inspect and replace.
Porous casting
Clean suspect area, Perform pressurized crankcase check. Run engine, check for leak. Replace casting.
Sealant in Crank Damper keyway omitted or inadequate
Replace sealant.
Sealant between Rear Main Cap and block omitted or inadequate
Perform pressurized crankcase leak check. Repair.
Excessive Crankshaft Main bearing or big end clearance. Excessive Crankshaft end play Excessive camshaft end play Excessive piston to bore clearance/damaged piston/bent connecting rod. Excessive hydraulic valve adjuster clearance Worn cam lobe or roller finger follower Excessive valve guide clearance Broken valve spring Loose timing chain Loose crank damper Worn/noisy Front End Accessory Drive Belt Worn/noisy tensioner/idler pulley Exhaust gas leakage
Inspect and repair. Refer relevant Section.
Soft or spongy lash adjusters
Check for excessively low or high oil level. Air leak in suction side of oil pump.
Carbon in combustion chamber/top land of piston
Remove carbon using proprietary carbon removal treatment
Component Tests
Pressurised leak check
Engine Oil Leaks
1. Clean the engine with a suitable cleaning fluid to remove all traces of oil. 2. Block off the line to the PCV valve. 3. Apply a regulated air supply line to the fresh air makeup point on the rocker cover. 4. Pressurise the crankcase to 35 kPa.
NOTE: Before installing new gaskets or oil seals, make sure that the fault is clearly established. If the oil leak cannot be identified clearly by a visual inspection, carry out a pressurized crankcase leak check.
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01/2003 2003.0 BA Falcon
303-01a-14
Engine — I6
303-01a-14
DIAGNOSIS AND TESTING (Continued) 5. Check for air leaks by washing the suspect area with a solution of soapy water and watching for bubbles. 6. Repair all leaks as necessary.
General Remarks NOTE: Removing fuses and disconnecting electrical components causes the powertrain control module (PCM) to log an error message. After the measurements have been carried out this error message should be cleared from memory by connecting to WDS. The compression pressure should be checked with the engine at operating temperature.
If the reading stays the same, the cause is either damaged valve seats, or valve stem seals. If the measurements for two adjacent cylinders are both too low, then it is very likely that the cylinder head gasket between the cylinder is burnt through. This can also be recognized by traces of engine oil in the coolant and/or coolant in the engine oil.
Excessive Engine Oil Consumption
The amount of oil an engine uses will vary with the way the vehicle is driven in addition to normal engine-to-engine variation. This is especially true during the first 15,000 km when a new engine is being broken in or until certain internal components become conditioned. Vehicles used in heavy-duty operation may use more oil. The following are examples of Check The Compression Pressure heavy-duty operation: trailer towing applications WARNING: On manual transmissions, shift the transmission into neutral. On automatic severe loading applications transmission vehicles, select ’’P’’. Failure to sustained high speed operation follow these instructions may result in personal Engines need oil to lubricate the following internal injury. components: 1. Remove the fuel pump relay. cylinder block cylinder walls 2. Start the engine and run for a few seconds, then pistons and piston rings stall. intake and exhaust valve stems 3. Remove the spark plugs. intake and exhaust valve guides 4. Install an adaptor and compression tester. all internal engine components 5. Install an auxiliary starter switch in the starting When the pistons move downward, a thin film of oil is circuit. With the ignition switch OFF, use the left on the cylinder walls. As the vehicle is operated, auxiliary starter switch to crank the engine a minimum of five compression strokes, and record some oil is also drawn into the combustion chambers past the intake and exhaust valve stem seals and the highest reading. Note the approximate number of compression strokes required to obtain burned. the highest reading. The following is a partial list of conditions that can affect oil consumption rates: 6. Repeat the test on each cylinder, cranking the engine approximately the same number of engine size compression strokes. operator driving habits 7. Install the components in reverse order, observing ambient temperatures the specified tightening torques. quality and viscosity of oil 8. Reset the PCM fault memory. Operation under varying conditions can frequently be Interpretation of the Results misleading. A vehicle that has been run for several thousand kilometers on short trips or in cold ambient The indicated compression pressure is considered to temperatures may have consumed a ’’normal’’ be within specification if the lowest reading cylinder is amount of oil. However, when checking the engine oil within 75% of the highest reading. level, it may measure up to the full mark on the oil level indicator due to dilution (condensation and fuel) CAUTION: If engine oil is sprayed into the in the engine crankcase. If the vehicle is then driven combustion chamber, run the engine at 2000rpm at high speeds on a highway where the condensation for about 15 minutes (in order to burn the oil and and fuel boil off, the next time the engine oil is prevent damage to the catalytic converter) after checked it may appear that a litre of oil was used in a carrying out the measurement. relatively short distance. If the measurement on one or more cylinders is Make sure the selected engine oil meets the Ford significantly lower than the specified value, spray specification and the recommended API performance some engine oil into the combustion chamber and category ’’SJ/CF’’ and SAE viscosity grade as shown repeat the compression measurement. in the vehicle’s Owner’s Manual. It is also important If the reading greatly improves, the piston rings are that the engine oil is changed at the intervals damaged. specified for the typical operating conditions. G99772 en
01/2003 2003.0 BA Falcon
303-01a-15
Engine — I6
303-01a-15
DIAGNOSIS AND TESTING (Continued) Oil consumption Test The following diagnostic procedure is used to determine the source of excessive oil consumption. NOTE: Oil use is normally greater during the first 15,000 km of service. As mileage increases, oil use decreases. High speed driving, towing, high ambient temperature and other factors may result in greater oil use. 1. Define excessive consumption such as the number of kilometers driven per litre of oil used. Also determine customer’s driving habits, such as sustained high speed operation, towing, extended idle and other considerations. 2. Verify that the engine has no external oil leaks as described in the Engine Oil Leaks section. 3. Verify that the engine has the correct oil level. 4. Verify that the engine is not being run in an overfilled condition. Check the oil level at least five minutes after a hot shutdown with the vehicle parked on a level surface. 5. Carry out an Oil Consumption Test: 1. For a 4.0L I6 engine, drain the engine oil and refill the engine. Run for 10 minutes, and allow the engine to stand for 5 minutes to allow the oil to drain to the crankcase. 2. Top up the oil level exactly to the full mark. Allow to stand for 5 minutes and re-check. NOTE: For engines other than the 4.0L I6, refill the engine with one litre less oil than specified. Run the engine for 10 minutes and allow to stand for 5 minutes. Clean the dipstick and scribe a line on the back face of the dipstick blade corresponding with this level, then reinsert. Add exactly 1 litre of oil to the engine. Run for 5 minutes and allow to stand for 5 minutes. Mark the new level on the back of the dipstick. This should correspond closely to the FULL mark. 3. Record the vehicle’s odometer reading. 4. Instruct the customer to drive the vehicle as usual and: Check the oil level regularly at intervals of 250 km. Return to the service point when the oil level drops below the ADD mark on the oil dipstick. Add only full litres of the same oil in an emergency. Note the mileage at which the oil is added. 5. Check the oil level under the same conditions and at the same location as in steps 1-3. 6. Measure the distance from the full mark to the current oil level on the oil dipstick and calculate the oil usage based on a volume of G99772 en
6. 7. 8. 9.
10. 11.
1.0 litres used for 10mm distance below the FULL mark for the 4.0L I6 engines. For engines employing the alternate method of marking the dipstick with levels corresponding to a volume difference of 1 litre, note the distance the new oil level is below the Top scribed mark and divide this by the distance between the original two scribed marks. This gives the volume of oil in litres used during the test. 7. Divide the distance travelled (kilometres) during the test by the amount of oil used (litres) to produce the oil consumption in kilometres per litre. 8. If the oil consumption is unacceptable go to Step 9. Check the positive crankcase ventilation (PCV) system. Make sure the system is not plugged. Check for plugged oil drain-back holes in the cylinder head and cylinder block. If the condition still exists after carrying out the above tests go to Step 9. Carry out a cylinder compression test as outlined in the Compression Test section. This can help determine the source of oil consumption such as valves, piston rings or other areas. Check valve guides for excessive guide clearance. Install new valve stem seals if required. Worn or damaged internal engine components can cause excessive oil consumption. Small deposits of oil on the tips of the spark plugs can be a clue to internal oil consumption.
Intake Manifold Vacuum Test Bring the engine to normal operating temperature. Connect a vacuum gauge or equivalent to the intake manifold. Run the engine at the specified idle speed. The vacuum gauge should read between 51-74 kPa depending upon the engine condition and the altitude at which the test is carried out. Subtract 4.0 kPa from the specified reading for every 300m of elevation above sea level. The reading should be steady. Adjust the gauge damper control (where used) if the needle is fluttering rapidly. Adjust damper until needle moves easily without excessive flutter.
01/2003 2003.0 BA Falcon
303-01a-16
Engine — I6
303-01a-16
GENERAL PROCEDURES
Cylinder Head Inspection
6. Measure the manifold contact surface distortion as shown.
WARNING: Continuous exposure with USED engine oil has caused skin cancer in laboratory mice. Protect your skin by washing with soap and water immediately after this work. 1. Conduct a dye penetrant (or similar) crack test. Replace the cylinder head if necessary. 2. Inspect for the following and repair if necessary. 1. Sunken valve seats 2. Excessive camshaft bearing clearance and end play 3. Excessive lash adjuster bore size 3. Measure the cylinder head for distortion. This can be achieved by using a straight edge and feeler gauge along the horizontal and vertically aligned Maximum distortion 0.15mm bolt holes on the shaded surface. 7. If the distortion exceeds the specification, grind 4. Repeat the procedure along the diagonal from the the surface. top left bolt hole to the bottom right bolt hole and along the diagonal from the top right bolt hole to Maximum grinding 0.20mm the bottom left bolt hole.
Valve Inspection Inspect the following valve areas: 1. The valve tip, for pitting and wear. 2. The keeper grooves, for burns and wear. 3. The stem, for wear, scuffing and bending. 4. The valve head, for burning, cracks and pitting of the seat. 5. The valve head thickness.
Maximum distortion
0.18mm lengthways or 0.075mm in 150mm transversely
5. If the cylinder head distortion exceeds the maximum, repair by grinding the joint face or replace the cylinder head. Maximum joint face machining Minimum surface combustion chamber volume
G99773 en
0.3mm 64.0cc
Item 1 2 3 4 5
Description Valve tip Keeper grooves Stem Valve head Valve head thickness
01/2003 2003.0 BA Falcon
303-01a-17
Engine — I6
303-01a-17
GENERAL PROCEDURES (Continued)
Valve Measurement 1. Measure the valve head margin thickness of each valve. Replace the valve if necessary.
Standard Inner Diameter Maximum diameter Margin thickness (min)
IN: 1.1mm EX: 1.1mm
2. Measure the stem diameter of each valve in X and Y directions at the three points (A, B, and C) shown. Replace the valve if necessary.
Standard Diameter (IN and EX) Minimum Diameter
5.975 - 5.995mm 5.950mm
6.015 - 6.044 mm 6.070mm
Valve Guide Replacement Removal 1. Remove the valve guide from the combustion chamber side by using a drift.
Installation 1. Install the guide using a drift so the protrusion (A) is as specified.
Valve Guide Inspection Measure the inner diameter of each valve guide in X and Y directions at the three points (A, B, and C) shown.
Protrusion A
G99777 en
13.5 - 14.1 mm
01/2003 2003.0 BA Falcon
303-01a-18
Engine — I6
303-01a-18
GENERAL PROCEDURES (Continued) 2. Ream the guide to size. Diameter
6.015 - 6.044 mm
3. Measure the protruding length (L) of the valve stem. Replace the valve or valve seat if necessary.
Valve Seat Inspection/Repair 1. Measure the seat contact width. If necessary, resurface the valve seat using a 45º valve seat cutter and/or resurface the valve face. NOTE: After resurfacing valves or seats, check collapsed lash adjuster clearance.
Standard dimension L Maximum dimension L
IN: 50.00 EX: 47.92 IN: 51.0 EX: 48.9
Valve Spring Inspection 1. Check the valve spring load at set length Intake Exhaust
1.0 - 1.4 mm 1.25 - 1.75 mm
2. Verify that the seating position is at the centre of the valve face. 1. If the seating position is too high, correct the valve seat using a 65º (IN) or 75º (EX) cutter, and a 45º cutter. 2. If the seating position is too low, correct the valve seat using a 35º cutter, and a 45º cutter.
Minimum Load
G99777 en
500N at 26.8 mm
01/2003 2003.0 BA Falcon
303-01a-19
Engine — I6
303-01a-19
GENERAL PROCEDURES (Continued) 2. Measure the out-of-square of the valve spring. Replace the valve spring if necessary.
Maximum valve spring out-of-square
1. Set the No.1 and No.7 journals on V-blocks. Measure the camshaft runout. Replace the camshaft if necessary.
1.75mm
Camshaft End Play Inspection 1. Remove the roller followers. Refer to section 303-00 for procedure. 2. Use a Dial Indicator with Bracketry to measure camshaft end play. 3. Position the camshaft to the rear of the cylinder head. 4. Zero the indicator. 5. Move the camshaft to the front of the cylinder head. Note and record the camshaft end play. 1. If camshaft end play exceeds specifications, install new camshaft and recheck end play. 2. If camshaft end play exceeds specification after camshaft installation, install a new cylinder head. Standard end play Maximum end play
Camshaft Inspection
0.1 - 0.3 mm 0.4 mm
Maximum runout
2. Check the cam lobe for cracks and pitting. Minor indentations are acceptable. Replace if necessary.
3. Measure the journal diameter in 2 directions. Replace the camshaft if necessary.
Standard diameter Journal 1 Journal 2 - 7 G99780 en
0.1mm
34.928 - 34.968 mm 29.928 - 29.968 mm 01/2003 2003.0 BA Falcon
303-01a-20
Engine — I6
303-01a-20
GENERAL PROCEDURES (Continued) Minimum diameter Journal 1 Journal 2 - 7
34.900 mm 29.900 mm
Lash Adjuster Bore Inspection 1. Measure the diameter of each lash adjuster bore
Camshaft Journal Clearance Plastigauge Method 1. Remove the camshaft bearing cap and lay the plastigauge across the surface. 2. Reinstall the camshaft bearing cap - DO NOT rotate the camshaft. 3. Remove the camshaft bearing cap and measure the width of the plastigauge with the scale provided to determine the clearance. Replace the components as required if necessary.
Standard diameter
13.990 - 14.007 mm
2. Measure the diameter of each lash adjuster. Standard diameter
13.972 - 13.984 mm
3. Calculate the clearance between the lash adjuster and the related lash adjuster bore. Replace the lash adjuster or cylinder head if necessary.
Standard clearance Maximum clearance
0.019 - 0.084 mm 0.100 mm
Roller Follower Inspection 1. Inspect the roller for flat spots or scoring. 2. Check the ball socket and valve pad for scuffing and wear.
Standard clearance Maximum clearance
0.006 - 0.035 mm 0.050 mm
Cylinder Block Inspection/Repair Measure the distortion of the cylinder block top surface in the two directions as shown. Repair by grinding or replace if necessary.
G99780 en
01/2003 2003.0 BA Falcon
303-01a-21
Engine — I6
303-01a-21
GENERAL PROCEDURES (Continued)
Maximum cylinder block distortion Direction A 0.15 mm Direction B 0.05 mm Maximum grinding Minimum Piston-Deck Maximum Surface finish Rz
0.20 mm 0.50 mm 13.5
Cylinder Bore - Taper Measure the cylinder bore at the top and bottom. Verify the cylinder bore is within the wear limit. The difference indicates the cylinder bore taper. Bore the cylinder to the next oversize.
Service limit
0.125 mm
Cylinder bore - Reboring sizes Size Diameter (mm) Standard 92.25 - 92.31 0.5 oversize 92.75 - 92.77 1.0 oversize 93.25 - 93.27
Piston Inspection Measure the outer diameter of each piston at a right angle (90º) to the piston pin, 45mm below the crown.
Piston Clearance Inspection/ Repair Service limit
0.25 mm
Cylinder Bore — Out-of-Round Measure the cylinder bore in two directions. The difference is the out-of-round. Verify the out-of-round is within the wear limit and bore the cylinder to the next oversize limit.
G99789 en
1. Calculate the piston-to-cylinder clearance. Replace the piston or rebore the cylinders to fit oversize piston if necessary. Standard Clearance Service Limit
0.020 mm interference to 0.030 mm clearance 0.09 mm clearance
2. If the piston is replaced, the piston rings must also be replaced.
01/2003 2003.0 BA Falcon
303-01a-22
Engine — I6
303-01a-22
GENERAL PROCEDURES (Continued)
Piston Ring Clearance Inspection 1. Measure the piston ring-to-ring land clearance around the entire circumference. Replace the piston ring if necessary.
Top Second Oil Top Second Oil
Standard Clearance 0.03 - 0.075 mm 0.03 - 0.075 mm Zero Service Limit 0.15 mm 0.15 mm 0.20 mm
Oil
1.0 mm
Piston Pin Clearance Inspection 1. Measure each piston pin hole diameter in X and Y directions at the four points (A, B, C, and D) as shown.
Standard Diameter DOHC VCT & LPG 23.173 - 23.178 mm 2. Measure each connecting rod small end inner diameter in X and Y directions as shown.
2. Insert the piston ring into the cylinder by hand and use the piston to push it to the bottom of the ring travel. 3. Measure each piston ring end gap using a feeler gauge. Replace the piston ring if necessary.
Standard Diameter DOHC VCT & LPG 23.132 - 23.144 mm
Top Second Oil Top Second G99789 en
Standard End Gap 0.21 - 0.36 mm 0.35 - 0.51 mm 0.30 - 0.90 mm Maximum End Gap 0.45 mm 0.60 mm 01/2003 2003.0 BA Falcon
303-01a-23
Engine — I6
303-01a-23
GENERAL PROCEDURES (Continued) 3. Measure each piston pin diameter in X and Y directions at the four points (A, B, C, and D) as shown.
Standard Diameter DOHC VCT & LPG 23.157 - 23.162 mm 4. Calculate the piston pin to piston -pin bore clearance. Replace the piston and/or piston pin if necessary Standard Clearance DOHC VCT & LPG 0.014 - 0.019 mm 5. Connecting rod bush as required. Standard Interference DOHC VCT & LPG 0.013 - 0.030 mm
Crankshaft Inspection 1. Measure the crankshaft runout. Replace the crankshaft if necessary.
Standard End Gap Maximum runout 0.05 mm between adjacent journals Maximum runout 0.08 mm between any journals
G99793 en
2. Measure the journal diameter in X and Y direction at the two points (A and B) as shown. Replace the crankshaft or grind the journal and install the undersize bearing if necessary.
Bearing Diameter Out-of-round Taper
Main Journal 67.481 - 67.505 mm 0.010 mm 0.008 mm
Bearing Diameter Out-of-round Taper
Crank Pin 53.93 - 53.95 mm 0.010 mm 0.010 mm (max)
Crankshaft Main Bearing Clearance 1. Position a plastigauge on top of the journals in the axial direction. 2. Install the main bearing cap. DO NOT rotate the crankshaft. 3. Remove the main bearing cap. 4. Measure the main journal clearance. If the clearance exceeds the maximum, replace the main bearing or grind the main journal and install the undersize bearings so that the specified clearance is obtained.
Standard Clearance Maximum Clearance
0.02 - 0.04 mm 0.06mm 01/2003 2003.0 BA Falcon
303-01a-24
Engine — I6
303-01a-24
GENERAL PROCEDURES (Continued) Bearing size Standard 0.250 mm undersize 0.508 mm undersize 1.016 mm undersize
Bearing thickness 1.996 - 2.000 mm 2.118 - 2.128 mm 2.245 - 2.255 mm 2.499 - 2.509 mm
Crankshaft End Play Inspection/Repair 1. Install the thrust main bearing and cap. 2. Measure the crankshaft end play. Use a dial indicator with bracketry to measure crankshaft end play. 3. Position the crankshaft to the rear of the cylinder block. 4. Zero the indicator. 5. Move the crankshaft to the front of the cylinder block. Note and record the crankshaft end play. 1. If the crankshaft end play exceeds specifications, install a new crankshaft thrust washer or crunkshaft thrust main bearing.
Twist
0.20 mm
Centre-to-centre distance
153.78 - 153.92 mm
Connecting Rod Big End Bearing Clearance Standard end play Maximum end play
0.10 - 0.20 mm 0.30 mm
Connecting Rod Inspection
1. Position a plastigauge on top of the journals in the axial direction. 2. Install the connecting rod cap. 3. Remove the connecting rod cap.
1. Measure each connecting rod for bending and twist. Replace the connecting rod if necessary.
Bending G99793 en
0.10 mm 01/2003 2003.0 BA Falcon
303-01a-25
Engine — I6
303-01a-25
GENERAL PROCEDURES (Continued) 4. Measure the crankpin clearance. If the clearance exceeds the maximum, replace the connecting rod bearing or grind the crankpin and use undersize bearing so that the specified clearance is obtained.
Timing Chain Elongation
Standard Clearance Maximum Clearance
0.02 - 0.04 mm 0.06mm
Bearing size Standard 0.051 mm undersize 0.254 mm undersize 0.508 mm undersize
Bearing thickness 1.445 - 1.458 mm 1.471 - 1.483 mm 1.572 - 1.585 mm 1.699 - 1.712 mm
Connecting Rod Side Clearance Inspection 1. Install the connecting rod cap. 2. Measure the connecting rod big end side clearance.
Standard clearance Maximum clearance
To establish the percentage elongation of the Timing chain: 1. Hang the chain vertically over a suitable pin & hook a weight to the free end. 2. Measure the length (from pin O.D. to pin O.D) over the maximum number of chain pins possible using vernier callipers. Note the number of pins measured. 3. Repeat the measurement across three separate lengths of the chain and average the results. 4. Measure the O.D of one chain pin with verniers. 5. Calculate the theoretical chain length = (measured number of pins - 1) x 8.0 mm pitch + measured pin O.D. 6. Compare the actual length measured with the theoretical length: maximum elongation permissible = 0.35 %. Alternatively measure the actual length of a new chain (as above) and compare with the original chain and compare as a percentage of the new chain length.
0.09 - 0.27 mm 0.36 mm
Piston and Connecting Rod Inspection Check the oscillation torque as shown. If the large end does not drop by its own weight, replace the piston or the piston pin.
G99799 en
01/2003 2003.0 BA Falcon
303-01a-26
Engine — I6
303-01a-26
IN-VEHICLE REPAIR
Oil Filter
3. With the tube reinstalled in the block, ensure the O-ring is fully seated in the block counterbore.
Removal 1. Unscrew filter using a filter wrench. Installation 1. Install as indicated. 2. Lubricate the seal with engine oil prior to installation.
Cylinder Head Temperature Sensor Removal and Installation 1. The cylinder head tapped hole is blind. 2. Do not use thread sealant/locker.
Oil Level Indicator & Tube Removal 1. Remove the Oil Level indicator from the Oil Level Tube. 2. Unscrew retaining bolt. 3. Remove Oil Level Tube.
Cam Position Sensor Removal and Installation 1. Check the condition of the O-ring prior to installation. 2. Lubricate the O-ring with engine oil prior to installation. Installation 1. Inspect the O-ring at the base of the tube for damage and renew if necessary. Lubricate with engine oil prior to reinstallation of the tube. 2. Insert the Oil Level Tube and secure with retaining screw.
G99801 en
01/2003 2003.0 BA Falcon
303-01a-27
Engine — I6
303-01a-27
IN-VEHICLE REPAIR (Continued)
Crankshaft Position Sensor
Combustion Knock Sensor
Removal and Installation 1. Check the condition of the O-ring prior to installation. 2. Lubricate the O-ring with engine oil prior to installation.
Removal and Installation 1. When re-installing the Knock sensor, coat the threads with Loctite 242 (or similar) thread locker.
Exhaust Gas Oxygen Sensor Oil Pressure & Oil Temperature Sensor Removal and Installation 1. When re-installing the original sensor, coat the threads with Loctite 567 (or similar) thread sealant. New replacement sensors are pre-coated.
Removal and Installation 1. Coat the threads with a Nickel Anti- Seize compound (Loctite 767 or similar) per ESE-FM99C100-A.
Temperature - Manifold Air Pressure Sensor 1. Remove the Electronic Throttle Body (ETB) to gain access to the attachment screw. 2. Inspect the condition of the O-ring prior to installation.
G99806 en
01/2003 2003.0 BA Falcon
303-01a-28
Engine — I6
303-01a-28
IN-VEHICLE REPAIR (Continued) 3. When re-installing the ETB, coat the threads with Loctite 242 (or similar) thread locker.
Crankshaft Front Oil Seal Removal 1. Disconnect the battery. 2. Remove the radiator cooling fan assembly. 3. Remove the radiator. 4. Remove the front end accessory drive belt. 5. Remove the Crankshaft Vibration Damper. 6. Protect the crankshaft with a piece of soft metal or plastic, and use a screwdriver to lever out the oil seal.
Crankshaft Vibration Damper Removal 1. Remove the Retaining Bolt. 2. Use SST 303-642 to remove the damper. 3. Remove key.
Item 1 2 3
Description Screwdriver (flathead) Crankshaft Front Oil Seal Soft Metal or Plastic (shim)
Installation 1. Clean the front cover recess and tap in the seal until it is fully seated. 2. Lubricate the lip of the seal with engine oil. Installation 1. Apply sealer in the keyway as shown. 2. Lubricate the seal rubbing area with engine oil. 3. Use SST 303-642 to install the damper. 4. Inspect key for damage. Replace if necessary.
3. Install the Crankshaft Vibration Damper.
Crankshaft Rear Oil Seal Removal 1. Remove the transmission. Refer to section 307-01A (Auto trans) or 308-03A/B (Man trans). G99806 en
01/2003 2003.0 BA Falcon
303-01a-29
Engine — I6
303-01a-29
IN-VEHICLE REPAIR (Continued) 2. Remove the flywheel. Refer to Section 307-01A (Auto trans) or 308-01 (Man trans). NOTE: Other potential sources of oil leak should be eliminated prior to replacing the seal. 3. Insert a suitable brass strip between the seal and the crankshaft to protect the crankshaft seal surface. 4. Insert a screwdriver between the seal and the protection strip and lever out the seal.
Installation 1. Clean the seal recess in the block. 2. Oil the lip of the seal and the shaft. 3. Install the seal evenly using the SST E9312.
Clutch Pilot Bearing Removal and Installation 1. Use a suitable tool to remove the pilot bearing and adaptor from the flywheel. The back of the adaptor is notched to facilitate removal. 2. Install the new adaptor and bearing into the flywheel until the adaptor bottoms out. Do not change the location of the bearing in the adaptor.
Water Pump Removal 1. Remove the radiator cooling fan assembly. Refer to Section 303-03A. 2. Remove the front end accessory drive belt. Refer to Section 303-05. 3. Remove the water pump pulley. Refer to Section 303-05. 4. Remove the alternator and brace. Refer to Section 303-04. 5. Remove the radiator lower hose (and coolant). Refer to Section 303-03A.
Flywheel/Drive Plate/Clutch Pilot Bearing Removal and Installation 1. Remove the transmission. Refer to section 307-01A (Auto trans) or 308-03A/B (Man trans). 2. Remove the clutch pressure and friction plates. Refer to Section 308-01. 3. Remove the flywheel/drive plate. Refer to Section 308-01. 4. Remove the clutch pilot bearing. Refer to Section 308-01.
G99813 en
Item 1 2 3
Description Water Pump Bolt (x4) Alternator Brace
01/2003 2003.0 BA Falcon
303-01a-30
Engine — I6
303-01a-30
IN-VEHICLE REPAIR (Continued) NOTE: Weeping and staining of coolant from the body 2. Remove the ETB. drain hole is normal and permitted. When the water pump is suspected of leaking, this should be confirmed with a cooling system pressure test. NOTE: The pump is a sealed unit, and should be replaced complete if faulty. Installation To install, reverse the removal procedure. 1. Check the condition of the heater pipe recess in the rear of the water pump. 2. Check the condition of the O-ring on the end of the heater pipe and renew if damaged. 3. Lubricate the O-ring to assist assembly. Item 1 2 3 4
Description Gasket - Throttle body Throttle body M6 screw (x4) Support bracket
3. Disconnect the brake booster vacuum hose, fuel pressure regulator hose from the manifold.
Electronic Throttle Body and Intake Manifold Removal 1. Remove the air duct assembly.
4. Remove the 2 upper manifold to cylinder head braces.
Item 1 2
Description Air Duct Retaining Bolt
G99813 en
01/2003 2003.0 BA Falcon
303-01a-31
Engine — I6
303-01a-31
IN-VEHICLE REPAIR (Continued) 5. Remove the upper intake manifold.
Item 1 2 3
Description Intake Manifold - Upper M8 screws (x14) Gasket - Intake manifold upper
8. Disconnect the main gallery oil pressure and temperature switch, knock sensor and crank timing sensor.
9. Remove the lower intake manifold.
6. Remove the 3 lower manifold to cylinder block braces.
7. Remove the fuel rail and injectors as an assembly.
Item 1 2 3 4
Description Fuel rail Support bracket Knock sensor M8 Bolts
NOTE: The Electronic Throttle Body is a non adjustable item. For fault finding see Section 303-14. Installation When re-installing the Upper intake manifold to Lower intake manifold bolts, coat the threads with Loctite 242 (or similar) thread locker. When reinstalling the Lower intake manifold bolts to the cylinder head, coat the threads with Loctite 242 (or similar) thread locker. The gaskets sealing the Upper to Lower Manifold and the Lower Manifold to the head should not be re-used. When reinstalling the ETB to the intake manifold, use a new gasket and new bolts or apply Loctite 242 (or similar) thread locker to the threads. Torque the M6 bolts to 8-12Nm. The Broadband throttle shaft Vacuum motor closed position stop is set in the factory and should not be touched, unless the vacuum motor or Broadband
G99816 en
01/2003 2003.0 BA Falcon
303-01a-32
Engine — I6
303-01a-32
IN-VEHICLE REPAIR (Continued) throttle shaft are serviced, in which case the setting must be adjusted as described below.
Broadband Throttle Plate
3. Screw in the set screw 1-1.5 turns clockwise so the screw now contacts the stop and the Broadband Throttle Plates are cracked open.
Removal 1. Unscrew the retaining bolts. 2. Remove Broadband Throttle Plates.
Installation 1. Insert plates with tabs facing upwards and to the screw head side. 2. Loosely install the plate retaining screws. 3. Rotate the shaft so the plates are closed and snap the plates shut a few times to centralize them in their bores. There must be no gap between the plates and their bores. 4. Apply Loctite 242 (or similar) thread locker to the threads and tighten the plate retaining screws to specification.
Item 1 2 3 4
Description Screws Activator - Throttle control Throttle lever Clip
Exhaust Manifold Assembly Removal 1. Remove the heat shield by unscrewing the retaining bolts.
Broadband Throttle Shaft Vacuum Motor Removal 1. When disconnecting the vacuum motor from throttle shaft level, remove retaining clip first. 2. Do not adjust the set screw on the throttle shaft lever. If adjustment is necessary, or of a new vacuum motor is fitted, reset screw by the following procedure. Installation 1. Apply a 40kPa vacuum to the motor or apply light finger pressure to push the lever in a clockwise direction against the stop. 2. Maintaining the pressure on the lever, unscrew the set screw until there is a 0.05mm gap between the screw and the stop.
G99816 en
01/2003 2003.0 BA Falcon
303-01a-33
Engine — I6
303-01a-33
IN-VEHICLE REPAIR (Continued) 2. Disassemble the items in the following order.
Item 1 2 3 4 5
Description Catalytic Converter Inlet Pipe Lifting Eye Retaining Bolt Heated Exhaust Gas Oxygen (HEGO) Sensor Exhaust Manifold Assembly
Installation 1. Fit 2 M10 x 1.5 bolts with heads removed as guide pins. 2. Fit gasket and loosely assembled manifold onto guide pins. Refer to Exhaust Manifold - Front and Rear section. 3. Install lower manifold to head bolts, and nip up the bolts. 4. Remove guide pins, install remainder of bolts excluding those used to attach the heat shield. 5. Tighten the bolts progressively to specification. 6. Tighten the front to rear manifold joint nuts to specification. 7. Lubricate the HEGO sensor thread with Loctite 767 (or similar) anti-seize compound per ESE-FM99C100-A.
4. Loosely assemble and finally torque when fitted ti engine.
Item 1 2 3 4
Description Exhaust Manifold - Rear Gasket M8 - Nut Exhaust Manifold - Front
Oil Control Valve Seal Removal 1. Check metal garter band is still in place on the seal.
Exhaust Manifold - Front and Rear
Item Description Removal 1 Plate - Gasket valve rocker arm cover 1. Remove the three nuts from the studs. 2 Bolt NOTE: If the studs screw out of the Rear Exhaust Manifold, simply refit the studs using two suitable Installation nuts locked together. 1. After tightening the Valve Cover retaining bolts, insert the Oil Control Valve seals into the Valve Installation Cover without displacing the metal garter band, 1. Clean all mating surfaces. and tighten the seal retaining bolts. 2. Fit a new front to rear manifold sealing ring. 3. Apply anti-seize compound to the manifold joint nut threads.
G99821 en
01/2003 2003.0 BA Falcon
303-01a-34
Engine — I6
303-01a-34
IN-VEHICLE REPAIR (Continued)
Valve Cover
4. Remove the Spark Plug Cover.
Removal 1. Remove the air duct assembly.
Item Description 1 Bolt & Washer 2 Cap - Oil filler Item Description 3 PCV valve 1 Intake duct 4 M5 screw 2 Screw 5 Clip-air line 2. Remove the Electronic Throttle Body (ETB) as per 6 Spark plug cover procedure. 5. Remove the Ignition Coils.
Item 1 2 3 4
Description Gasket - Throttle body Throttle body Screw Bracket
3. Remove the oil filler cap, PCV valve, brake and PCV hoses.
G99821 en
01/2003 2003.0 BA Falcon
303-01a-35
Engine — I6
303-01a-35
IN-VEHICLE REPAIR (Continued) 6. Remove the Oil control valve seals retaining bolts. 8. Slide the valve cover backwards 20-30mm, then Check metal garter band is still in place on the lift the front to clear the oil control valves, and seal. then slide the cover forwards, raising the rear to clear the camshafts and dash panel.
Item 1 2
Description Plate - Gasket valve rocker arm cover Bolt
7. Remove valve cover retaining bolts (8).
Item 1 2 3
Description Bolt and washer Bolt and washer Valve cover
Installation 1. Clean the cover including PCV and fresh air chambers, and seal grooves. Fit new seals.
G99821 en
01/2003 2003.0 BA Falcon
303-01a-36
Engine — I6
303-01a-36
IN-VEHICLE REPAIR (Continued) 2. Apply sealer WSS-M4G323 A7 in 2 places on the 2. Remove the Electronic Throttle Body (ETB). Valve Cover to cylinder head/front cover joints as shown, refit the cover, check the peripheral seal is not displaced out of the groove using a mirror for the rear of the engine. 3. When re-installing the six short bolts which retain the Valve Cover to the cylinder head assembly, coat the threads with Loctite 242 (or similar) thread locker. 4. Check the Oil Control Valve Seals, replace if necessary and refit after the Valve Cover is tightened down.
Item 1 2 3 4
Description Gasket Electronic Throttle Body Bolt Bracket
3. Remove the oil filler cap, PCV valve, brake and PCV hoses. 4. Remove the Spark Plug Cover.
Ignition Coils/Wiring Loom Removal 1. Remove the air duct assembly.
Item 1 2
Description Air intake tube assembly Bolt
G99821 en
Item 1 2 3 4 5 6
Description Bolt Oil filler cap PCV valve Screw Vacuum hose clip Spark plug cover
01/2003 2003.0 BA Falcon
303-01a-37
Engine — I6
303-01a-37
IN-VEHICLE REPAIR (Continued) Installation 2. Refit the ignition coils and reconnect the wiring 1. Every time the Ignition Coils are removed, apply 2 loom to the coils & oil control valves. grams of synthetic grease ESF-M1C229-A NOTE: The short lead is attached to the intake oil (Dupont Krytox) using a suitable applicator (cotton control valve and the long lead is connected to bud) to the inside of the tapered section of the coil the exhaust oil control valve. boot, smearing it evenly over the surface. 3. Ensure all of the wiring is clear of the Spark Plug Cover seal surfaces, and that the wiring does not obstruct any hardware mounting points. 4. Ensure that the wiring is located correctly in the grooves in the Valve Cover where it exits the Spark Plug Cover when refitting the Spark Plug Cover.
Camshafts, VCT Phaser, Oil Control Valves, & OCV Filters
G99824 en
01/2003 2003.0 BA Falcon
303-01a-38
Engine — I6
303-01a-38
IN-VEHICLE REPAIR (Continued) Item 1 2 3 4 5 6 7
Description VCT Oil Control Valve Camshaft Bearing caps Camshaft - Intake Chain Guide Variable Cam Timing ( VCT) unit Camshaft - exhaust Filter- VCT Oil Control Valve
Camshaft Removal Removal Remove valve cover. Refer to section 303-01.
Camshaft and VCT Phasers
3. Release the timing chain tension by compressing the tensioner using SST 303-777. Refer to section 303-01.
Special Tool(s) Timing chain tensioner special service tool
Camshaft holding tool
1. Rotate the crankshaft so the VCT timing marks (on the sprocket) are vertically upwards and the crankshaft at Top Dead Centre. 2. Mark the two timing chain links above the timing marks with a marker pen. NOTE: The yellow and orange coloured links used for original assembly, and assembly with the front cover removed, are only synchronized with the timing marks once every 38 crankshaft revolutions, and should be ignored when working with the front cover in place (unless synchronized).
4. Fit the SST 303-778 to the camshafts in the central position between the caps and tighten to prevent rotation.
5. Loosen the bolt attaching the VCT units to the camshafts.
G99824 en
01/2003 2003.0 BA Falcon
303-01a-39
Engine — I6
303-01a-39
IN-VEHICLE REPAIR (Continued) 6. Do not use the chain to prevent rotation when 7. Whilst holding the VCT phaser and timing chain, loosening the central bolt as this load will be slide the VCT phaser forward off the camshafts transmitted through the locked phaser mechanism and rest on top of the timing cover. and could cause damage. NOTE: Do not remove the timing chain from the VCT phasers. 8. Remove the tool.
9. Loosen the camshaft cap bolts 2 turns at a time in the order shown below.
G99826 en
01/2003 2003.0 BA Falcon
303-01a-40
Engine — I6
303-01a-40
IN-VEHICLE REPAIR (Continued) 10. Remove camshaft caps. 11. Remove inlet & exhaust camshaft.
Camshaft Installation
3. Fit the respective Intake and Exhaust camshafts with the timing pin positioned vertically upwards. Take care not to damage the thrust surfaces on journal #2.
Installation 1. Check the camshaft journal clearance. 2. Lubricate the head-cam bearing surfaces with engine oil.
NOTE: Use the following illustration to identify the Exhaust and Inlet camshafts.
Item 1 2
4. Check for burrs and damage on the cap-to-head joints and the cam-to-VCT phaser joint. Tighten bolts 2 turns at a time in the same order shown in the removal section. NOTE: The cam-cap oil passage must be absolutely clean. 5. Rotate the crankshaft so the VCT timing marks (on the sprocket) are vertically upwards and the crankshaft at Top Dead Centre. 6. Align the marked the two timing chain links with the VCT timing marks sprocket. NOTE: The yellow and orange coloured links used for original assembly, and assembly with the front cover removed, are only synchronized with the timing marks once every 38 crankshaft revolutions, and should be ignored when working with the front cover in place (unless synchronized).
Description Exhaust Inlet
NOTE: If a camshaft timing error is suspected, and it is necessary to check the basic cam timing using the valve lift loss method, then the cams must be fully advanced and both VCT Phaser locking pins engaged.
G99826 en
01/2003 2003.0 BA Falcon
303-01a-41
Engine — I6
303-01a-41
IN-VEHICLE REPAIR (Continued) 7. Check that the cams are fully advanced and the locking pins engaged by gripping each camshaft between the journals numbers 4 & 5 with a suitable wrench using soft protective pads, and attempt to rotate the camshaft backwards and forwards relative to the VCT Phaser. 8. Establish the point of maximum lift on a No. 1 cylinder intake cam lobe by determining the positions where the lift is reduced by 0.25 mm either side of maximum lift. Note the crankshaft angles while rotating the crankshaft in a clockwise direction only. 9. Average the two crankshaft angles to give the point of maximum lift. 10. Repeat this procedure for the No.1 cylinder exhaust cam lobe. 11. Check the piston TDC in a similar way by fitting an adaptor in the spark plug hole in cylinder No. 1 with an adjustable length pin protruding into the cylinder so that it just prevents the piston from reaching TDC. Lock the adjustment using a suitable locknut. 12. Rotate the engine clockwise until the piston touches the pin and noting the crankshaft angle, and then rotating it anti-clockwise, and again note the angle. 13. Average the two crankshaft angles to give TDC, and compare it to the timing mark on the Crankshaft Vibration Damper to ensure that the Damper outside element has not rotated. If there is a significant discrepancy, replace the Damper. Refer to Crankshaft Vibration Damper in this section. Standard Intake Cam Timing Standard Exhaust Cam Timing
1. Release the timing chain tension by compressing the tensioner. Refer this section.
VCT Phaser Special Tool(s) Camshaft holding tool 303-778
Removal 1. Remove valve cover. Refer to Valve Cover in this section. 2. Fit the SST 303-778 to the camshafts in the central position between caps and tighten to prevent rotation.
Maximum lift @ 97.5° ATDC Maximum lift @ 126.5° BTDC
Timing Chain Tensioner Special Tool(s) Timing chain tensioner special service tool 303-777 3. Loosen the bolt attaching the VCT units to the camshafts.
G99828 en
01/2003 2003.0 BA Falcon
303-01a-42
Engine — I6
303-01a-42
IN-VEHICLE REPAIR (Continued) 4. Do not use the chain to prevent rotation when 3. The filters and cam cap oil passages must be loosening the central bolt as this load will be absolutely clean. transmitted through the locked phaser mechanism and could cause damage.
5. Whilst holding the VCT phaser and timing chain, slide the VCT phaser forward off the camshafts and rest on top of the timing cover. NOTE: Do not remove the timing chain from the VCT phasers.
Rocker Arm, Lash Adjuster, Valve Spring and Valve Stem Seal 1. Disassemble in the order indicated in the table.
6. Remove the tool. Installation 1. To install, reverse the removal procedure. 2. The oil control valves & cam cap bores must be absolutely clean.
Item 1 2 3 4 5 G99828 en
Description Cam follower Lash adjuster retaining clip Lash adjuster Valve spring retainers Valve spring retainer keys 01/2003 2003.0 BA Falcon
303-01a-43
Engine — I6
303-01a-43
IN-VEHICLE REPAIR (Continued) Item 6 7
Description Valve spring Valve stem seal
2. Remove the keys, retainers and valve spring using a suitable valve spring compressor.
Rocker Arm and Lash Adjuster The rocker arm and lash adjuster are clipped together to prevent rocker displacement under extraordinary start up conditions. Care should be taken when removing the assembly, so as not to strain the clip. Do not remove the clip unless either the rocker arm or lash adjuster are to be replaced and fit a new clip. If the clip is loose on the rocker arm it should be replaced when the rocker and lash adjuster assembly is removed from the cylinder head. Removal 1. Remove the camshaft. Refer to Camshaft in this section. 2. Disengage the rocker arm from the valve tip. 3. The rocker arm & lash adjuster assembly can be raised and the lash adjuster removed from the cylinder head. Installation 1. To install, reverse the removal procedure.
Valve spring and Valve Stem Seal
3. Remove the valve stem seal/spring seat assembly with pliers or multi-grips, being careful not to mark the valve stem. Installation 1. Pressurise the cylinder via an air line and adaptor. Do not exceed 800 KPa. 2. Use an 18mm inside diameter tube to gently seat the valve stem seal. 3. Reassemble in the reverse order to the procedure above. NOTE: The valve spring must be fitted with the smaller diameter end upwards.
Removal 1. Remove the appropriate spark plug, and pressurise the cylinder via an air line and adaptor. DO NOT exceed 800 KPa.
G99833 en
01/2003 2003.0 BA Falcon
303-01a-44
Engine — I6
303-01a-44
IN-VEHICLE REPAIR (Continued)
Front Cover
Item 1 2 3 4 5 6 7 8
Description Idle pulley Front cover Gasket front cover Crankshaft sensor Drive belt tensioner assembly Crankshaft vibration damper Dowel front cover location Bolt - Front cover
Removal 1. Disconnect the battery. 2. Remove the radiator cooling fan assembly. Refer to Section 303-03A. 3. Remove the radiator. 4. Remove the valve cover. 5. Remove the front-end accessory drive components (except A/C compressor), alternator bracket and power steering pump. 6. Remove the water pump. 7. Remove the crankshaft vibration damper. 8. Disconnect the crankshaft sensor wiring connector. G99834 en
9. Remove the two bolts and hollow dowels locating cover to block. 10. Remove the four oil pan to cover bolts. 11. Remove all the cover to cylinder block bolts. 12. Remove the Front cover. 13. Raise cover before moving forward to avoid damage to oil pan seal.
Inspection 1. Remove any sealant from the oil pan to block/front cover joints and the front cover to cylinder head/rocker cover joints. 01/2003 2003.0 BA Falcon
303-01a-45
Engine — I6
303-01a-45
IN-VEHICLE REPAIR (Continued) 2. Check the condition of the oil pan, front cover to 4. Place the front cover against the cylinder block, block and crankshaft rotary seals and replace if sitting on the uncompressed oil pan seal. required. 5. Place two cross head type screwdrivers or similar 3. Ensure the joint surfaces are clean and free of oil. through two bolt holes in the front cover and into the cylinder block and lever the front cover down Installation into position. 1. Apply a small bead of sealant meeting Ford 6. Fit the two lower dowels into the front cover and specification WSS M4G323 A7 to the oil pan to into the cylinder block. Check the peripheral seals block to front cover joint in 2 places as shown. are not displaced out of the grooves.
2. Apply a small bead of sealant WSS M4G323 A7 to the front face joint between the cylinder head and cylinder block in 2 places as shown.
Item 1 2 3 4
Description Bolt Front cover Dowel Dowel
3. Apply a small bead of sealant WSS M4G323 A7 to the rocker cover to head to front cover joint in 2 places as shown.
G99834 en
01/2003 2003.0 BA Falcon
303-01a-46
Engine — I6
303-01a-46
IN-VEHICLE REPAIR (Continued)
Camshaft Drive
Item 1 2 3 4 5 6 7 8 9 10
Description Front cover Gasket - Front cover Tensioner assembly timing chain Timing chain guide tension Timing chain guide fixed Timing chain Crankshaft tone wheel Crankshaft sensor Front seal Crankshaft vibration damper
Removal 1. Remove the front cover. 2. Remove the tensioner. 3. Remove the timing chain. 4. Remove the crank sprocket/timing wheel. 5. Remove the moving chain guide.
G99834 en
6. Remove the fixed chain guide. 7. Remove the chain guide (top run).
Timing Chain Tensioner Release Special Tool(s) Timing chain tensioner special service tool 303-777
Removal 1. Rotate Lever A anti clockwise by engaging pin of SST 303-777 into hole in lever. 2. Push in plunger until 3-4mm is visible. 3. Release load from Lever A so ratchet teeth engage with 1st teeth on plunger.
01/2003 2003.0 BA Falcon
303-01a-47
Engine — I6
303-01a-47
IN-VEHICLE REPAIR (Continued) 4. Push in plunger slightly so hole in A aligns with hole C and is locked with SST.
Installation 1. Set the crankshaft position to Top Dead Centre: Cylinder #1 Firing (both VCT phaser timing marks vertically upwards).
2. Align yellow link at 6 o’clock with its position indicator. Align orange link at 1 o’clock with the timing indicator on tone wheel. The orange link should be half visible within the tone wheel cut away hole.
Item 1 2 3 4
Description Yellow link Yellow link position indicator Timing indent on tone wheel Orange link
3. Remove the SST 303-777 to release the tensioner. 4. Rotate crankshaft back and forwards to check that the slack is removed from chain. 5. Reverse removal procedure for camshaft drive components.
Cylinder Head Item 1 2
Description Yellow links Timing dot on VCT
G99837 en
Removal 1. Remove the radiator cooling fan assembly. 2. Remove the radiator. 3. Remove the valve cover. Refer to Valve Cover in this section. 4. Remove front cover. Refer to Front Cover in this section. 5. Remove timing chain. 6. Remove camshafts. Refer to Camshaft in this section. 7. Remove intake manifold. Refer to Throttle Body and Intake Manifold in this section. 8. Remove exhaust manifold. Refer to Exhaust Manifold in this section.
01/2003 2003.0 BA Falcon
303-01a-48
Engine — I6
303-01a-48
IN-VEHICLE REPAIR (Continued) 9. Disconnect the Cylinder Head Temperature (CHT), and two Camshaft position sensors from rear of cylinder head.
8. Rotate bolts 90º ± 5º in the sequence shown.
Engine 10. Loosen the cylinder head bolts in the sequence shown.
Removal 1. Disconnect Hood struts and securely tie back Engine Hood, or remove bonnet. 2. Disconnect battery leads and remove battery cover and battery. Refer to section 414-01. 3. Remove engine accessory drive belt. Refer to section 303-05. 4. Remove Power steering pump to engine attachment bolts.
Installation 1. Ensure all joint surfaces are clean and free of oil and grease. NOTE: A new cylinder head gasket must be used. 2. Lightly lubricate the bolt threads and washer surfaces with engine oil. 3. Tighten the cylinder head bolts in the sequence shown. 4. Rundown all bolts to 30 Nm. 5. Retighten in sequence to 90º. 6. Back off all bolts by approx. 1 turn each. 7. Tighten all bolts to 40Nm in sequence.
Item 1 2 3
Description Reservoir and Pump Bolts Bolts
NOTE: Leave hoses attached and locate pump clear of engine. 5. Remove Air Cleaner assembly and induction tubes. Refer to section 303-12. 6. Drain engine coolant at radiator tap. 7. Remove the radiator cooling fan assembly. Refer to section 303-03a. 8. Remove the radiator assembly. Refer to section 303-03a.
G99837 en
01/2003 2003.0 BA Falcon
303-01a-49
Engine — I6
303-01a-49
IN-VEHICLE REPAIR (Continued) 9. Remove air conditioning compressor to engine attachment bolts.
NOTE: Leave compressor hoses attached and locate pump clear of engine.
13. Disconnect vacuum hoses from intake manifold.
14. Disconnect Fuel lines at filter feed pipe under left hand side of firewall.
10. Remove PCM module. Refer to section 303-14. 11. Disconnect the engine loom wiring plugs from the underside of PCM.
Item 1 2
Description PCM Module Engine electrical connectors
12. Disconnect transmission wiring plugs. Refer to section 307-01.
G99830 en
Item 1 2 3 4 5
Description Fuel Tube Return Fuel Vapor Hose Fuel Tank to Vapor Hose Rear Brake Lines Fuel Tube Return
15. Disconnect Heater hoses from rear of manifold
01/2003 2003.0 BA Falcon
303-01a-50
Engine — I6
303-01a-50
IN-VEHICLE REPAIR (Continued) 16. Remove Hego sensor electrical connector.
23. Connect suitable engine lifter to the lift brackets supplied and carefully remove engine assembly.
17. Remove the transmission front dust cover. Installation 18. Remove the Converter to drive plate bolts (4) (Automatic Trans Vehicles Only). Refer to section 1. For installation of the engine reverse the removal procedure. 307-01. 19. Remove starter motor. Refer to section 303-06. Engine Mounting 20. Remove Transmission to engine bolts (4). Refer to section 307-01. 1. Mount the engine on an engine rollover stand. 21. Disconnect Exhaust at engine pipe flange to WARNING: Self-locking brake system of manifold. the engine stand may not be effective when the engine is held in an unbalanced position. This could lead to sudden, rapid movement of the engine and mounting stand handle and cause serious injury. Never keep the engine in an unbalanced position, and always hold the rotating handle firmly when turning the engine.
Engine Oil Pan
22. Remove front engine mount Through bolts.
G99830 en
Removal 1. Remove the main bearing cross bolts. NOTE: There are 5 main bearing cross bolts on the right hand side and 4 on the left hand side of the oil pan.
01/2003 2003.0 BA Falcon
303-01a-51
Engine — I6
303-01a-51
IN-VEHICLE REPAIR (Continued) 2. Remove the oil pan flange bolts. NOTE: The 24 oil pan flange bolts are slightly longer than the bearing cross bolts. Store them separately when removed.
4. Apply a bead of sealant Loctite 5900 (or similar) at the front cover to block joint (2 places), and the rear main bearing cap to block joint (2 places).
NOTE: Only 12 right hand side pan flange bolts are shown. There are a further 12 on left hand side.
3. Remove the oil pan. 4. Remove the oil pan seal.
5. Align the rear face of the oil pan with the rear face of the block when tightening the oil pan flange bolts. 6. Coat the main bearing cross bolt threads with Loctite 567 (or similar) thread sealant. Installation 1. Clean all the joint surfaces. 2. Check the oil pan baffle plates for cracks and loose rivets. 3. Fit a new seal.
7. Install oil pan flange bolts to specified torque.
Oil Pump Pickup Tube Removal 1. Remove the oil pump. Refer to Oil Pump in this section. G99840 en
01/2003 2003.0 BA Falcon
303-01a-52
Engine — I6
303-01a-52
IN-VEHICLE REPAIR (Continued) 2. Remove the oil pump pickup tube. 3. Remove the pickup tube attachment bolts to oil pump. Installation 1. Inspect the intake flanges on the oil pump and pickup tube for signs of damage. 2. Fit a new O-ring to this joint 3. Tighten the pickup tube to oil pump bolts and check that the mounting bracket is sitting lightly on the head of the main bearing bolt, or just clear by up to 1mm, before fitting the nut. NOTE: Heavy bearing, or a large gap could cause an air leak and should be corrected by adjusting the bracket.
Oil pump Removal
1. Remove the pickup tube mounting bracket nut (attached to main bearing bolt stud). 2. Remove the oil pump to block mounting bolts. 3. Remove the Front Cover. Refer to Front Cover in this section. 4. Remove the engine oil pan. Refer to Engine Oil Pan in this section. 5. Remove the oil pump pickup tube. 6. Remove the oil pump. NOTE: The oil pump is a non-repairable item and should be replaced if damaged. Installation 1. Engage the drive flats in the oil pump rotor bore with the two flats on the crankshaft. 2. Gently push the oil pump into position against the cylinder block. NOTE: Rotating the oil pump body and gently rocking it fore and aft will assist assembly. 3. DO NOT use force.
Piston and Rod Assembly Removal Place the engine on a rollover stand and invert before performing this procedure. 1. Remove the main bearing bolts. 2. Remove the windage baffle. 3. Remove the main bearing caps and lower main bearings. 4. Rotate the crankshaft to Bottom Dead Centre on the respective cylinders to improve access to the connecting rod bolts. 5. Fit Connecting rod bolt protectors prior to disengaging the connecting rod from the crankshaft.
Item 1 2 3 4 5
Description Nut Bolt Oil pump Pickup tube Bolt
G99840 en
01/2003 2003.0 BA Falcon
303-01a-53
Engine — I6
303-01a-53
IN-VEHICLE REPAIR (Continued) Installation 1. Use bolt protectors when installing the assembly. NOTE: Ensure new connecting rod bolts have been fitted, as the ’Torque to Yield’ bolts are not reusable.
2. Ensure the cap and the connecting rod carry the same cylinder number marking on the same side of the rod. 3. Tighten each pair of bolts to 25Nm, then a further 90 degrees.
Item 1 2 3 4 5 6
Description Main bearing bolts Windage baffle Main bearing caps Lower main crankshaft bearings Crankshaft Upper main crankshaft bearings
Item 1 2 3
Description Upper main crankshaft thrust bearing Upper main crankshaft bearings Crankshaft
Main bearings/Crankshaft Place the engine on a rollover stand and invert before performing this procedure. Removal 1. Remove the main bearing bolts. 2. Remove the windage baffle. 3. Remove the main bearing caps and lower main bearings. 4. Remove the connecting rod caps, upper and lower connecting rod bearings, and piston & rod assemblies. Refer to Piston and Rod Assembly in this section. 5. Remove the crankshaft. 6. Remove the upper main bearings.
G99841 en
01/2003 2003.0 BA Falcon
303-01a-54
Engine — I6
303-01a-54
IN-VEHICLE REPAIR (Continued) Item 4
Description Pivot bearing (Manual transmission only)
Installation 1. For installation reverse the removal procedure.
3. Ensure the notch on the piston is facing the front of the engine, the valve cut-outs are on the exhaust side, and the connecting rod oil squirt hole is on the exhaust side of the engine.
Rear Main Bearing Cap Assembly 1. Apply silicone sealant Loctite 5900 (or a sealant which meets the Ford specification WSS-M4G323-A7) to the rear main bearing cap to block joint as shown. 2. Fit the rear main bearing cap and tighten within 5 minutes of application of the sealant. 3. Reverse the removal procedure.
Piston Ring Installation 1. Verify the second piston ring is installed with the dot upwards. 2. Position the end gaps of the piston rings as shown.
G99841 en
01/2003 2003.0 BA Falcon
303-01a-55
Engine — I6
303-01a-55
DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES
Key Retainer — Valve Spring Disassembly 1. Remove the keys using a valve spring compressor. 2. Remove the valve spring retainer. 3. Remove the valve spring. 4. Remove the valve stem seal.
2. Ensure the cylinder head joint face is free from scratches and nicks in the sealing areas around the cylinder bore and oil and waterways. 3. Lubricate the valve guides with engine oil.
4. Fit new seals using an 18 mm inside diameter drift.
Item 1 2 3 4
Description Key - Valve spring retainer Valve spring retainer Valve spring Valve stem seal
Assembly 1. To assemble Reverse the disassemble procedure. NOTE: The LPG intake valve is identified with an "L" forged into the combustion chamber face.
Valve Stem Seal Disassembly 1. Remove the seal using a pair of pliers. Assembly 1. Ensure the cylinder head is clean.
G99849 en
01/2003 2003.0 BA Falcon
303-01a-56
Engine — I6
303-01a-56
DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES (Continued)
Piston and Connecting Rod Assembly Piston and Connecting Rod Disassembly and Assembly
Assembly
Item 1 2 3 4 5 6 7 8 9
Description Compression ring upper Compression ring lower Oil rings Piston Connecting rod Connecting rod bolt Connecting rod cap Connecting rod nut Gudgeon Pin
G99850 en
Assembly 1. Use SST 303-D034 to remove and install the piston from the connecting rod assembly. NOTE: Do not separate the piston and rod unless the rod, pin or piston is to be replaced.
Connecting Rod Bolt The connecting rod bolts are permanently stretched each time they are tightened and should only be used once. Replace the connecting rod bolts prior to rebuilding the engine. The old bolts can be used to establish bearing clearances. The correct level bolts are marked WR/AB.
01/2003 2003.0 BA Falcon
303-01a-57
Engine — I6
303-01a-57
DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES (Continued)
Item 1 2 3 4
Description WR/AA marking Straight knurl Diamond knurl Pilot point
G99852 en
01/2003 2003.0 BA Falcon
303-01b-1
Engine — 5.4L (3V)
303-01b-1
SECTION : 303-01b Engine — 5.4L (3V) VEHICLE APPLICATION : 2003.0 BA Falcon CONTENTS
PAGE
SPECIFICATIONS Specifications .......................................................................................................................303-01b-3 DESCRIPTION AND OPERATION Engine ..................................................................................................................................303-01b-6 DIAGNOSIS AND TESTING Engine ..................................................................................................................................303-01b-8 IN-VEHICLE REPAIRS Intake Manifold Upper ..........................................................................................................303-01b-9 Valve Cover LH and RH (shown) .......................................................................................303-01b-10 Crankshaft Pulley ..............................................................................................................303-01b-13 Crankshaft Front Oil Seal .................................................................................................303-01b-14 Engine Front Cover ...........................................................................................................303-01b-15 Timing Gears, Chains, Tensioners, VCT Sprocket Assemblies and VCT Housings ........303-01b-19 Camshaft (LH shown, RH opposite hand) ........................................................................303-01b-30 Rocker Arm, Lash Adjuster, Valve Spring and Valve Stem Seal ......................................303-01b-38 Valve Spring and Valve Stem Seal ....................................................................................303-01b-38 Exhaust Manifold (LH shown, RH opposite hand) .............................................................303-01b-39 Oil Filter Adapter ................................................................................................................303-01b-40 Oil Pressure Sender ..........................................................................................................303-01b-41 Oil Level Indicator and Tube ..............................................................................................303-01b-41 Oil Pan ...............................................................................................................................303-01b-42 Oil Pump Screen and Pickup Tube ....................................................................................303-01b-44 Flywheel .............................................................................................................................303-01b-44 Crankshaft Rear Oil Seal ..................................................................................................303-01b-45 Engine Mounts - RH ...........................................................................................................303-01b-46 Engine Mounts - LH ...........................................................................................................303-01b-47 Engine Removal .................................................................................................................303-01b-47 DISASSEMBLY Engine ................................................................................................................................303-01b-56 01/2003 2003.0 BA Falcon
303-01b-2
Engine — 5.4L (3V)
303-01b-2
(Continued) DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES Cylinder Head ....................................................................................................................303-01b-67 ASSEMBLY Engine ................................................................................................................................303-01b-71
01/2003 2003.0 BA Falcon
303-01b-3
Engine — 5.4L (3V)
303-01b-3
SPECIFICATIONS General Specifications Description Specification Lubricants and Sealants SAE 5W-20 Premium WSS-M2C153-H Synthetic Blend Motor Oil XO-5W20-QSP or equivalent Motorcraft Premium Gold WSS-M97B51-A1 (yellow Engine Coolant VC-7-A color) (in Oregon VC-7-B) or equivalent¹ Metal Surface Prep ZC-31 Silicone Gasket and WSE-M4G323-A4 Sealant F7AZ-19554-EA or equivalent Instant Adhesive WSK-M2G402-A4 E8AZ-19554-A or equivalent Silicone Gasket Remover ZC-30 Engine Displacement 5.4L (330 CID) Number of cylinders 8 Bore 90.2 mm (3.55 in) Stroke 105.8 mm (4.17 in) Firing order 1-3-7-2-6-5-4-8 Oil pressure minimum at 275.8-413.7 kPa (40-60 2,000 rpm (engine at psi) normal operating temperature) Oil capacity 7.0 liters with filter Compression ratio 9. 8:1 Cylinder Head and Valve Train Combustion chamber 42.45-45.45 cc (2.59-2.77 volume cu in) Valve arrangement (front I-E-I-I-E-I-I-E-I-I-E-I to rear) — LH Valve arrangement (front I-E-I-I-E-I-I-E-I-I-E-I to rear) — RH Valve guide bore 6.015-6.044 diameter Valve stem diameter 5.975-5.995 intake Valve stem diameter 5.95-5.97 exhaust Valve stem-to-guide 0.020-0.045 clearance — intake Valve stem-to-guid 0.069-0.094 clearance — exhaust Valve head diameter 33.62-33.98 intake Valve head diameter 37.32-37.68 exhaust Valve face runout 0.05 G89770 en
Description Valve face angle Valve seat width intake Valve seat width exhaust Valve seat runout Valve seat angle cyl head Valve spring free length Valve spring squareness Valve spring compression pressure at specified height (lbs) Valve spring installed height Valve spring installe pressure Roller follower ratio Hydraulic Lash Adjuster Diameter Clearance-to-bore Service limit Hydraulic leakdown rate Collapsed lash adjuster gap Camshaft Theoretical valve lift @ lash Lobe lift Allowable lobe lift loss Journal diameter Camshaft journal bore inside diameter Camshaft journal-to-bearing clearance Runout End play Cylinder Block Cylinder bore diameter —grade 1 Cylinder bore diameter —grade 2 Cylinder bore diameter —grade 3 Cylinder bore maximum taper Cylinder bore maximum out-of-round Main bearing bore inside diameter
Specification 45.5 deg 1.2-1.4mm 1.4-1.6mm TBD 44.5-45.0 deg Does not apply TBD 350N +/- 17.5N at 42.04mm +13N for creep when stored 760N +/39N at 31.04mm 42.04 mm 350N +/- 17.5N at 42.04mm +13N for creep when stored TBD TBD TBD TBD TBD TBD
intake 11.1 mm exhaust 11.0 mm 0.584 mm 0.127 mm 28.607-28.633 mm 28.657-28.682 mm 0.04-0.095 mm 0.05 mm 0.075-0.185 mm 90.200-90.210 mm (3.5512-3.5516 in) 90.210-90.220 mm (3.5516-3.5520 in) 90.220-90.230 mm (3.5520-3.5524 in) 0.006 mm (0.0002 in) 0.020 mm (0.0008 in) 72.401-72.422 mm (2.850-2.851 in)
01/2003 2003.0 BA Falcon
303-01b-4
Engine — 5.4L (3V)
303-01b-4
SPECIFICATIONS (Continued) Description Specification Crankshaft Main bearing journal 67.483-67.503 mm diameter (2.6568-2.6576 in) Main bearing journal 0.004 mm (0.0002 in) maximum taper (straightness) Main bearing journal 0.0075 mm (0.0003 in) maximum out-of-round between cross sections Main bearing 0.048-0.024 mm journal-to-cylinder block (0.0019-0.0009 in) clearance Connecting rod journal 53.003-52.983 mm diameter (2.0867-2.0859 in) Connecting rod journal 0.004 mm (0.0002 in) maximum taper Connecting rod journal 0.0075 mm (0.0003 in) maximum out-of-round between cross sections Crankshaft maximum end 0.075-0.377 mm play (0.0030-0.0148 in) Piston and Connecting Rod Piston diameter — grade 90.175-90.165 mm 1 (at right angle to pin (3.5502-3.5498 in) bore) Piston diameter — grade 90.185-90.175 mm 2 (at right angle to pin (3.5506-3.5502 in) bore) Piston diameter — grade 90.195-90.185 mm 3 (at right angle to pin (3.5510-3.5506 in) bore) Piston-to-cylinder bore 0.025-0.045 mm clearance (at grade size) (0.0010-0.0018 in) Piston ring end gap — 0.13-0.28 mm top (0.0051-0.0110 in) Piston ring end gap 0.25-0.40 mm —intermediate (0.0098-0.0158 in) Piston ring end gap — oil 0.15-0.65 mm control (0.0059-0.0256 in) Piston ring groove width 1.53-1.55 mm — top (0.0602-0.0610 in) Piston ring groove width 1.52-1.54 mm — intermediate (0.0598-0.0606 in) Piston ring groove width 3.030-3.050 mm — oil control (0.1193-0.1201 in) Piston ring width 1.49-1.46 mm (0.0587-0.0575 in) Piston ring-to-groove 0.030-0.050 mm clearance — top (0.0012-0.0020 in) Piston ring-to-groove 0.030-0.080 mm clearance — intermediate (0.0012-0.0031 in) Piston pin bore diameter 22.008-22.014 mm (0.8665-0.8667 in) Piston pin diameter 22.0005-22.0030 mm (0.8662-0.8663 in) G89770 en
Description Specification Piston pin length 61.8 mm (2.433 in) Piston pin-to-piston fit 0.005-0.0135 mm (clearance) (0.0002-0.0005 in) Connecting rod-to-pin 0.009-0.0235 mm clearance (0.0004-0.0093 in) Connecting rod pin bore 22.012-22.024 mm diameter (0.8666-0.8671 in) Connecting rod length 169.1 mm (6.6575 in) (centerline bore-to-bore) Connecting rod maximum ± 0.038 mm (0.0015 in) allowed bend Connecting rod maximum ± 0.05 mm (0.0020 in) allowed twist Connecting rod bearing 53.049-53.027 mm bore diameter (with (2.0885-2.0877 in) assembled liners) Connecting rod 0.064-0.026 mm bearing-to-crankshaft (0.0025-0.0010 in) clearance Connecting rod side 0.475-0.125 mm clearance (0.0187-0.0049 in) Accessory Drive Belt Drive belt 6 ribs ¹ The addition of Motorcraft Cooling System Stop Leak Pellets, VC-6, darkens Motorcraft Premium Gold Engine Coolant from yellow to golden tan. Torque Specifications Description Nm Valve cover bolts 10 Camshaft bearing cap bolts¹ — Variable camshaft timing (VCT) — sprocket assembly bolts¹ Cylinder head temperature sensor 26 (CHT) Camshaft position (CMP) sensor bolt 10 Crankshaft position (CKP) sensor bolt 10 Connecting rod bolts¹ — Crankshaft damper pulley bolt¹ — Crankshaft main bearing bolts — (cross-mounted)¹ Crankshaft main bearing bolts — (vertical)¹ Cylinder heads bolts¹ — Exhaust manifold nuts 25 Exhaust manifold studs 12 Exhaust manifold-to-Y-pipe nuts 40 Drive belt idler pulley bolt 25 Flywheel bolts 80 Engine front cover bolts¹ — Transmission-to-engine bolts 48
01/2003 2003.0 BA Falcon
303-01b-5
Engine — 5.4L (3V)
303-01b-5
SPECIFICATIONS (Continued) Description Torque converter-to-flexplate nuts Fuel injection supply manifold bracket bolts Generator upper mounting bracket bolts Generator lower mounting bolts Ignition coil Intake manifold to cylinder head bolts¹ Knock sensor Oil filter Oil filter adapter bolts Oil level indicator tube bolt Oil pan bolts¹ Oil pan drain plug Oil pressure switch Oil pump bolts Oil pump screen and pickup tube bolts Oil pump screen and pickup tube spacer Oil pump screen and pickup tube spacer bolt Power steering pump bolts Rear main oil seal retainer bolts Spark plugs Spark plugs Thermostat housing bolts Throttle body spacer-to-intake manifold bolts Timing chain guide bolts Timing chain hydraulic tensioner bolts Coolant pump bolts Coolant pump pulley bolts Motor mount-to-cylinder block bolts Motor mount through bolt Motor mount nut Oil pressure switch Power steering reservoir bracket bolts Power steering reservoir bracket nut Ground strap nut Fuel injection supply manifold bolts Generator bracket bolts Intake manifold bolts¹ Transmission cooler line bracket nut ¹ Refer to the procedure in this section.
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Nm 35 10 10 25 6 — 20 16 25 10 — 14 14 10 10 25 25 25 10 18 10 10 10 25 25 25 63 200 103 14 25 25 10 10 10 — 10
01/2003 2003.0 BA Falcon
303-01b-6
Engine — 5.4L (3V)
303-01b-6
DESCRIPTION AND OPERATION
Engine
Valve Train
The 5.4L (3V) is a V-8 engine with the following features: dual overhead camshafts three valves per cylinder sequential multiport fuel injection (SFI) an aluminum intake manifold aluminum cylinder heads a cast iron, 90-degree V-cylinder block individually chain-driven camshafts with a hydraulic timing chain tensioner on each timing chain the electronic ignition system with eight ignition coils
The valve train operates as follows: Ball tip hydraulic lash adjusters provide automatic lash adjustment. Roller followers ride on the camshaft lobes, transferring the up-and-down motion of the camshafts to the valves in the cylinder heads.
Positive Crankcase Ventilation System All engines are equipped with a closed-type positive crankcase ventilation system recycling the crankcase vapors to the upper intake manifold.
Lubrication System
The engine lubrication system operates as follows: Oil is drawn into the oil pump through the oil Identification pump screen cover and tube in the sump of the oil pan. Always refer to these labels when new parts are Oil enters the main oil gallery where it is required or when checking engine calibrations. The distributed to the crankshaft main journals and to engine parts often differ within a CID family. both cylinder heads. Verification of the identification codes will make sure that the correct parts are obtained. These codes From the main journals, the oil is routed through contain all the pertinent information relating to the cross-drilled passages in the crankshaft to dates, optional equipment and revisions. The Ford lubricate the connecting rod bearings. Controlled Master Parts Catalog contains a complete listing of leakage through the crankshaft main bearings and the codes and their application. connecting rod bearings is slung radially outward to cool and lubricate the cylinder walls as well as Code Information the entire connecting rod, piston and piston rings assembly. The engine code information label, located on the side of the LH valve cover towards the rear, contains the The left cylinder head is fed from a drilling into the following: supply passage feeding the main gallery at the front of the cylinder block. The right cylinder head engine build date is fed from a drilling into the rear of the main engine plant code gallery. Main gallery pressure is reduced as it engine code enters the cylinder head galleries through fixed serviceable orifices located at the upper part of Induction System the feed passages. It is this reduced pressure in The sequential multiport fuel injection (SFI) provides the cylinder head galleries which feeds the the fuel/air mixture needed for combustion in the camshaft journals, the hydraulic lash adjusters cylinders. The eight solenoid-operated fuel injectors: and the primary and secondary timing chain tensioners. are mounted in the fuel injection supply manifold and the intake manifold above the cylinder heads. The camshaft lobe and roller followers are lubricated by splash created through valve train meter fuel into the air intake stream in accordance operation. with engine demand.
are positioned so that their tips direct fuel just ahead of the engine intake valves. are connected in series with the fuel pressure regulator. supply fuel from the fuel tank by a fuel pump mounted in the fuel tank. A constant fuel pressure drop is maintained across the fuel injectors by the fuel pressure regulator. The fuel pressure regulator: is positioned upstream from the fuel injectors on the fuel injection supply manifold.
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Oil Pump The lubrication system of the 5.4L (3V) engine is designed to provide optimum oil flow to critical components of the engine through its entire operating range. The heart of the system is a positive displacement internal gear oil pump using top seal rotors. Generically this design is known as a gerotor pump, which operates as follows: The oil pump is mounted on the front face of the cylinder block.
01/2003 2003.0 BA Falcon
303-01b-7
Engine — 5.4L (3V)
303-01b-7
DESCRIPTION AND OPERATION (Continued) The inner rotor is piloted on the crankshaft post and is driven through flats on the crankshaft. System pressure is limited by an integral, internally-vented relief valve which directs the bypassed oil back to the inlet side of the oil pump. Oil pump displacement has been selected to provide adequate volume to ensure correct oil pressure both at hot idle and maximum speed. The relief valve calibration protects the system from excessive pressure during high viscosity conditions. The relief valve is designed to provide adequate connecting rod bearing lubrication under high-temperature and high-speed conditions.
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01/2003 2003.0 BA Falcon
303-01b-8
Engine — 5.4L (3V)
303-01b-8
DIAGNOSIS AND TESTING
Engine For basic engine mechanical concerns, refer to Section 303-00. For driveability concerns, Refer to Powertrain Control/Module in Section 303-14.
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01/2003 2003.0 BA Falcon
303-01b-9
Engine — 5.4L (3V)
303-01b-9
IN-VEHICLE REPAIR
Intake Manifold Upper
10. Remove the ten (10) bolts that secure the intake manifold.
Removal 1. Relieve the fuel pressure. Refer to chapter 310-00 Fuel System. 2. Disconnect the battery ground cable. For additional information, refer to Section 414-01. 3. Remove PCV hose from LH valve cover. 4. Remove the air cleaner outlet from throttle body. For additional information, refer to Section 303-12. 5. Disconnect the electrical connectors from throttle body motor. 6. Disconnect the electrical connectors from the MAP sensor. 7. Disconnect the electrical connectors from the alternator. 8. Remove the four (4) screws securing the fuel rail to the intake manifold.
9. Remove the fuel rail and fuel injectors as one assembly gently.
11. Lift intake manifold and throttle body. 12. Disconnect the brake booster vacuum line from the intake manifold. 13. Remove the intake manifold. 14. Remove the intake gasket. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all traces of old sealant.
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01/2003 2003.0 BA Falcon
303-01b-10
Engine — 5.4L (3V)
303-01b-10
IN-VEHICLE REPAIR (Continued) 15. Clean and inspect the sealing surfaces.
Installation Install in reverse order applying intake sealant to the mating surfaces of the intake manifold. Tighten the intake manifold bolts in the order illustrated below.
Materials Metal Surface Prep Silicone Gasket and Sealant F7AZ-19554-EA or equivalent Instant Adhesive E8AZ-19554-A
ZC-31 WSE-M4G323-A4
WSK-M2G402-A4
Removal 1. Disconnect the battery and remove. Refer to Chapter 414-01, Battery, Mounting and Cables 2. Remove the coolant supply tank and secure out of the way. (RH side only) Refer to chapter 303-03 Engine Cooling. 3. Unclip the positive battery cable from the valve cover. And secure out of the way. (RH side only) 4. Disconnect the variable cam timing connection at the front of each valve cover 5. Disconnect the ignition coils
Valve Cover LH and RH (shown) Materials SAE 5W-20 Premium WSS-M2C153-H Synthetic Blend Motor Oil XO-5W20-QSP or equivalent Silicone Gasket Remover ZC-30 G89773 en
01/2003 2003.0 BA Falcon
303-01b-11
Engine — 5.4L (3V)
303-01b-11
IN-VEHICLE REPAIR (Continued) 6. Remove the ignition coils.
7. Disconnect the valve cover ventilation hose from the RH valve cover. (RH side only) 8. Disconnect the PCV valve and hose. Secure out of the way. (LH side only) 9. Remove the rear RH and front LH lifting eyes. 10. Remove the valve cover bolts. 11. Remove the valve cover. 12. Remove the valve cover gasket.
RH Valve Cover shown
Item 1 2 3
Description Bolt Valve Cover Valve Cover Gasket
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Installation 1. Clean and inspect the sealing surfaces with silicone gasket remover and metal surface prep. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all traces of old sealant.
01/2003 2003.0 BA Falcon
303-01b-12
Engine — 5.4L (3V)
303-01b-12
IN-VEHICLE REPAIR (Continued) 2. Apply instant adhesive completely around the gasket groove in the valve cover. Install a new valve cover gasket.
3. Apply silicone gasket and sealant in two places where the engine front cover meets the cylinder head. NOTE: If not secured within four minutes, the sealant must be removed and the sealing area cleaned. To clean the sealing area, use silicone gasket remover and metal surface prep. Follow the directions on the packaging. Failure to follow this procedure can cause future oil leakage.
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4. Position the valve cover and gasket on the cylinder head and install the bolts loosely. Tighten the bolts in the sequence shown. (RH side shown LH side is a mirror image)
5. Install the rear RH and front LH lifting eyes. 6. Reconnect the PCV valve and hose. (LH side only) 7. Reconnect the valve cover ventilation hose from the RH valve cover. (RH side only) 8. Install the ignition coils. 9. Reconnect the variable cam timing connection at the front of each valve cover 10. Install the coolant supply tank (RH side only) 11. Install the battery. (RH side only) 12. Clip the positive battery cable to the valve cover. (RH side only)
01/2003 2003.0 BA Falcon
303-01b-13
Engine — 5.4L (3V)
303-01b-13
IN-VEHICLE REPAIR (Continued) 4. Using the special tool, remove the crankshaft pulley.
Crankshaft Pulley Special Tool(s) Remover, Crankshaft Vibration Damper 303-009 (T58P-6316-D)
Installer, Crankshaft Vibration Damper 303-102 (T74P-6316-B)
Materials Silicone Gasket and Sealant F7AZ-19554-EA or LOCTITE 5900 or equivalent
WSE-M4G323-A4
Installation 1. Apply silicone gasket or LOCKTITE 5900 or equivalent to the Woodruff key slot on the crankshaft pulley. NOTE: The crankshaft pulley must be installed within four minutes after applying the silicone.
Removal 1. Remove the drive belt. For additional information, refer to Section 303-05. 2. Raise and support the vehicle. For additional information, refer to Section 100-02. 3. Remove the crankshaft pulley bolt.
2. Using the special tool, install the crankshaft pulley.
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01/2003 2003.0 BA Falcon
303-01b-14
Engine — 5.4L (3V)
303-01b-14
IN-VEHICLE REPAIR (Continued) 3. Install the bolt and washer. Tighten the bolt in four Materials stages: SAE 5W-20 Premium WSS-M2C910-A2 Stage 1: Tighten to 90 Nm Synthetic Blend Motor Oil 10W-30GF2 Engine Oil Stage 2: Loosen one full turn. or equivalent Stage 3: Tighten to 50 Nm Stage 4: Tighten an additional 85-95 degrees. Removal 1. Remove the crankshaft pulley. For additional information, refer to Crankshaft Pulley in this section. 2. Using the special tool, remove the crankshaft front oil seal.
4. Lower the vehicle. 5. Install the drive belt. For additional information, refer to Section 303-05.
Crankshaft Front Oil Seal Special Tool(s) Installer, Crankshaft Front Oil Seal 303-635
Installation 1. Apply silicone gasket sealant to outer perimeter surface of crankshaft front seal. 2. Lubricate the engine front cover and the crankshaft front oil seal inner lip with clean engine oil.
Installer, Front Cover Oil Seal 303-335 (T88T-6701-A)
Remover, Crankshaft Front Oil Seal 303-107 (T74P-6700-A) Item 1 2
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Description Lubricate with engine oil Seal with silicone gasket sealant
01/2003 2003.0 BA Falcon
303-01b-15
Engine — 5.4L (3V)
303-01b-15
IN-VEHICLE REPAIR (Continued) 3. Using the special tools, install the crankshaft front 2. Remove the water pump pulley. oil seal into the engine front cover. Remove the four bolts Remove the water pump pulley
4. Install the crankshaft pulley. For additional information, refer to Crankshaft Pulley in this section.
Engine Front Cover Materials Metal Surface Cleaner F4AZ-19A536-RA or equivalent Silicone Gasket and Sealant F7AZ-19554-EA or LOCTITE 5900 or equivalent 10W-30GF2 Engine Oil or equivalent
WSE-M5B392-A WSE-M4G323-A4
Item 1 2
Description Bolts Water pump pulley
3. Remove the crankshaft pulley. For additional information, refer to Crankshaft Pulley in this section. 4. Remove the Power Steering (P/S) bolts and position the power steering pump aside.
WSS-M2C910-A2
Removal 1. Remove the left and right valve cover (6582). For additional information, refer to Valve Cover-LH and Valve Cover-RH in this section.
5. Remove A/C Compressor. 6. Disconnect the crankshaft position (CKP) sensor.
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01/2003 2003.0 BA Falcon
303-01b-16
Engine — 5.4L (3V)
303-01b-16
IN-VEHICLE REPAIR (Continued) 7. Drain the engine oil.
11. Remove the bolt and the belt idler pulley (8678).
8. Remove the four front sump bolts (as shown).
12. Remove the engine front cover, bolts, studs, and the gaskets.
9. Remove the crankshaft front oil seal. For additional information, refer to Crankshaft Front Oil Seal in this section. 10. Disconnect the camshaft position (CMP) sensor.
13. Clean and inspect the sealing surfaces with silicone gasket remover and metal surface prep.
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CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all traces of old sealant.
01/2003 2003.0 BA Falcon
303-01b-17
Engine — 5.4L (3V)
303-01b-17
IN-VEHICLE REPAIR (Continued) Installation 1. Apply silicone gasket and sealant in the locations shown. NOTE: If the front cover and gasket are not secured within four minutes, the sealant must be removed and the sealing surface cleaned with metal surface cleaner.
2. Position the engine front cover and install the bolts and the studs in three stages: Stage 1: Tighten numbers one through five to 25 Nm Stage 2: Tighten numbers six and seven to 50 Nm Stage 3: Tighten numbers 11 through 15 to 25 Nm
Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
G89777 en
Description Bolt, Hex Flange Head Pilot, M8 x 1.25 x 50 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 50 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 50 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 50 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 50 Stud, Hex-Head Pilot, M10 x 1.5 x 30 Stud, Hex-Head Pilot, M10 x 1.5 x 30 Bolt, Hex-Head Flange, M8 x 1.25 x 50 Bolt, Hex-Head Flange, M8 x 1.25 x 50 Bolt, Hex-Head Flange, M8 x 1.25 x 50 M8 x 1.25 x 53 M8 x 1.25 x 53 Bolt Hex Shoulder Pilot, M8 x 1.25 x 65 Stud Hex Shoulder Pilot, M8 x 1.25 x 65 M8 x 1.25 x 27 Bolt Hex Shoulder Pilot, M8 x 1.25 x 65
01/2003 2003.0 BA Falcon
303-01b-18
Engine — 5.4L (3V)
303-01b-18
IN-VEHICLE REPAIR (Continued) 3. Install the belt idler and the bolt.
8. Install the drain plug.
4. Connect the CMP sensor.
9. Connect the CKP sensor.
5. Raise the vehicle. 6. Tighten the sump bolts in three stages: a. Stage 1: Tighten to 2 Nm b. Stage 2: Tighten to 20 Nm c. Stage 3: Tighten an additional 60 degrees.
10. Refit A/C compressor. 11. Position the power steering pump and install the bolts.
7. Install the crankshaft front oil seal. For additional information, refer to Crankshaft Front Oil Seal in this section.
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12. Install the crankshaft pulley. For additional information, refer to Crankshaft Pulley in this section.
01/2003 2003.0 BA Falcon
303-01b-19
Engine — 5.4L (3V)
303-01b-19
IN-VEHICLE REPAIR (Continued) 13. Install the water pump pulley and install the bolts.
VCT Sprocket Assemblies and VCT Housings Special Tool(s) SST303-775 3 Valve Camshaft Holding Tool
SST303-448 Crankshaft Position Tool 14. Install the left and right valve cover. For additional information, refer to Valve Cover-LH and Valve Cover-RH in this section. 15. Refill the engine crankcase with clean engine oil.
Timing Gears, Chains, Tensioners,
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Materials Super Premium SAE 5W-20 XO-5W20-QSP or equivalent Hydraulic Chain Tensioner Retaining Clip
WSS-M2C153-H
1L3Z-6P250-AA
01/2003 2003.0 BA Falcon
303-01b-20
Engine — 5.4L (3V)
303-01b-20
IN-VEHICLE REPAIR (Continued)
Item 1 2 3 4 5 6
Description RH timing chain tensioner RH timing chain tensioner arm LH timing chain tensioner arm LH timing chain tensioner bolts LH timing chain tensioner RH timing chain tensioner bolts
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01/2003 2003.0 BA Falcon
303-01b-21
Engine — 5.4L (3V)
303-01b-21
IN-VEHICLE REPAIR (Continued)
Item 1 2 3 4
Description RH timing chain LH timing chain Crankshaft sprocket Ignition pulse wheel
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01/2003 2003.0 BA Falcon
303-01b-22
Engine — 5.4L (3V)
303-01b-22
IN-VEHICLE REPAIR (Continued)
Item 1 2 3 4 5 6
Description RH timing chain guide bolt RH timing chain guide LH timing chain guide bolt RH timing chain guide bolt LH timing chain guide bolt LH timing chain guide
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01/2003 2003.0 BA Falcon
303-01b-23
Engine — 5.4L (3V)
303-01b-23
IN-VEHICLE REPAIR (Continued)
Item 1 2 3 4
Description RH camshaft phaser sprocket assembly RH camshaft phaser sprocket assembly bolt LH camshaft phaser sprocket assembly bolt LH camshaft phaser sprocket assembly
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01/2003 2003.0 BA Falcon
303-01b-24
Engine — 5.4L (3V)
303-01b-24
IN-VEHICLE REPAIR (Continued)
Item 1 2 3 4
4. Remove the bolts, the RH timing chain tensioner Description and tensioner arm. RH variable camshaft timing (VCT) housing assembly RH VCT housing assembly bolts LH VCT housing assembly bolts LH variable camshaft timing (VCT) housing assembly
Removal 1. Remove the engine front cover. For additional information, refer to Engine Front Cover in this section. 2. Remove the LH and RH valve covers. For additional information, refer to Valve Cover in this section. 3. Remove the bolts, the LH timing chain tensioner and tensioner arm.
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01/2003 2003.0 BA Falcon
303-01b-25
Engine — 5.4L (3V)
303-01b-25
IN-VEHICLE REPAIR (Continued) 5. Remove the ignition pulse wheel from the crankshaft.
6. Remove the RH and LH timing chains and the crankshaft sprocket. Remove the RH timing chain from the camshaft sprocket. Remove the RH timing chain from the crankshaft sprocket. Remove the LH timing chain from the camshaft sprocket. Remove the LH timing chain.
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01/2003 2003.0 BA Falcon
303-01b-26
Engine — 5.4L (3V)
303-01b-26
IN-VEHICLE REPAIR (Continued) 7. Remove the crankshaft sprocket. 8. Remove both timing chain guides. CAUTION: Unless otherwise instructed, at no time when the timing chains are removed and the cylinders heads are installed is the crankshaft or camshaft to be rotated. Severe piston and valve damage will occur. Remove the bolts. Remove both timing chain guides.
12. Remove the bolts and the variable camshaft timing housing. Discard the gasket.
13. Repeat steps 9 to 11 for removal of LH components. Installation 1. Install a new gasket, the variable camshaft timing housing and the bolts. 9. Fit the SST 303-775 to camshaft in the central position between caps and tighten to prevent rotation. WARNING: When tightening hex key bolts on SST 303-775 make sure both bolts are tightened evenly.
2. Install the RH camshaft variable timing sprocket assembly and loosely install a new bolt and washer.
10. Remove bolt and washer on RH camshaft. CAUTION: Apply an even force on hand tools to remove the camshaft phaser sprocket assembly or damage may occur to the camshaft or camshaft phaser unit. 11. Discard RH Phasor sprocket.
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01/2003 2003.0 BA Falcon
303-01b-27
Engine — 5.4L (3V)
303-01b-27
IN-VEHICLE REPAIR (Continued) 3. With SST303-775 in place holding the camshafts, 8. Pre-position the camshafts. tighten the bolts in two stages Rotate the LH camshaft until the timing mark Stage 1: Tighten to 40 Nm. is approximately at 12 o’clock. Stage 2: Tighten an additional 90 degrees. Rotate the RH camshaft until the timing mark is approximately at 11 o’clock. CAUTION: Only use hand tools to remove the camshaft phaser sprocket assembly or damage may occur to the camshaft or camshaft phaser unit. 4. Repeat steps 1 to 3 for the LH camshaft phaser sprocket. 5. Compress the tensioner plunger, using a vice. CAUTION: Timing chain procedures must be followed exactly or damage to valves and pistons will result.
9. Position the crankshaft so the number on cylinder is at TDC using special tool 303-448 NOTE: The number one cylinder is at top dead centre (TDC) when the stud on the engine block fits into the slot in the handle of the special tool.
6. Install a retaining clip on the tensioner to hold the plunger in during installation. NOTE: If the retaining clip is not available insert a paper clip into the tensioner spring hole.
10. Install the timing chain guides
7. Remove the tensioner from the vise.
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01/2003 2003.0 BA Falcon
303-01b-28
Engine — 5.4L (3V)
303-01b-28
IN-VEHICLE REPAIR (Continued)
11. Remove the crankshaft holding tool 12. Install the crankshaft sprocket, making sure the flange faces forward.
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13. If copper links are not visible on timing chains, hold chains straight mark two links on one end and one link on the other end and use as timing marks.
01/2003 2003.0 BA Falcon
303-01b-29
Engine — 5.4L (3V)
303-01b-29
IN-VEHICLE REPAIR (Continued) 14. Position the lower end of the LH (inner) timing chain on the crankshaft sprocket, aligning the timing mark on the outer flange of the crankshaft sprocket with the single copper link (or single marked link) on the chain.
16. Position the LH timing chain tensioner arm on the dowel pin and install the LH timing chain tensioner bolts. NOTE: The LH timing chain tensioner arm has a bump near the dowel hole for identification.
15. Position the timing chain on the camshaft sprocket with the camshaft sprocket timing mark positioned between the two copper (marked) chain links. NOTE: Make sure the upper half of the timing chain is below the tensioner arm dowel.
17. Remove The retaining clip or paperclip from the LH timing chain tensioner.
18. Position the lower end of the RH (outer) timing chain on the crankshaft sprocket, aligning the timing mark on the sprocket with the single copper (marked) chain link.
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01/2003 2003.0 BA Falcon
303-01b-30
Engine — 5.4L (3V)
303-01b-30
IN-VEHICLE REPAIR (Continued) 19. Position the RH timing chain on the camshaft 23. Install the crankshaft sensor ring on the sprocket. Make sure the camshaft sprocket timing crankshaft. mark is positioned between the two copper WARNING: Check markings on sensor (marked) chain links. ring to ensure correct installation. NOTE: The lower half of the timing chain must be positioned above the tensioner arm dowel. 20. Position the RH timing chain tensioner arm on the dowel pin and install the RH timing chain tensioner bolts.
21. Remove the retaining clip from the RH timing chain tensioner.
24. Install the engine front cover. For additional information, refer to Engine Front Cover in this section. 25. Install the LH and RH Valve covers. For additional information, refer to Valve Covers in this section.
Camshaft (LH shown, RH opposite hand) Special Tool(s) Crankshaft position tool 303-448
Camshaft holding tool 303-775 22. As a post-check, verify correct alignment of all timing marks.
Materials Super Premium SAE 5W-20 XO-5W20-QSP or equivalent Metal Surface Prep
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WSS-M2C153-H
ZC-31
01/2003 2003.0 BA Falcon
303-01b-31
Engine — 5.4L (3V)
303-01b-31
IN-VEHICLE REPAIR (Continued)
Item 1 2 3 4
G89779 en
Description RH camshaft phaser sprocket assembly RH camshaft phaser sprocket assembly bolt LH camshaft phaser sprocket assembly bolt LH camshaft phaser sprocket assembly
01/2003 2003.0 BA Falcon
303-01b-32
Engine — 5.4L (3V)
303-01b-32
IN-VEHICLE REPAIR (Continued)
Item 1 2 3 4 5 6
Description LH camshaft bearing cap bolt Front LH camshaft bearing cap LH camshaft bearing cap LH camshaft Camshaft roller follower Hydraulic lash adjuster
3. Position the crankshaft so the number one cylinder is at TDC with the special tool, 303-448. NOTE: The number one cylinder is at top dead center (TDC) when the stud on the engine block fits into the slot in the handle of the special tool.
Removal 1. Remove the LH and RH valve covers. For additional information, refer to Valve Cover in this section. 2. Remove the engine front cover. For additional information, refer to Engine Front Cover in this section.
G89779 en
01/2003 2003.0 BA Falcon
303-01b-33
Engine — 5.4L (3V)
303-01b-33
IN-VEHICLE REPAIR (Continued) 4. Remove the bolts, the timing chain tensioner and tensioner arm.
8. Fit the SST 303-775 to the camshaft in the central position between the caps and tighten to prevent rotation. WARNING: When tightening hex key bolts on SST 303-775 make sure both bolts are tightened evenly. 9. Remove the bolt and the camshaft phaser sprocket assembly. Discard the bolt and washer. CAUTION: Apply an even force on hand tools to remove the camshaft phaser sprocket assembly or damage may occur to the camshaft or camshaft phaser unit.
5. Compress the tensioner plunger, using a vice. CAUTION: Timing chain precedure must be followed exactly or damage to valves and pistons will result.
6. Install a retaining clip on the tensioner to hold the plunge in during installation.
CAUTION: Do not use the timing chains to prevent rotation when loosening the central bolt as this load will be transmitted through the locked phaser mechanism and could cause damage.
10. Do not allow the timing chains to slip off the crankshaft sprocket. 11. Remove SST 303-775.
7. Remove the tensioner from the vise.
G89779 en
01/2003 2003.0 BA Falcon
303-01b-34
Engine — 5.4L (3V)
303-01b-34
IN-VEHICLE REPAIR (Continued) 12. Remove the camshaft bearing cap bolts in the sequence shown.
2. Install the camshaft and the camshaft bearing caps in their original locations. NOTE: The camshaft bearing caps must be installed in their original locations. Record camshaft bearing cap locations. Lubricate the camshaft bearing caps with clean engine oil. Position the camshaft bearing caps. Install the bolts loosely. 3. Tighten the bolts in the sequence shown to 10 Nm.
13. Remove the camshaft bearing caps and the camshaft. NOTE: The camshaft bearing caps must be installed in their original locations. Record camshaft bearing cap locations. 14. Clean and inspect the camshaft bearing caps. 15. Repeat steps 4 to 11 for RH camshaft. Installation 1. Lubricate the camshaft journals with clean engine oil.
G89779 en
4. Fit the SST 303-775 to the LH camshaft in the central position between the caps and tighten to prevent rotation.
01/2003 2003.0 BA Falcon
303-01b-35
Engine — 5.4L (3V)
303-01b-35
IN-VEHICLE REPAIR (Continued) 5. Install the camshaft variable timing sprocket assembly and loosley install a new bolt and washer. (RH shown)
9. Rotate the LH camshaft with the Camshaft positioning tool until the timing mark is approxiamately at 12 o’clock.
6. Tighten the bolt in two stages:
10. Rotate the RH camshaft with the Camshaft positioning tool until the timing mark is CAUTION: Only use hand tools to remove approxiamately at 11 o’clock. the camshaft phaser sprocket assembly or 11. Tighten the camshaft holding tools. damage may occur to the camshaft or camshaft phaser unit. CAUTION: Do not turn the engine over 1. Stage 1: Tighten to 40 Nm. with the camshaft positioning tool or damage to the camshaft sprocket or bolt may occur. 2. Stage 2: Tighten an an additional 90 degrees. 7. Loosen SST 303-775 camshaft holding tool but do CAUTION: Unless otherwise instructed, at not remove. no time when the timing chains are removed and the cylinder heads are installed is the 8. If copper links are not visible on timing chains, crankshaft or camshaft to be rotated. Severe hold chains straight mark two links on one end piston and valve damage wil occur. and one link on the other end and use as timing marks. CAUTION: Rotate the crankshaft counterclockwise only. Do not rotate past position and/or valve damage can occur.
G89779 en
01/2003 2003.0 BA Falcon
303-01b-36
Engine — 5.4L (3V)
303-01b-36
IN-VEHICLE REPAIR (Continued) 12. Position the crankshaft so the number one cylinder is at TDC with the special tool. NOTE: The number one cylinder is at top dead center (TDC) when the stud on the engine block fits into the slot in the handle of the special tool.
13. Install the timing chain guide. NOTE: Illustration shows both LH and RH timing guides.
G89779 en
01/2003 2003.0 BA Falcon
303-01b-37
Engine — 5.4L (3V)
303-01b-37
IN-VEHICLE REPAIR (Continued) 14. Position the lower end of the LH (inner) timing chain on the crankshaft sprocket, aligning the timing mark on the outer flange of the crankshaft sprocket with the single copper (marked) link on the chain.
17. Position the LH timing chain tensioner arm on the dowel pin and install the LH timing chain tensioner. NOTE: The LH timing chain tensioner arm has a bump near the dowel hole for identification.
15. Position the timing chain on the camshaft sprocket with the camshaft sprocket timing mark positioned between the two copper (marked) chain links. NOTE: Ensure the upper half of the timing chain is below the tensioner arm dowel.
18. Remove the retaining clip or paperclip from the LH timing chain tensioner.
19. Repeat steps 4 to 18 for the RH camshaft. 20. As a post-check, verify correct alignment of all timing marks.
16. Remove the camshaft holding tool.
G89779 en
01/2003 2003.0 BA Falcon
303-01b-38
Engine — 5.4L (3V)
303-01b-38
IN-VEHICLE REPAIR (Continued) 21. Install the crankshaft sensor ring on the crankshaft. WARNING: Check markings on sensor ring to ensure correct installation.
4. Remove the hydraulic lash adjusters. NOTE: Mark each hydraulic lash adjuster to make sure it is returned to its original position.
Installation Install in the reverse order to the removal.
22. Install the engine front cover. For additional information, refer to Engine Front Cover in this Valve spring and Valve Stem Seal section. 23. Install the LH and RH Valve covers. For additional Removal information, refer to Valve Covers in this section. 1. Remove the appropriate spark plug, and pressurise the cylinder via an air line and adaptor. Rocker Arm, Lash Adjuster, Valve DO NOT exceed 800 KPa. Spring and Valve Stem Seal 2. Remove the keys, retainers and valve spring using a suitable valve spring compressor. Materials Super Premium SAE 5W-20 XO-5W20-QSP or equivalent
WSS-M2C153-H
Removal The rocker arm and lash adjuster are clipped together to prevent rocker displacement under extraordinary start up conditions. Care should be taken when removing the assembly, so as not to strain the clip. Do not remove the clip unless either the rocker arm of lash adjuster are to be eplafed and fit a new clip. Do not remove the clip unless either the rocker arm of lash adjuster are to be replaced and fit a new clip. If the clip is loose on the rocker arm it should be replaced when the rocker and lash adjuster assembly is removed from the cylinder head. 1. Remove the valve cover. For additional information, refer to Valve Cover removal in this section. 2. Remove the camshaft. For additional information, refer to camshaft removal in this section. 3. Remove the camshaft roller follower(s) NOTE: Mark each camshaft roller followers to make sure it is returned to its original position.
G89779 en
3. Remove the valve stem seal/spring seat assembly with pliers or multi-grips, being careful not to mark the valve stem. Installation 1. Pressurise the cylinder via an air line and adaptor. Do not exceed 800 KPa. 2. Use an appropriate inside diameter tube to gently seat the valve stem seal.
01/2003 2003.0 BA Falcon
303-01b-39
Engine — 5.4L (3V)
303-01b-39
IN-VEHICLE REPAIR (Continued) 3. Reassemble in the reverse order to the procedure above. NOTE: The valve spring must be fitted with the smaller diameter end upwards.
Exhaust Manifold (LH shown, RH opposite hand)
Item 1 2 3
Description Exhaust manifold gasket Exhaust manifold Exhaust manifold nuts
Removal 1. Remove the exhaust manifold. Discard the gasket. Clean the sealing surfaces with metal surface prep. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs, or other abrasive means to clean the sealing surfaces. These may cause scratches and gouges resulting in leak paths. Use a
G89782 en
01/2003 2003.0 BA Falcon
303-01b-40
Engine — 5.4L (3V)
303-01b-40
IN-VEHICLE REPAIR (Continued) plastic scraper to clean the sealing surfaces. Installation 1. Install a new gasket 2. Install the exhaust manifold to the cylinder head. Tighten the exhaust manifold nuts in the sequence shown.
4. Disconnect the oil pressure sensor.
5. Remove the oil pressure sender.
Oil Filter Adapter Removal 1. Raise and support the vehicle. For additional information, refer to Section 100-02. 2. Drain the cooling system. For additional information, refer to Section 303-03. 3. Remove the oil filter.
G89782 en
6. Disconnect the radiator lower hose.
01/2003 2003.0 BA Falcon
303-01b-41
Engine — 5.4L (3V)
303-01b-41
IN-VEHICLE REPAIR (Continued) 7. Remove the four bolts and the filter adapter. Discard the gasket
2. Disconnect the oil pressure sender electrical connector.
3. Remove the oil pressure sender.
Installation Install in the reverse order to the removal. NOTE: Install a new oil filter adapter gasket.
Oil Pressure Sender Materials Pipe Sealant with Teflon© D8AZ-19554-A or equivalent
WSK-M2G350-A2 and ESR-M18P7-A
Installation Install in the reverse order to the removal.
Oil Level Indicator and Tube Removal 1. Remove the oil level indicator 2. Remove the bolt.
Removal 1. Raise and support the vehicle. For additional information, refer to Section 100-02.
G89785 en
01/2003 2003.0 BA Falcon
303-01b-42
Engine — 5.4L (3V)
303-01b-42
IN-VEHICLE REPAIR (Continued) 3. 3. Remove the oil level indicator tube. a. Install a new O-ring seal.
Installation Install in the reverse order to the removal.
Oil Pan
2. Install the special tool.
3. Raise and support the vehicle. For additional information, refer to Section 100-02. 4. Remove through bolts from the engine mount bracket and chassis. 5. Drain the engine oil.
Special Tool(s) 3-Bar Engine Support 303-F073
Materials Metal Surface Cleaner F4AZ-19A536-RA or equivalent Silicone Gasket and Sealant F7AZ-19554-EA or LOCTITE 5900 or equivalent 10W-30 GF2 Engine Oil or equivalent
WSE-M5B392-A WSE-M4G323-A4
6. Lower the vehicle. 7. Raise the engine 63.5 mm.
WSS-M2C910-A2
Removal 1. Remove alternator, refer to Section 414-02.
8. Raise the vehicle
G89785 en
01/2003 2003.0 BA Falcon
303-01b-43
Engine — 5.4L (3V)
303-01b-43
IN-VEHICLE REPAIR (Continued) 9. Remove the bolts, oil pan and gasket. Inspect the oil pan gasket for damage. NOTE: Be careful when removing oil pan gasket. It is re-usable if not damaged.
3. Apply silicone gasket and sealant at the front cover-to-cylinder block sealing surface. NOTE: If the oil pan and the oil pan gasket are not secured within four minutes, the sealant must be removed and the sealing area cleaned with metal surface cleaner. Allow to dry until there is no sign of wetness, or four minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage.
Installation 1. Clean the mating surfaces. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. 4. Install the oil pan gasket and the oil pan and loosely install the 16 bolts. These tools cause scratches and gouges which make leak paths. Use a plastic scraping 5. Tighten the bolts in three stages, in the sequence shown. tool to remove all traces of old sealant Stage 1: Tighten to 2 Nm. 2. Apply silicone gasket and sealant at the rear oil seal retainer-to-cylinder block sealing surface. Stage 2: Tighten to 20 Nm. NOTE: If the oil pan and the oil pan gasket are not secured within four minutes, the sealant must be removed and the sealing area cleaned with metal surface cleaner. Allow to dry until there is no sign of wetness, or four minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage.
Stage 3: Tighten an additional 60 degrees 6. Lower the vehicle.
G89786 en
01/2003 2003.0 BA Falcon
303-01b-44
Engine — 5.4L (3V)
303-01b-44
IN-VEHICLE REPAIR (Continued) 7. Lower the engine. Remove the special tool.
8. Raise the vehicle. 9. Install through bolt to the engine mount bracket and chassis.
Removal 1. Remove the oil pan. For additional information, refer to Oil Pan in this section 2. Remove the three (A) bolts and the (B) oil pump screen cover and tube.
Installation 1. Clean and inspect the mating surfaces. Inspect the O-ring seal 2. Install the oil pump screen cover and tube and install the bolts. CAUTION: Make sure the O-ring is in place and not damaged. A missing or damaged O-ring can cause foam in the lubrication system, low oil pressure and severe engine damage. NOTE: Clean and inspect the mating surfaces and install a new O-ring. Lubricate with clean engine oil.
10. Lower the vehicle. 11. Install the alternator. For additional information, refer to Section 414-02. 12. Install the lower intake manifold. For additional information, refer to Intake Manifold-Upper. 13. Refill the engine crankcase with clean engine oil.
Oil Pump Screen and Pickup Tube Materials 10W-30 GF2 engine oil or equivalent
G89786 en
WSS-M2C910-A2
3. Install the oil pan. For additional information, refer to Oil Pan Installation in this section.
Flywheel Removal 1. Remove the transmission. For additional information, refer to Automatic Transmission chapter 307-01 or for Manual Transmission chapter 308-03B. 2. Remove the clutch disc and pressure plate. Manual transmission only. For additional information, refer to Clutch chapter 308-01
01/2003 2003.0 BA Falcon
303-01b-45
Engine — 5.4L (3V)
303-01b-45
IN-VEHICLE REPAIR (Continued) 3. Remove six of the eight bolts. Loosen the two remaining bolts but leave in place. CAUTION: Two bolts should be loosened but left in to prevent the flywheel (6375) from falling
Crankshaft Rear Oil Seal Special Tool(s) Installer, Crankshaft Rear Oil Seal 303-518 (T95P-6701-DH)
Remover, Crankshaft Rear Oil Seal 303-519 (T95P-6701-EH)
4. Separate the flywheel from the crankshaft 5. Remove the bolts remaining in the crankshaft. 6. Remove the flywheel. Installation 1. Position the flywheel onto the crankshaft and install the flywheel-to-crankshaft bolts (6379). Apply the threadlock and sealer to bolt threads.
Installer, Crankshaft Rear Oil Seal 303-516 (T95P-6701-BH)
Remover, Crankshaft Rear Oil Slinger 303-514 (T95P-6701-AH)
Installer, Crankshaft Rear Oil Slinger 303-517 (T95P-6701-CH)
Impact Slide Hammer 100-001 (T50T-100-A) 2. Install the disc and pressure plate. Manual transmission only. For additional information, refer to Clutch chapter 308-01 3. Install the transmission. Refer to Automatic Transmission chapter 307-01 or for Manual Transmission chapter 308-03B. Removal 1. Remove the Flywheel. For additional information, refer to Flywheel in this section.
G89788 en
01/2003 2003.0 BA Falcon
303-01b-46
Engine — 5.4L (3V)
303-01b-46
IN-VEHICLE REPAIR (Continued) 2. Using the special tools, remove the crankshaft oil slinger.
2. Using the special tools, install the crankshaft oil slinger
3. Using the special tools, remove the crankshaft rear oil
3. Install the Flywheel. For additional information, refer to Flywheel in this section.
Engine Mounts - RH Special Tool(s) 3-Bar Engine Support 303-F073
Removal 1. Install the special tool. Installation 1. Using the special tool, install the crankshaft rear oil seal.Using the special tools, install the crankshaft rear oil seal.
G89788 en
01/2003 2003.0 BA Falcon
303-01b-47
Engine — 5.4L (3V)
303-01b-47
IN-VEHICLE REPAIR (Continued) 2. Raise and support the vehicle. For additional information, refer to Section 100-02.
3. Remove the engine mount bracket through bolt. 4. Remove crossmember 5. Remove engine mount & bracket assembly from the engine. 6. Remove engine mount heat shield. 7. Remove the engine mount. Installation Install in the reverse order to the removal.
4. 4. Remove the through bolt.
5. 5. Lower the vehicle. 6. 6. Raise the engine 63.5 mm
Engine Mounts - LH Special Tool(s) 3-Bar Engine Support 303-F073 7. 7. Remove the engine mount from the vehicle. Installation 1. Install in the reverse order to the removal. Removal 1. 1. Remove the lower intake manifold. For additional information, refer to Intake Manifold-Upper in this section 2. 2. Install the special tool
Engine Removal Special Tool(s) Modular Engine Lifting Bar 303-F047 (014-00073)
Holding Wrench, Fan Pulley 303-239 (T84T-6312-C)
3. 3. Raise and support the vehicle. For additional information, refer to Section 100-02. G89792 en
01/2003 2003.0 BA Falcon
303-01b-48
Engine — 5.4L (3V)
303-01b-48
IN-VEHICLE REPAIR (Continued) Special Tool(s) Wrench, Fan Clutch Hub Nut 303-240 (T84T-6312-D)
Materials 10W-30 GF2 engine oil or equivalent
6. Drain coolant from engine at tap left hand lower corner. 7. Disconnect the lower radiator hose from the radiator and the engine.
WSS-M2C910-A2
Removal 1. Disconnect lower pivot hood struts. 2. Tie hood back. 3. Remove the radiator upper hose from the engine. 4. Remove the fan shroud. Remove the screws. Lift and remove the fan pack, out of the vehicle.
8. Disconnect the surge tank hose from the radiator. Release the clamp. Slide the hose off the radiator fitting. 9. Remove the surge tank from vehicle Disconnect vent and supply hoses from surge tank Remove surge tank from vehicle. 10. Remove the radiator. Remove the bolts Remove the upper radiator support brackets Remove bolts attaching condensor to radiator Lift the radiator off the radiator mounting insulators. Remove the radiator mounting insulators. 11. Remove the accessory drive belt. For additional 5. Disconnect the transmission fluid cooler fittings. information, refer to Section 303-05. Disconnect the upper transmission fluid cooler 12. Disconnect the alternator electrical connectors. fitting. 13. Disconnect battery and alternator cables from RH Disconnect the lower transmission fluid cooler Relay box. fitting. 14. Remove PCM, refer to Section 303-14. NOTE: To avoid disturbing the transmission oil cooler fittings, use a support spanner when 15. Disconnect the wiring harness (PCM ’A’ connector & 24 pin connector) from vehicle. releasing cooling lines. 16. Disconnect transmission wiring harness from transmission. 17. Disconnect hego sensor wiring plugs. Refer to chapter Section 303-14p106 for more information.
G89792 en
01/2003 2003.0 BA Falcon
303-01b-49
Engine — 5.4L (3V)
303-01b-49
IN-VEHICLE REPAIR (Continued) 18. Remove the ground strap retaining bolt.
27. Disconnect the starter motor electrical connections. Remove the two nuts Remove the battery cable. Remove the starter solenoid wire.
19. 20. 21. 22. 23.
Disconnect the lower radiator hose. Disconnect the heater hoses from rear of engine. Disconnect brake booster vacuum hose. Disconnect purge valve connection. Disconnect air intake to throttle body and remove 28. Remove the nut and the starter motor ground cable entire air cleaner assembly. 24. Disconnect fuel lines using special tool, as outlined in Section 310-00. 25. Disconnect the power steering pressure (PSP) sensor. 26. Remove the bolts and position the power steering pump out of the way
29. Remove the 2 bolts and the starter motor.
G89792 en
01/2003 2003.0 BA Falcon
303-01b-50
Engine — 5.4L (3V)
303-01b-50
IN-VEHICLE REPAIR (Continued) 30. Disconnect the crankshaft position (CKP) sensor.
36. Remove the through bolt from the RH motor mount
31. Disconnect the A/C compressor electrical connector.
37. Remove the plate bolts and the inspection cover
32. Remove the bolts and the A/C compressor. NOTE: Do not degas, position A/C compressor out of the way.
38. Remove the four bolts from the torque converter and discard (Auto tran only). NOTE: Gain access to the nuts by turning the crank dampener counterclockwise.
33. Remove nut holding exhaust heatshield and discard, then remove heatshield. 34. Disconnect the pipes at the exhaust manifolds. NOTE: If studs are removed from exhaust manifolds during disassembly, then discard studs and nut and replace with new parts. 35. Remove the through bolt from the LH engine mount.
G89792 en
01/2003 2003.0 BA Falcon
303-01b-51
Engine — 5.4L (3V)
303-01b-51
IN-VEHICLE REPAIR (Continued) 39. Remove the 6 bolts from the transmission.
40. Lower the vehicle. 41. Install rear lifting hook and front lifting hook. 42. Support the transmission with a floor jack and a block of wood. 43. Remove the engine from the vehicle.
5. Position the transmission level indicator tube and install the bolt.
6. Install the five bolts to the bell housing.
7. Install the oil filter.
Installation 1. Support the transmission with a floor jack and a block of wood. 2. Install the engine in the vehicle. 3. Remove the special tool.
4. Raise the vehicle. For additional information, refer to Section 100-02.
G89792 en
01/2003 2003.0 BA Falcon
303-01b-52
Engine — 5.4L (3V)
303-01b-52
IN-VEHICLE REPAIR (Continued) 8. Install 4 new bolts to the torque converter (Auto trans only). NOTE: Gain access to the nuts by turning the crank dampener counterclockwise.
11. Install the bolt to the RH engine motor mount.
12. Install the bolt to the LH engine motor mount. 9. Install the plug (Auto trans only).
13. Install the starter motor and 2 bolts. 10. Install the inspection cover and the bolts.
G89792 en
01/2003 2003.0 BA Falcon
303-01b-53
Engine — 5.4L (3V)
303-01b-53
IN-VEHICLE REPAIR (Continued) 14. Connect the cable and install the motor nut.
20. Install the A/C compressor and bolts.
15. Connect the starter motor electrical connectors. Position the starter solenoid wire. Position the battery cable. Install the nuts.
21. Connect the A/C compressor electrical connector.
22. Connect the crankshaft position sensor.
16. Install the starter motor solenoid terminal cover. 17. Install the RH exhaust manifold studs. 18. Connect the exhaust pipes to the exhaust manifolds and torque nuts to specification.
19. Install the heatshield and fasten with a new heatshield nut.
G89792 en
01/2003 2003.0 BA Falcon
303-01b-54
Engine — 5.4L (3V)
303-01b-54
IN-VEHICLE REPAIR (Continued) 23. Position the power steering pump and install the bolts.
34. Connect the transmission wiring harness to transmission.
24. 25. 26. 27. 28. 29.
35. Connect wiring harness (PCM ’A’ connector and 24 pin connector) to vehicle. 36. Install the alternator and alternator bracket.
Connect the power steering pressure sensor. Lower the vehicle. Connect the lower radiator hose. Install the stud and reposition the A/C muffler. Install battery into vehicle. Connect the heater hoses to rear of engine.
37. Connect the alternator electrical connectors.
30. 31. 32. 33.
Install surge tank into vehicle. Connect vent and supply hoses to surge tank. Connect the surge tank return hose. Install the two bolts retaining the transmission to the engine.
38. Connect battery and alternator cables to RH relay box. 39. Install the accessory drive belt. For additional information, refer to Section 303-05. 40. Install the intake manifold. For additional information, refer to Intake Manifold-Upper in this section.
G89792 en
01/2003 2003.0 BA Falcon
303-01b-55
Engine — 5.4L (3V)
303-01b-55
IN-VEHICLE REPAIR (Continued) 41. Install the radiator. Install the radiator mounting insulators. Position the radiator on the radiator mounting insulators. Position the brackets. Install the bolts.
45. Install the fan shroud. Install the fan blade and fan shroud, as a unit, in the vehicle. Install the screws.
42. Install the surge tank hose to the radiator. Release the clamp. Slide the hose onto the radiator fitting.
46. Recharge the A/C system. For additional information, refer to Section 412-00. 47. Fill the engine with oil. 48. Fill the engine cooling system. For additional information, refer to Section 303-03. 43. Connect the lower radiator hose and the upper radiator hose. 44. Connect the transmission fluid cooler fittings. Connect the lower transmission fluid cooler fitting. Connect the upper transmission fluid cooler fitting. NOTE: To avoid disturbing the transmission oil cooler fittings, use a support hammer when tightening fuel lines.
G89792 en
01/2003 2003.0 BA Falcon
303-01b-56
Engine — 5.4L (3V)
303-01b-56
DISASSEMBLY
Engine Special Tool(s) Remover, Crankshaft Rear Oil Slinger 303-514 (T95P-6701-AH)
Disassembly NOTE: The crankshaft rear oil seal, the oil seal slinger and the oil seal retainer plate must be removed before mounting the engine on the engine stand. 1. Remove the bolts and the flexplate or the flywheel.
Remover, Crankshaft Rear Oil Seal 303-519 (T95P-6701-EH)
Slide Hammer 100-001 (T50T-100-A) 2. Using the special tools, remove the crankshaft rear oil slinger.
Installer, Connecting Rod 303-442 (T93P-6136-A)
Lift Bracket Set, Engine 303-DS086 (D93P-6001-A) 3. Using the special tools, remove the crankshaft rear oil seal. Remover, Crankshaft Vibration Damper 303-009 (T58P-6316-D)
Remover, Crankshaft Front Oil Seal 303-107 (T74P-6700-A)
G89796 en
01/2003 2003.0 BA Falcon
303-01b-57
Engine — 5.4L (3V)
303-01b-57
DISASSEMBLY (Continued) 4. Remove the bolts, oil pan and oil pan gasket. Clean and inspect the sealing surfaces.
9. Remove the intake manifold gaskets. Clean and inspect the sealing surfaces. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all traces of old sealant.
5. Remove the bolts and the crankshaft rear oil seal retainer plate. Clean and inspect the sealing surfaces.
10. Remove the bolts and the generator support bracket.
6. Install the engine onto a suitable engine stand. 7. With the engine on the engine stand, remove the engine control sensor wiring harness. 8. Remove the bolts and the intake manifold assembly. 11. Remove the bolts and the generator.
G89796 en
01/2003 2003.0 BA Falcon
303-01b-58
Engine — 5.4L (3V)
303-01b-58
DISASSEMBLY (Continued) 12. Remove the bolt.
soap and water or a suitable solvent. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all traces of old sealant. NOTE: The bolts are part of the valve cover and should not be removed. NOTE: LH is shown, RH is similar.
13. Remove the bolts and the water bypass tube assembly.
16. Remove the nuts and the two radio interference capacitors. NOTE: RH is shown, LH is similar.
14. Remove the eight bolts and the eight coil packs. NOTE: RH is shown, LH is similar.
15. Remove the bolts and the valve covers. Fully loosen the bolts and remove the valve cover. Clean the valve cover mating surface of the cylinder head with silicone gasket remover and metal surface prep. Follow the directions on the packaging. Inspect the valve cover gasket. If the gasket is damaged, remove and discard the gasket. Clean the valve cover gasket groove with G89796 en
01/2003 2003.0 BA Falcon
303-01b-59
Engine — 5.4L (3V)
303-01b-59
DISASSEMBLY (Continued) 17. Remove the eight nuts and the RH exhaust manifold. Clean and inspect the sealing surfaces.
20. Remove the bolt and the crankshaft position (CKP) sensor.
18. Remove the bolts and the A/C compressor.
21. Remove the eight nuts and the LH exhaust manifold. Clean and inspect the sealing surfaces.
19. Remove the bolts and the A/C compressor bracket.
22. Remove the bolts and the power steering pump.
G89796 en
01/2003 2003.0 BA Falcon
303-01b-60
Engine — 5.4L (3V)
303-01b-60
DISASSEMBLY (Continued) 23. Remove the bolts and the oil filter adapter.
26. Remove the bolts.
24. Remove the bolts, the coolant pump pulley, and the accessory drive belt idler pulley.
27. Remove the coolant pump from the cylinder block.
25. Remove the bolts and the accessory drive belt tensioner.
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28. Remove and discard the crankshaft pulley bolt. Using the special tool, remove the crankshaft pulley.
01/2003 2003.0 BA Falcon
303-01b-61
Engine — 5.4L (3V)
303-01b-61
DISASSEMBLY (Continued) 29. Using the special tool, remove the crankshaft front 32. Remove the crankshaft sensor ring from the seal. crankshaft.
30. Remove the fasteners. NOTE: Correct fastener location is essential for assembly procedure. Record fastener location.
33. Compress the valve springs, and remove the camshaft roller followers. NOTE: The use of a special tool may be required for this step. NOTE: The camshaft roller followers must be reinstalled in their original locations. Record the camshaft roller follower locations. 34. Position the crankshaft with the keyway at the 9 o’clock position.
31. Remove the engine front cover from the cylinder block.
35. Remove the bolts, the RH timing chain tensioner and tensioner arm.
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Engine — 5.4L (3V)
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DISASSEMBLY (Continued) 36. Remove the bolts, the LH timing chain tensioner and tensioner arm.
37. Remove the RH and LH timing chains and the crankshaft sprocket. Remove the RH timing chain from the camshaft sprocket. Remove the RH timing chain from the crankshaft sprocket. Remove the LH timing chain from the camshaft sprocket. Remove the LH timing chain and crankshaft sprocket.
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Engine — 5.4L (3V)
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DISASSEMBLY (Continued) 38. Remove both timing chain guides. Remove the bolts. Remove both timing chain guides.
39. Remove the bolt and the oil level indicator tube. 40. Remove the bolts and discard. RH is shown; LH is similar. 2. Remove the cylinder heads. CAUTION: The cylinder head bolts must be discarded and new bolts must be installed. They are tighten-to-yield designed and cannot be reused. CAUTION: Place cylinder head on a cardboard or wood surface to prevent damage to the joint face. CAUTION: Aluminum surfaces are soft and can be scratched easily. Never place the cylinder head gasket surface, unprotected, on a bench surface. NOTE: The cylinder heads are cleaned as part of the cylinder head disassembly process.
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41. Discard the cylinder head gaskets. Clean the engine block sealing surfaces with silicone gasket remover and metal surface prep. Follow the directions on the packaging. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges which make leak paths. Use a plastic scraper to remove all traces of the head gasket. 42. Remove the bolts and the oil pump screen and pickup tube. 43. Remove the oil pump screen and pickup tube spacer.
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Engine — 5.4L (3V)
303-01b-64
DISASSEMBLY (Continued) 44. Remove the oil pump. 1. Remove the bolts. 2. Remove the oil pump.
46. Remove the bolts and the connecting rod cap. Discard the bolts. CAUTION: Verify that the connecting rods and rod caps have orientation numbers cast into them. If not, number the connecting rods and rod caps for correct orientation.
45. Before removing the pistons, inspect the top of the cylinder bores. If necessary, remove the ridge or carbon deposits from each cylinder using a cylinder ridge reamer, following the manufacturer instructions.
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Engine — 5.4L (3V)
303-01b-65
DISASSEMBLY (Continued) 47. Use the special tool to push the piston through the top of the cylinder block. CAUTION: Do not scratch the cylinder walls or crankshaft journals with the connecting rod.
48. Remove the fasteners. 1. Remove and discard the cross-mounted main cap bolts. 2. Remove the dowels. 3. Remove and discard the main bearing cap bolts.
49. Remove the five main bearing caps, the lower crankshaft main bearings and the lower thrust washer.
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Engine — 5.4L (3V)
303-01b-66
DISASSEMBLY (Continued) 50. Remove the crankshaft, the upper crankshaft main bearings and the upper thrust washers from the cylinder block.
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303-01b-67 — 5.4L (3V) DISASSEMBLY AND ASSEMBLY OFEngine SUBASSEMBLIES
303-01b-67
2. Remove the bolts and the variable camshaft timing housing.
Cylinder Head Special Tool(s) Installer, Valve Stem Oil Seal 303-383 (T91P-6571-A)
Materials Motorcraft Silicone — Gasket Remover ZC-30 Motorcraft Metal Surface — Prep ZC-31 SAE 10W-30 Premium WSS-M2C153-H Synthetic Blend Motor Oil XO-10W30-QSP
3. Remove the bolts and the bearing caps. NOTE: The camshaft bearing caps must be reinstalled in their original locations. Record the camshaft bearing cap locations.
Disassembly CAUTION: Cylinder head machining or milling is not authorized by the Ford Motor Company. Cylinder head flatness must be within 0.0254 mm (0.001 in) across a 38.1 mm (1.5 in) square area. CAUTION: Place the cylinder head on a cardboard or wood surface to prevent damage to the joint face. 1. Install the special tool and remove the bolt and the camshaft phaser sprocket assembly. Discard the bolt and washer. CAUTION: Only use hand tools to remove the camshaft phaser sprocket assembly or damage may occur to the camshaft or camshaft phaser unit.
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Engine — 5.4L (3V)
303-01b-68
DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES (Continued) 4. Remove the camshaft.
7. Remove the valve stem seals. 5. Remove the hydraulic lash adjusters. NOTE: The hydraulic lash adjusters must be reinstalled in their original locations. Record the hydraulic lash adjuster locations.
6. Compress the valve springs and remove the valves. 1. Remove the valve spring retainer keys. 2. Remove the valve spring retainers. 3. Remove the valve springs. 4. Remove the valves. CAUTION: Keep the valves and valve spring retainer keys in order so they can be reinstalled in their original locations. NOTE: The use of a special tool may be required for this step.
8. Clean the cylinder head sealing surfaces. 1. Remove any large deposits of silicone or gasket material with a plastic scraper. 2. Apply silicone gasket remover, following package directions, and allow to set for several minutes. 3. Remove the silicone gasket remover with a plastic scraper. A second application of silicone gasket remover may be required if residual traces of silicone or gasket material remain. 4. Apply metal surface prep, following package directions, to remove any remaining traces of oil or coolant, and to prepare the surfaces to bond with the new gasket. Do not attempt to make the metal shiny. Some staining of the metal surfaces is normal. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges that make leak paths. Use a plastic scraping tool to remove all traces of the head gasket. CAUTION: Observe all warnings or cautions and follow all application directions contained on the packaging of
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Engine — 5.4L (3V)
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DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES (Continued) the silicone gasket remover and the metal surface prep. NOTE: If there is no residual gasket material present, metal surface prep can be used to clean and prepare the surfaces.
5. Install the hydraulic lash adjusters in their original locations. NOTE: Lubricate the hydraulic lash adjusters using clean engine oil.
Assembly 1. Install the valves in the valve guides located in the cylinder head. NOTE: Lubricate the valve stems using clean engine oil.
6. Lubricate the camshaft journals with clean engine oil.
2. Install the valve stem seals. NOTE: The use of a special tool may be required for this step. 3. Install the valve springs and the valve spring retainers onto the valves.
7. Install the camshaft. NOTE: Lubricate the camshaft using clean engine oil.
4. Compress the valve springs. Install the valve spring retainer keys. NOTE: The use of a special tool may be required for this step.
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Engine — 5.4L (3V)
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DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES (Continued) 8. Install the bearing caps and the bolts and tighten in the sequence shown. NOTE: The camshaft bearing caps must be reinstalled in their original locations. Record the camshaft bearing cap locations.
10. Install the camshaft variable timing sprocket assembly and loosely install the bolt.
NOTE: Lubricate the bearing caps using clean engine oil.
11. Install the special tool.
12. Tighten the bolt in two stages: Stage 1: Tighten to 40 Nm (30 lb-ft). Stage 2: Tighten an additional 90 degrees.
9. Install a new gasket, the variable camshaft timing housing and the bolts.
CAUTION: Only use hand tools to remove the camshaft phaser sprocket assembly or damage may occur to the camshaft or camshaft phaser unit.
13. Remove the special tool.
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Engine — 5.4L (3V)
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ASSEMBLY Special Tool(s)
Engine Special Tool(s) Installer, Connecting Rod 303-442 (T93P-6136-A)
Installer, Crankshaft Vibration Damper 303-102 (T74P-6316-B)
Installer, Crankshaft Rear Oil Seal 303-516 (T95P-6701-BH)
Installer, Crankshaft Rear Oil Slinger 303-517 (T95P-6701-CH)
Lifting Bracket Set, Engine 303-DS086 (D93P-6001-A) Installer, Crankshaft Front Oil Seal 303-635
Installer, Front Cover Oil Seal 303-335 (T88T-6701-A)
Compressor, Piston Ring 303-D032 (D81L-6002-C) or equivalent
Holding Tool, Crankshaft 303-448 (T93P-6303-A)
Installer, Crankshaft Rear Oil Seal 303-518 (T95P-6701-DH)
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Modular Engine Lift Bracket 303-F047 (014-00073) or equivalent
Materials Motorcraft Silicone Gasket Remover ZC-30 Motorcraft Metal Surface Prep ZC-31 Silicone Gasket and Sealant F7AZ-19554-EA or equivalent Instant Adhesive E8AZ-19554-A SAE 10W-30 Premium Synthetic Blend Engine Oil XO-10W30-QSP or equivalent Motorcraft Premium Engine Coolant VC-4-A (in Canada CXC-10; in Oregon VC-5) or equivalent. Do not mix coolant types.
— — WSE-M4G323-A4
WSK-M2G402-A4 WSS-M2C153-H
ESE-M97B44-A (green in color)
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Engine — 5.4L (3V)
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ASSEMBLY (Continued) Materials Motorcraft Premium Gold WSS-M97B51-A1 (yellow Engine Coolant in color) VC-7-A (in Oregon VC-7-B) or equivalent. Do not mix coolant types. Hydraulic Chain 1L3Z-6P250-AA Tensioner Retaining Clip
the correct bearing grade for this main bearing is a ‘‘2’’. Repeat this process for the remaining four main bearings.
Assembly All Engines 1. Record the main bearing code found on the front of the engine block.
2. Record the main bearing code found on the back of the crankshaft.
3. Using the data recorded earlier and the Bearing Select Fit Chart, Standard Bearings, determine the required bearing grade for each main bearing. Read the first letter of the engine block main bearing code and the first letter of the crankshaft main bearing code. Read down the column below the engine block main bearing code letter, and across the row next to the crankshaft main bearing code letter, until the two intersect. This is the required bearing grade for the number one crankshaft main bearing. As an example, if the engine block code letter is ‘‘F’’ and the crankshaft code letter is ‘‘D’’, G89799 en
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Engine — 5.4L (3V)
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ASSEMBLY (Continued) Bearing Select Fit Chart, Standard Bearings
4. If oversize bearings are being used, use the procedure in the previous step and the Bearing Select Fit Chart, Oversize Bearings to determine the required bearing grade for each main bearing.
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Engine — 5.4L (3V)
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ASSEMBLY (Continued) Bearing Select Fit Chart, Oversize Bearings
5. Install the crankshaft upper main bearings into the cylinder block and lubricate them with clean engine oil. NOTE: Before assembling the cylinder block, all sealing surfaces must be free of chips, dirt, paint and foreign material. Also, make sure the coolant and oil passages are clear. 6. Install the crankshaft onto the upper crankshaft main bearings. NOTE: The upper thrust washers are shown for location purposes only. Do not install the upper thrust washers until the crankshaft is installed. Refer to the following two steps.
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Engine — 5.4L (3V)
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ASSEMBLY (Continued) 7. Push the crankshaft rearward and install the rear crankshaft upper thrust washer at the back of the No. 5 main boss. NOTE: The oil groove on the thrust washer must face toward the front of the engine (against the crankshaft thrust surface).
10. Install the crankshaft lower main bearings into the main bearing caps and lubricate them with clean engine oil. Locate the main bearing cap on the cylinder block and tap into place using a plastic or dead-blow hammer. 8. Push the crankshaft forward and install the front crankshaft upper thrust washer at the front of the No. 5 main boss. NOTE: The oil groove on the thrust washer must face toward the front of the engine (against the crankshaft surface).
9. Install the lower crankshaft thrust washer to the back side of the No. 5 main bearing cap, with oil grooves facing the crankshaft surface. NOTE: To aid in assembly, apply petroleum jelly to the back of the crankshaft thrust washer. NOTE: The oil groove on the thrust washer must face toward the rear of the engine (crankshaft surface).
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Engine — 5.4L (3V)
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ASSEMBLY (Continued) 11. Install the dowel pins so the flat sides face the crankshaft.
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12. Install the vertical main bearing cap fasteners and tighten in the sequence shown. Tighten to 40 Nm (30 lb-ft). Tighten an additional 90 degrees.
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Engine — 5.4L (3V)
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ASSEMBLY (Continued) 13. Install the side bolts and tighten them in the sequence shown. Tighten to 30 Nm (22 lb-ft). Tighten an additional 90 degrees.
15. Once the connecting rod is seated on the crankshaft journal, remove the Connecting Rod Installer. CAUTION: Do not scratch the cylinder walls or crankshaft journals with the connecting rod.
14. Use the special tools to install the piston and connecting rod with the upper connecting rod bearing in place. CAUTION: Do not scratch the cylinder walls or crankshaft journals with the connecting rod. NOTE: The next three steps are for all eight connecting rods, rod caps and pistons. Only one connecting rod, rod cap and piston is shown. NOTE: Make sure the identification marks on the piston and connecting rod face toward the front of the engine.
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16. Position the lower bearing and connecting rod, and install the new bolts loosely. CAUTION: The rod cap installation must keep the same orientation as marked during disassembly. NOTE: The connecting rod caps are of the ‘‘cracked’’ design and must mate with the connecting rod ends. Excessive bearing clearance will result if not mated correctly.
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Engine — 5.4L (3V)
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ASSEMBLY (Continued) 17. Tighten the bolts in two stages, using the sequence shown. Stage 1: Tighten to 43 Nm (32 lb-ft). Stage 2: Tighten an additional 105 degrees. NOTE: Main bearing caps are removed for clarity.
19. Position the head gasket over the dowel pins. RH is shown; LH is similar. CAUTION: Make sure all coolant residue and foreign material are cleaned from the block surface and cylinder bore. CAUTION: The use of sealing aids (aviation cement, copper spray, and glue) is not permitted. The gasket must be installed dry.
20. Rotate the crankshaft until the crankshaft keyway points toward the 9 o’clock position.
18. Position the oil pump and install the bolts loosely. Tighten the bolts in the sequence shown.
21. Position the cylinder head over the dowels and head gasket and install the cylinder head bolts loosely. RH is shown; LH is similar. CAUTION: The cylinder head bolts must be discarded and new bolts installed. They are tighten-to-yield designed and cannot be reused. NOTE: NOTE: Do not turn the crankshaft until instructed to do so.
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Engine — 5.4L (3V)
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ASSEMBLY (Continued) 23. Install the oil level indicator tube. Install a new O-ring seal on the oil level indicator tube. Install the oil level indicator tube. Install the bolt and tighten to 10 Nm (89 lb-in). 24. Install the RH exhaust manifold gaskets and the exhaust manifold. Tighten the nuts in the sequence shown.
22. Tighten the bolts in three stages, in the sequence shown. RH is shown; LH is similar. Stage 1: Tighten to 40 Nm (30 lb-ft). Stage 2: Tighten an additional 90 degrees. Stage 3: Tighten an additional 90 degrees.
25. Install the LH exhaust manifold and the exhaust manifold gaskets. Tighten the nuts in the sequence shown.
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Engine — 5.4L (3V)
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ASSEMBLY (Continued) 26. Compress the tensioner plunger, using a vise.
30. Install the RH timing chain guide.
CAUTION: Timing chain procedures must be followed exactly or damage to valves and pistons will result.
31. Install the LH timing chain guide.
27. Install a retaining clip on the tensioner to hold the plunger in during installation.
28. Remove the tensioner from the vise. 29. If the copper links are not visible, mark two links on one end and one link on the other end, and use as timing marks.
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32. Pre-position the camshafts. 1. Rotate the LH camshaft until the timing mark is approximately at 6 o’clock. 2. Rotate the RH camshaft until the timing mark is approximately at 12 o’clock.
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Engine — 5.4L (3V)
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ASSEMBLY (Continued)
33. Remove the Crankshaft Holding Tool. 34. Install the crankshaft sprocket, making sure the flange faces forward.
36. Position the timing chain on the camshaft sprocket with the camshaft sprocket timing mark positioned between the two copper (marked) chain links. NOTE: Make sure the upper half of the timing chain is below the tensioner arm dowel. NOTE: If necessary, use the Camshaft Alignment Set to adjust the camshaft sprocket slightly to obtain timing mark alignment.
35. Position the lower end of the LH (inner) timing chain on the crankshaft sprocket, aligning the timing mark on the outer flange of the crankshaft sprocket with the single copper (marked) link on the chain.
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Engine — 5.4L (3V)
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ASSEMBLY (Continued) 37. Position the LH timing chain tensioner arm on the dowel pin and install the LH timing chain tensioner. NOTE: The LH timing chain tensioner arm has a bump near the dowel hole for identification.
40. Position the RH timing chain on the camshaft sprocket. Make sure the camshaft sprocket timing mark is positioned between the two copper (marked) chain links. NOTE: The lower half of the timing chain must be positioned above the tensioner arm dowel. NOTE: If necessary, use the Camshaft Alignment Set to adjust the camshaft sprocket slightly to obtain timing mark alignment.
38. Remove the retaining clip from the LH timing chain tensioner.
41. Position the RH timing chain tensioner arm on the dowel pin and install the RH timing chain tensioner.
39. Position the lower end of the RH (outer) timing chain on the crankshaft sprocket, aligning the timing mark on the sprocket with the single copper (marked) chain link. 42. Remove the retaining clip from the RH timing chain tensioner.
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Engine — 5.4L (3V)
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ASSEMBLY (Continued) 43. As a post-check, verify correct alignment of all timing marks.
44. Install the camshaft roller followers. 1. Compress the valve spring. 2. Install the camshaft roller followers in their original locations. 47. Install a new engine front cover gasket on the engine front cover. Position the engine front NOTE: Lubricate the camshaft roller followers cover. Install the fasteners finger-tight. using clean engine oil. NOTE: The use of a special tool may be required. 45. Install the crankshaft sensor ring on the crankshaft.
48. Tighten the engine front cover fasteners in sequence in three stages. Stage 1: Tighten fasteners 1 through 5 to 25 Nm (18 lb-ft). Stage 2: Tighten fasteners 6 and 7 to 48 Nm 46. Apply a bead of silicone gasket and sealant along (35 lb-ft). the cylinder head-to-cylinder block surface at the Stage 3: Tighten fasteners 8 through 15 to 48 locations shown. Nm (35 lb-ft). NOTE: If the front cover is not secured within four minutes, the sealant must be removed and the sealing area cleaned. To clean the sealing area, use silicone gasket remover and metal surface prep. Follow the directions on the packaging. Failure to follow this procedure can cause future oil leakage.
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Engine — 5.4L (3V)
303-01b-84
ASSEMBLY (Continued)
Item 1 2 3 4 5 6 7 8 9 10 11 12 13
Description N806177 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 53 N806177 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 53 N806177 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 53 N806177 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 53 N806177 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 53 N808529 Stud, Hex Head Pilot, M10 x 1.5 x 59 — M10 x 1.5 x 30 N808529 Stud, Hex Head Pilot, M10 x 1.5 x 59 — M10 x 1.5 x 30 N808142 Screw and Washer, Hex Pilot, M10 x 1.5 x 57.5 N808142 Screw and Washer, Hex Pilot, M10 x 1.5 x 57.5 N808142 Screw and Washer, Hex Pilot, M10 x 1.5 x 57.5 N808140 Stud and Washer, Hex Head Pilot, M10 x 1.5 x 68 — M8 x 1.25 x 27 N808140 Stud and Washer, Hex Head Pilot, M10 x 1.5 x 68 — M8 x 1.25 x 27 N808140 Stud and Washer, Hex Head Pilot, M10 x 1.5 x 68 — M8 x 1.25 x 27
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Item 14 15
Description N808140 Stud and Washer, Hex Head Pilot, M10 x 1.5 x 68 — M8 x 1.25 x 27 N808140 Stud and Washer, Hex Head Pilot, M10 x 1.5 x 68 — M8 x 1.25 x 27
49. Install the oil pump screen and pickup tube spacer.
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Engine — 5.4L (3V)
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ASSEMBLY (Continued) 50. Position the oil pump screen and pickup tube and 53. Position the belt idler pulley and install the bolt. install the bolts. CAUTION: Make sure the O-ring is in place and not damaged. A missing or damaged O-ring can cause foam in the lubrication system, low oil pressure and severe engine damage. NOTE: Clean and inspect the mating surfaces and install a new O-ring. Lubricate with the O-ring with clean engine oil. 51. Position the oil filter adapter and install the four bolts. NOTE: NOTE: Clean and inspect the mating surfaces, and install new gaskets. 54. Install the coolant pump. 1. Lubricate the new O-ring seal using engine coolant and install the O-ring seal onto the coolant pump. 2. Position the coolant pump into the engine block. 3. Install the bolts. CAUTION: Do not rotate the coolant pump housing once the coolant pump has been positioned in the cylinder block. Damage to the O-ring seal will occur. 52. Position the power steering pump and install the three bolts.
55. Lubricate the engine front cover and the front oil seal inner lip with clean engine oil.
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Engine — 5.4L (3V)
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ASSEMBLY (Continued) 56. Use the special tools to install the crankshaft front 59. Tighten the new crankshaft pulley bolt in four oil seal into the engine front cover. stages. Stage 1: Tighten to 90 Nm (66 lb-ft). Stage 2: Loosen 360 degrees. Stage 3: Tighten to 50 Nm (37 lb-ft). Stage 4: Tighten an additional 90 degrees.
57. Apply silicone gasket and sealant to the Woodruff key slot on the crankshaft pulley. NOTE: If not secured within four minutes, the sealant must be removed and the sealing area cleaned. To clean the sealing area, use silicone 60. Position the coolant pump pulley on the coolant gasket remover and metal surface prep. Follow pump and install the bolts. the directions on the packaging. Failure to follow this procedure can cause future oil leakage.
58. Use the special tool to install the crankshaft pulley.
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Engine — 5.4L (3V)
303-01b-87
ASSEMBLY (Continued) 61. Position the accessory drive belt tensioner and install the bolts.
62. Install the crankshaft position (CKP) sensor and the bolt.
63. Position the A/C compressor bracket and install the bolts.
64. Position the A/C compressor and install the bolts.
65. Install the oil drain plug.
66. If a new gasket is being installed, apply instant adhesive completely around the gasket groove in the RH valve cover. Install the new valve cover gasket. NOTE: RH shown, LH similar. 67. Apply silicone gasket and sealant in two places where the engine front cover meets the cylinder head. NOTE: RH is shown, LH is similar. NOTE: If not secured within four minutes, the sealant must be removed and the sealing area cleaned. To clean the sealing area, use silicone gasket remover and metal surface prep. Follow the directions on the packaging. Failure to follow this procedure can cause future oil leakage.
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Engine — 5.4L (3V)
303-01b-88
ASSEMBLY (Continued) 69. Position the LH valve cover and gasket on the cylinder head and install the bolts loosely. Tighten the bolts in the sequence shown.
68. Position the RH valve cover and gasket on the cylinder head and install the bolts loosely. Tighten the bolts in the sequence shown.
70. Install the eight ignition coils and bolts. NOTE: NOTE: RH is shown, LH is similar.
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Engine — 5.4L (3V)
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ASSEMBLY (Continued) 71. Position the water bypass tube assembly and install the bolts.
74. Position the generator support bracket and install the bolts.
72. Install the bolt.
75. Install the intake manifold gaskets.
73. Position the generator and install the bolts.
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Engine — 5.4L (3V)
303-01b-90
ASSEMBLY (Continued) 76. Install the intake manifold and tighten the bolts in the sequence shown.
80. Install the special tool.
81. Install the special tool.
77. Install the crankcase ventilation tube on the LH valve cover. 78. Install the radio frequency interference capacitors. NOTE: RH shown, LH similar.
79. Install the engine control sensor wiring.
82. Install the special tool and remove the engine from the work stand.
83. Inspect the rear seal retainer plate. Clean the mating surface for the rear seal retainer plate with silicone gasket remover and metal surface prep. Follow the directions on the packaging. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the aluminum retainer plate. These tools cause scratches and gouges, which make leak paths. Use a plastic scraping tool to remove all traces of old sealant.
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Engine — 5.4L (3V)
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ASSEMBLY (Continued) 84. Apply a 4 mm (0.16 in) bead of silicone gasket and sealant around the rear oil seal retainer sealing surface. NOTE: If not secured within four minutes, the sealant must be removed and the sealing area cleaned. To clean the sealing area, use silicone gasket remover and metal surface prep. Follow the directions on the packaging. Failure to follow this procedure can cause future oil leakage.
87. Inspect the oil pan. Clean the mating surface for the oil pan with silicone gasket remover and metal surface prep. Follow the directions on the packaging. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges, which make leak paths. Use a plastic scraping tool to remove all traces of old sealant. 88. Apply silicone gasket and sealant at the rear oil seal retainer-to-cylinder block sealing surface. NOTE: If not secured within four minutes, the sealant must be removed and the sealing area cleaned. To clean the sealing area, use silicone gasket remover and metal surface prep. Follow the directions on the packaging. Failure to follow this procedure can cause future oil leakage.
85. Install the rear oil seal retainer plate and loosely install the six bolts.
86. Tighten the bolts in the sequence shown.
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89. Apply silicone gasket and sealant at the engine front cover-to-cylinder block sealing surface. NOTE: If not secured within four minutes, the sealant must be removed and the sealing area cleaned. To clean the sealing area, use silicone gasket remover and metal surface prep. Follow the directions on the packaging. Failure to follow this procedure can cause future oil leakage.
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Engine — 5.4L (3V)
303-01b-92
ASSEMBLY (Continued)
90. Install the oil pan gasket and the oil pan and loosely install the bolts.
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91. Tighten the bolts in three stages, in the sequence shown. Stage 1: Tighten to 2 Nm (18 lb-in). Stage 2: Tighten to 20 Nm (15 lb-ft). Stage 3: Tighten an additional 90 degrees.
01/2003 2003.0 BA Falcon
303-01b-93
Engine — 5.4L (3V)
303-01b-93
ASSEMBLY (Continued) 92. Using the special tools, install a new crankshaft rear oil seal.
94. Install the flexplate or the flywheel and bolts. Tighten the bolts in the sequence shown.
CAUTION: Lubricate the inner lip of the crankshaft rear oil seal with clean engine oil.
93. Using the special tools, install the crankshaft rear oil slinger.
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01/2003 2003.0 BA Falcon
303-01c-1
Engine — V8 (4V)
303-01c-1
SECTION : 303-01c Engine — V8 (4V) VEHICLE APPLICATION : 2003.0 BA Falcon CONTENTS
PAGE
SPECIFICATIONS Specifications .......................................................................................................................303-01c-3 DESCRIPTION AND OPERATION Engine .................................................................................................................................303-01c-6 Identification ......................................................................................................................303-01c-6 Code Information ...............................................................................................................303-01c-6 Induction System ...............................................................................................................303-01c-6 Valve Train ........................................................................................................................303-01c-6 Positive Crankcase Ventilation System ............................................................................303-01c-6 Lubrication System ............................................................................................................303-01c-6 Oil Pump ...........................................................................................................................303-01c-7 Cooling System .................................................................................................................303-01c-7 Drive Belt System ..............................................................................................................303-01c-7 DIAGNOSIS AND TESTING Engine ...............................................................................................................................303-01c-17 IN-VEHICLE REPAIRS Intake Manifold Upper ........................................................................................................303-01c-18 Intake Manifold — Lower ...................................................................................................303-01c-18 Valve Cover — RH .............................................................................................................303-01c-20 Valve Cover — LH .............................................................................................................303-01c-22 Crankshaft Pulley ..............................................................................................................303-01c-22 Crankshaft Front Oil Seal ..................................................................................................303-01c-24 Engine Front Cover ...........................................................................................................303-01c-24 Timing Drive Components .................................................................................................303-01c-28 Valve — Springs, Retainer and Valve Stem Seal ..............................................................303-01c-33 Hydraulic Lash Adjusters ..................................................................................................303-01c-35 Roller Followers ................................................................................................................303-01c-35 Camshaft ...........................................................................................................................303-01c-36 Exhaust Manifold — LH .....................................................................................................303-01c-40 Oil Filter Adapter ...............................................................................................................303-01c-40 Oil Pressure Sender ..........................................................................................................303-01c-41 Oil Level Indicator and Tube .............................................................................................303-01c-42 Oil Pan ..............................................................................................................................303-01c-42 Oil Pump Screen and Pickup Tube ...................................................................................303-01c-44 Flexplate ............................................................................................................................303-01c-45 Crankshaft Rear Oil Seal ..................................................................................................303-01c-45 Engine Mounts — RH ........................................................................................................303-01c-47 Engine Mounts — LH .........................................................................................................303-01c-47 REMOVAL Engine ...............................................................................................................................303-01c-48
01/2003 2003.0 BA Falcon
303-01c-2
Engine — V8 (4V)
303-01c-2
(Continued) DISASSEMBLY Engine ...............................................................................................................................303-01c-52 DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES Piston ................................................................................................................................303-01c-62 Cylinder Head RH and LH .................................................................................................303-01c-63 ASSEMBLY Engine ...............................................................................................................................303-01c-70 INSTALLATION Engine ...............................................................................................................................303-01c-89
01/2003 2003.0 BA Falcon
303-01c-3
Engine — V8 (4V)
303-01c-3
SPECIFICATIONS General Specifications Description Magnetic clutch Air gap between pulley and hub Displacement No. cylinders Bore/stroke Firing order Camshaft Lobe lift exhaust LH Lobe lift exhaust RH Lobe lift intake Lobe lift – allowable lift loss Valve lift @ zero lash-intake Valve lift @ zero lash-exhaust Camshaft end play Camshaft end play service limit Camshaft journal to bearing clearance Clearance service limit-journal diameters Clearance service limit-journal inside diameter (cap assembled) Clearance service limit-Camshaft runout: Full indicator measurement on all journals when supported on front and rear journals. Connecting Rod Big end journal inside diameter with assembled liners Rod bearing to journal clearance Pin bore diameter (rod) Rod length (centerline bore-to-bore) Alignment bore-to-bore max. twist
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Specification 0.35 mm-0.75 mm (0.014 in 0.029 in) 5.4L (4V) 8 90.215/105.8 mm (3.552/4.165 in) 1-3-7-2-6-5-4-8 6.5958 mm (0.2597 in) 6.5855 mm (0.2593 in) 6.58077 mm (0.250847 in) 0 10.00 mm (0.3937 in) 10.00 mm (0.3937 in) 0.027-0.190 mm (0.0011-0.0075 in) 0.025-0.190 mm (0.0010-0.0075 in) 0.076-0.025 mm (0.0030-0.0010 in) 26.962-26.936 mm (1.0615-1.0605 in) 27.012-26.987 mm (1.0635-1.0625 in) 0.09 mm (0.0035 in) (4 places)
53.049-53.027 mm (2.0885-2.0877 in) 0.064-0.026 mm (0.0025-0.001 in) 22.024-22.012 mm (0.867-0.8666 in) 169.1 mm (6.6575 in) ± 0.05 mm (0.0021 in)
Description Alignment bore-to-bore max. bend Side play (as assembled to crank)-standard play Side play (as assembled to crank)-max. play Piston Cylinder bore diameter Grade 1 Cylinder bore diameter Grade 2 Cylinder bore diameter Grade 3 Piston diameter (Grade 2) at right angle to pin bore Piston to bore clearance
Specification ± 0.038 mm (0.0015 in) 0.300 ± 0.175 mm (0.0118 ± 0.0069 in) 0.475 mm (0.0187 in)
90.200-90.210 mm (3.5511-3.5515 in) 90.210-90.220 mm (3.5516-3.5521 in) 90.220-90.230 mm (3.5519-3.5524 in) 90.180 ± 0.005 mm (3.5504 ± 0.0002 in)
-0.005 to +0.025 mm (-0.0002 to 0.001 in) Pin bore diameter 22.008-22.014 mm (piston) (0.8665-0.8667 in) Pin diameter 22.0005-22.0030 mm (0.8662-0.8663 in) Pin clearance (negative 0.01395-0.005 mm or positive) (0.001-0.0002 in) Pin bore diameter (rod) 22.012-22.024 mm (0.8666-0.8671 in) Pin clearance (negative 0.009-0.0235 mm or positive) (rod) (0.0002-0.0009 in) Ring groove width top 1.53-1.55 mm (0.0602-0.061 in) Ring groove width 1.52-1.54 mm intermediate (0.0598-0.0606 in) Ring groove width oil 3.030-3.050 mm control (0.1193-0.1201 in) Piston ring gap top 0.13-0.28 mm (0.0051-0.0111 in) Piston ring gap 0.25-0.40 mm intermediate (0.0098-0.0157 in) Piston ring gap oil control 0.15-0.65 mm (0.0059-0.0256 in) Crankshaft Main bearing journal 67.483-67.503 mm diameter (2.6568-2.6576 in) Main bearing journal 0.0075 mm (0.0003 in) diameter: maximum between cross sections out-of-round Main bearing journal 0.004 mm (0.0002 in) diameter: maximum taper (straightness) Runout: FIM of center 0.05 mm (0.0019 in) (3 journals when located on places) front and rear journal
01/2003 2003.0 BA Falcon
303-01c-4
Engine — V8 (4V)
303-01c-4
SPECIFICATIONS (Continued) Description Crankshaft journal to main bearing clearance Connecting rod journal diameter Connecting rod journal diameter: maximum out-of-round Connecting rod journal diameter: maximum taper Crankshaft end play
Specification 0.048-0.024 mm (0.001891-0.0009 in) 53.003-52.983 mm (2.0867-2.0859 in) 0.0075 mm (0.0003 in) between cross sections 0.004 mm (0.0002 in) 0.075-0.377 mm (0.003-0.0148 in)
Cylinder Head/Valve Train Combustion chamber 53 ± 1.5cc volume (3.2342-0.0915 ci) Valve seat width - intake 2.1-1.9 mm (0.0827-0.0748 in) Valve seat width 2.1-1.9 mm exhaust (0.0827-0.0748 in) Valve seat angle 45.00-44.50 degrees Valve seat runout (TIR) 0.025 mm (0.001 in) Valve stem guide 0.069-0.020 mm clearance - intake (0.0027-0.0008 in) Valve stem guide 0.095-0.045 mm (0.0037 clearance - exhaust - 0.0018 in) Valve head diameter 37.11-36.86 mm intake (1.461-1.4512 in) Valve head diameter 30.12-29.87 mm exhaust (1.1858-1.176 in) Valve face runout (limit) 0.05 mm (0.0019 in) Valve face angle 45.75-45.25 degrees Valve stem diameter 6.995-6.975 mm intake (0.2754-0.2746 in) Valve stem diameter 6.970-6.949 mm exhaust (0.2744-0.2736 in) Valve spring compression 711.7 N @ 26.4 pressure - intake Valve spring compression 711.7 N @ 26.4 pressure - exhaust Valve spring free length - 45.5 intake Valve spring free length - 50.2 mm (1.9764 in) exhaust Valve spring installed 289.1 N @ 36.14 pressure - intake Valve spring installed 289.1 N @ 36.14 pressure - exhaust Valve spring installed 272.6 N @ 36.15 pressure service limit intake Valve spring installed 272.6 N @ 36.15 pressure service limit exhaust G89770 en
Description Valve spring out of square limit - intake Valve spring out of square limit - exhaust Valve guide inside diameter Lubricants Silicone Gasket and Sealant F7AZ-19554-EA Metal Surface Cleaner F4AZ-19A536-RA Engine Coolant 10W30 GF2 Engine Oil Pipe Sealant with Teflon® D8AZ-19554-A or equivalent
Specification 2.5 degrees 2.5 degrees 7.044-7.015 mm (0.2773-0.2762 in) WSE-M4G323-A4 WSE-M5B392-A ESE-M97B44-A /WSS-M97B51-A WSS-M2C910-A WSK-M2G350-A2 and ESR-M18P7-A
Torque Specifications Description Valve cover bolts¹ Camshaft bearing cap bolts¹ Camshaft sprocket bolts Connecting rod bolts¹ Crankshaft damper pulley bolt¹ Crankshaft main bearing bolts (cross mounted)¹ Crankshaft main bearing bolts (vertical)¹ Cylinder heads bolts¹ Exhaust manifold nuts Drive belt idler pulley bolt Flywheel bolts Engine front cover bolts¹ Heater return tube bolt Heater supply tube screw & washer Ignition coil cover bolts Lower intake manifold bolts¹ Upper intake manifold bolts¹ Oil filter adapter bolt Oil level indicator tube bolt Oil pan bolts¹ Oil pan drain plug Oil pressure switch Oil pump bolts Oil pump screen cover and tube bolts Oil pump screen cover and tube spacer Power steering pump bolts
Nm — — 120 — — — — — 23-27 25 73-87 — 20-30 8-12 10 — — 25 10 — 11-16 12-16 10 10 25 25
01/2003 2003.0 BA Falcon
303-01c-5
Engine — V8 (4V)
303-01c-5
SPECIFICATIONS (Continued) Description Radio ignition interference capacitor bolts Rear main oil seal retainer bolts Spark plugs Timing chain guide bolts Timing chain hydraulic tensioner bolts Water pump bolts Water pump pulley bolts Power steering bracket lower bolts Motor mount cross bolts Motor mount through bolts ¹ Refer to the procedure in this section.
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Nm 10 10 10 10 25 20-30 25 25 80 80
01/2003 2003.0 BA Falcon
303-01c-6
Engine — V8 (4V)
303-01c-6
DESCRIPTION AND OPERATION
Engine The 5.4L (4V) is a V-8 engine with the following features: dual overhead camshafts four valves per cylinder sequential multiport fuel injection (SFI) an aluminum intake manifold aluminum cylinder heads a cast iron, 90-degree V-cylinder block individually chain-driven camshafts with a hydraulic timing chain tensioner on each timing chain the electronic ignition system with eight ignition coils
Identification Always refer to these labels when new parts are required or when checking engine calibrations. The engine parts often differ within a CID family. Verification of the identification codes will make sure that the correct parts are obtained. These codes contain all the pertinent information relating to the dates, optional equipment and revisions. The Ford Master Parts Catalog contains a complete listing of the codes and their application.
A constant fuel pressure drop is maintained across the fuel injectors by the fuel pressure regulator. The fuel pressure regulator: is positioned upstream from the fuel injectors on the fuel injection supply manifold.
Valve Train The valve train operates as follows: Ball tip hydraulic lash adjusters provide automatic lash adjustment. Roller followers ride on the camshaft lobes, transferring the up-and-down motion of the camshafts to the valves in the cylinder heads.
Positive Crankcase Ventilation System All engines are equipped with a closed-type positive crankcase ventilation system recycling the crankcase vapors to the upper intake manifold.
Lubrication System
The engine lubrication system operates as follows: Oil is drawn into the oil pump through the oil pump screen cover and tube in the sump of the oil pan. Oil enters the main oil gallery where it is distributed to the crankshaft main journals and to both cylinder heads. Code Information From the main journals, the oil is routed through cross-drilled passages in the crankshaft to The engine code information label, located on the side lubricate the connecting rod bearings. Controlled of the LH valve cover towards the rear, contains the leakage through the crankshaft main bearings and following: connecting rod bearings is slung radially outward engine build date to cool and lubricate the cylinder walls as well as engine plant code the entire connecting rod, piston and piston rings assembly. engine code The left cylinder head is fed from a drilling into the Induction System supply passage feeding the main gallery at the front of the cylinder block. The right cylinder head The sequential multiport fuel injection (SFI) provides is fed from a drilling into the rear of the main the fuel/air mixture needed for combustion in the gallery. Main gallery pressure is reduced as it cylinders. The eight solenoid-operated fuel injectors: enters the cylinder head galleries through fixed are mounted in the fuel injection supply manifold serviceable orifices located at the upper part of and the intake manifold above the cylinder heads. the feed passages. It is this reduced pressure in meter fuel into the air intake stream in accordance the cylinder head galleries which feeds the with engine demand. camshaft journals, the hydraulic lash adjusters are positioned so that their tips direct fuel just and the primary and secondary timing chain ahead of the engine intake valves. tensioners. are connected in series with the fuel pressure The camshaft lobe and roller followers are regulator. lubricated by splash created through valve train operation. supply fuel from the fuel tank by a fuel pump mounted in the fuel tank.
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01/2003 2003.0 BA Falcon
303-01c-7
Engine — V8 (4V)
303-01c-7
DESCRIPTION AND OPERATION (Continued) Oil Pump The lubrication system of the 5.4L (4V) engine is designed to provide optimum oil flow to critical components of the engine through its entire operating range. The heart of the system is a positive displacement internal gear oil pump using top seal rotors. Generically this design is known as a gerotor pump, which operates as follows: The oil pump is mounted on the front face of the cylinder block. The inner rotor is piloted on the crankshaft post and is driven through flats on the crankshaft. System pressure is limited by an integral, internally-vented relief valve which directs the bypassed oil back to the inlet side of the oil pump. Oil pump displacement has been selected to provide adequate volume to ensure correct oil pressure both at hot idle and maximum speed. The relief valve calibration protects the system from excessive pressure during high viscosity conditions. The relief valve is designed to provide adequate connecting rod bearing lubrication under high-temperature and high-speed conditions.
Cooling System The engine cooling system includes the following: radiator water pump twin electric fans surge tank(aids in maintaining the correct volume of engine coolant) & vent hoses water thermostat housing upper radiator hose lower radiator hose heater water hoses & tubes water bypass tube
Drive Belt System The 5.4L (4V) DOHC engine is equipped with a serpentine drive belt. To make sure of maximum life, a new drive belt should be of the same type as originally installed. The accessories mounted on the front of the engine are belt-driven by the crankshaft. The serpentine drive belt is routed over each accessory pulley, driven by the crankshaft pulley bolted to the crankshaft. For service procedures, including tensioning, refer to Section 303-05.
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01/2003 2003.0 BA Falcon
303-01c-8
Engine — V8 (4V)
303-01c-8
DESCRIPTION AND OPERATION (Continued)
Item 1 2 3 4 5 6 7 8 9 10 11 12
Description Bolt Washer Bolt (4 req’d) Bolt Belt idler pulley Water pump pulley Crankshaft pulley Stud (5 req’d) Bolt Camshaft position sensor Bolt Crankshaft position sensor
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Item 13 14 15 16 17 18 19 20 21 22 23 24
Description Bolt (3 req’d) Engine front cover Bolt (4 req’d) Timing chain tensioner Timing chain tensioner arm Timing chain (2 req’d) Timing chain guide Timing chain tensioner Timing chain tensioner arm Timing chain (2 req’d) Bolt (3 req’d) Timing chain guide 01/2003 2003.0 BA Falcon
303-01c-9
Engine — V8 (4V)
303-01c-9
DESCRIPTION AND OPERATION (Continued) Item 25 26 27 28 29 30 31 32
Description Bolt Crankshaft sprocket (2 req’d) Ignition pulse ring Power steering pump Bolt (3 req’d) Stud (2 req’d) Bolt (8 req’d) Crankshaft front seal
Item 1 2 3
Description Pipe plug (4 req’d) Dowel (2 req’d) Oil level indicator
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Item 4 5 6
Description Oil level indicator tube Bolt Pipe plug 01/2003 2003.0 BA Falcon
303-01c-10
Engine — V8 (4V)
303-01c-10
DESCRIPTION AND OPERATION (Continued) Item 7 8 9 10 11 12 13 14 15 16 17
Description Retention Spring (11 mm) Oil filter adapter gasket Oil bypass filter Oil pressure sender Bolt (4 req’d) Oil filter adapter (4 x 2) Oil pan Oil pan gasket Dowel (2 req’d) Plug Water bypass tube
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01/2003 2003.0 BA Falcon
303-01c-11
Engine — V8 (4V)
303-01c-11
DESCRIPTION AND OPERATION (Continued) Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28
Description Bolt (2 req’d) (part of 6100) Connecting rod (8 req’d) (part of 6100) Connecting rod bearing (16 req’d) Piston pin retainer (16 req’d) (part of 6100) Piston pin (8 req’d) (part of 6100) Piston (8 req’d) (part of 6100) Piston ring (8 req’d) (part of 6100) Piston ring (8 req’d) (part of 6100) Piston ring (8 req’d) (part of 6100) Crankcase vent tube and connector Valve cover Camshaft Chain tensioner Bolts (2 req’d) Camshaft Bushing Washers (2 req’d) Bolts (2 req’d) Gear Chain Gear Exhaust manifold gasket Cylinder head gasket Exhaust manifold HEX Screw (8 req’d) Washer (8 req’d) Gasket PCV Valve
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01/2003 2003.0 BA Falcon
303-01c-12
Engine — V8 (4V)
303-01c-12
DESCRIPTION AND OPERATION (Continued)
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01/2003 2003.0 BA Falcon
303-01c-13
Engine — V8 (4V)
303-01c-13
DESCRIPTION AND OPERATION (Continued) Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29
Description Cylinder head gasket Gear Bolt (2 req’d) Washer (2 req’d) Secondary timing chain (2 req’d) Screw and washer (2 req’d) Timing chain vibration damper Camshaft bearing cap (2 req’d) Bolt (19 req’d) Bolt (6 req’d) Camshaft Roller follower (8 req’d) Bolt (10 req’d) Hydraulic lash adjuster Camshaft Camshaft bearing cap (2 req’d) Exhaust manifold gasket Exhaust manifold HEX Screw (8 req’d) Washer (8 req’d) Gasket Oil filler cap Bolt (4 req’d) Ignition coil cover Spark plug (8 req’d) Valve cover Bolt (16 req’d) Stud (4 req’d) PCV Connector
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01/2003 2003.0 BA Falcon
303-01c-14
Engine — V8 (4V)
303-01c-14
DESCRIPTION AND OPERATION (Continued)
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01/2003 2003.0 BA Falcon
303-01c-15
Engine — V8 (4V)
303-01c-15
DESCRIPTION AND OPERATION (Continued) Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
Description Heater water tube (in) Heater water tube (out) Engine block Dowel (4 req’d) Bolt (10 req’d) Thrust bearing (2 req’d) Crankshaft Thrust bearing Crankshaft bearing cap adjusting screw (10 req’d) Bolt Spacer Oil pump screen cover and tube Bolt Oil pan gasket Oil pan Oil pan drain plug Bolt (16 req’d) Oil pan reinforcements Bolt (2 req’d) Bolt (9 req’d) Main bearing cap Crankshaft main bearing (5 req’d) Oil pump Bolt (3 req’d) Woodruff key Crankshaft main bearing #1 Crankshaft main bearing upper (4 req’d) Water pump Bolt (4 req’d) Screw & Washer Water thermostat housing
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01/2003 2003.0 BA Falcon
303-01c-16
Engine — V8 (4V)
303-01c-16
DESCRIPTION AND OPERATION (Continued)
Item 1 2 3 4 5 6 7 8
Description Bolt (8 req’d) Crankshaft oil slinger Crankshaft rear oil seal Crankshaft rear retainer Plug Plug Bolt (6 req’d) Flexplate
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01/2003 2003.0 BA Falcon
303-01c-17
Engine — V8 (4V)
303-01c-17
DIAGNOSIS AND TESTING
Engine For basic engine mechanical concerns, refer to Section 303-00. For driveability concerns, Refer to Powertrain Control/Module in Section 303-14.
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01/2003 2003.0 BA Falcon
303-01c-18
Engine — V8 (4V)
303-01c-18
IN-VEHICLE REPAIR
Intake Manifold Upper
4. Tighten the bolts to 8-12 Nm (89 lb-in) in the sequence shown.
Removal All vehicles 1. Disconnect the battery ground cable. For additional information, refer to Section 414-01. 2. Remove PCV hose from LH valve cover. 3. Remove the air cleaner outlet from throttle body. For additional information, refer to Section 303-12. 4. Disconnect the electrical connectors from throttle body motor. 5. Disconnect the electrical connectors from the MAP sensor. All vehicles 1. Remove the screws and bracket for alternator support. 2. Remove the four (4) appearance plate screws and lift the appearance plate off. 3. Remove the eight (8) upper manifold mounting screws. 4. Disconnect brake booster hose from brake booster. 5. Lift upper intake manifold from throttle body, resting LHS on lower manifold. Release the quick connectors for purge and PCV tubes and remove the tubes. 6. Disconnect the brake booster vacuum line from brake booster. 7. Remove the bolts and the upper intake manifold. 8. Remove the intake gasket.
5. Fit the appearance plate to the top of the manifold cover with four (4) screws. NOTE: Allow engine to sit unstarted for min 2 hrs to allow manifold to seal. O-Ring is now used. 6. Fit the alternator mounting bracket with four (4) screws. 7. Connect the brake booster vacuum line to brake booster. 8. Fit electrical connectors to throttle body motor. 9. Fit electrical connector to MAP sensor. 10. Fit air cleaner tube to throttle body. 11. Install PCV hose to LH valve cover. 12. Connect the battery ground cable. For additional information, refer to Section 414-01. 13. Refill the engine cooling system. For additional information, refer to Section 303-03. NOTE: If this procedure is being performed in conjunction with the engine installation procedure, do not fill the engine cooling system at this time.
CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges which make leak paths. Use a plastic scraping Intake Manifold — Lower tool to remove all traces of old sealant. Clean and inspect the sealing surfaces. Removal Installation 1. Remove the upper intake manifold. For additional 1. Apply intake sealant. information, refer to Intake Manifold — Upper. 2. Position upper intake manifold and loosely install 2. Disconnect the fuel lines. For additional new bolts. information, refer to Section 310-00. 3. Install purge and PCV tube connections by pushing tubes onto quick connectors. NOTE: Ensure quick connectors are on the upper manifold before installing upper to lower.
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01/2003 2003.0 BA Falcon
303-01c-19
Engine — V8 (4V)
303-01c-19
IN-VEHICLE REPAIR (Continued) 3. Disconnect the electrical connector from the water 6. Remove the bolts and the radio ignition temperature indicator sender. interference capacitors.
4. Disconnect the eight fuel injectors.
7. Remove the gaskets, install new gaskets.
5. Remove the bolts and lower intake manifold.
8. Clean the sealing surfaces.
CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all traces of old sealant.
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01/2003 2003.0 BA Falcon
303-01c-20
Engine — V8 (4V)
303-01c-20
IN-VEHICLE REPAIR (Continued) Installation 1. Install the lower intake gaskets.
4. Tighten the retaining bolts to 8-10 Nm in following order.
2. Install the radio ignition interference capacitors.
3. Position the lower intake manifold. Loosely install the retaining bolts.
5. Connect the water temperature indicator sensor. 6. Connect the eight fuel injectors. 7. Connect the fuel lines. For additional information, refer to Section 310-00. 8. Install the upper intake manifold. For additional information, refer to Intake Manifold—Upper in this section.
Valve Cover — RH Materials Silicone Gasket and Sealant F7AZ-19554-EA or equivalent
WSE-M4G323-A4
Removal and Installation 1. Remove surge tank from vehicle. 2. Disconnect brake lines from brake booster. 3. Partially drain the cooling system. For additional information, refer to Section 303-03. 4. Disconnect the battery ground cable. For additional information, refer to Section 414-01.
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01/2003 2003.0 BA Falcon
303-01c-21
Engine — V8 (4V)
303-01c-21
IN-VEHICLE REPAIR (Continued) 5. Remove the positive crankcase ventilation (PCV) nylon tube from PCV valve and position the tube aside.
6. Remove the bolts and the ignition coil cover.
7. Disconnect the four ignition coils.
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8. Remove the four ignition coils.
9. Separate the engine control wiring harness from the valve cover studs.
10. Remove the eight bolts, two studs and the valve cover. Clean and inspect the sealing surfaces. 11. To install, reverse the removal procedure. NOTE: Apply silicone gasket and sealant in the locations shown.
01/2003 2003.0 BA Falcon
303-01c-22
Engine — V8 (4V)
303-01c-22
IN-VEHICLE REPAIR (Continued) 6. Separate the engine wiring harness from the valve cover studs.
Valve Cover — LH Materials Silicone Gasket and Sealant F7AZ-19554-EA or equivalent
WSE-M4G323-A4
Removal and Installation 1. Remove the upper intake manifold. For additional information, refer to Intake Manifold—Upper in this section. 2. Remove the engine oil level indicator tube bracket bolt and position the tube aside. 7. Remove the bolts, studs and the left valve cover. Clean and inspect the sealing surfaces. 8. To install, reverse the removal procedure. NOTE: Apply silicone gasket and sealant in the locations shown.
3. Remove the bolts and the ignition coil cover. 4. Disconnect the four ignition coils. 5. Remove the four ignition coils.
Crankshaft Pulley Special Tool(s) Remover, Crankshaft Vibration Damper 303-009 (T58P-6316-D)
Installer, Crankshaft Vibration Damper 303-102 (T74P-6316-B)
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01/2003 2003.0 BA Falcon
303-01c-23
Engine — V8 (4V)
303-01c-23
IN-VEHICLE REPAIR (Continued) Materials Silicone Gasket and Sealant F7AZ-19554-EA or LOCTITE 5900 or equivalent
WSE-M4G323-A4
Installation 1. Apply silicone gasket or LOCKTITE 5900 or equivalent to the Woodruff key slot on the crankshaft pulley. NOTE: The crankshaft pulley must be installed within four minutes after applying the silicone.
Removal 1. Remove the drive belt. For additional information, refer to Section 303-05. 2. Raise and support the vehicle. For additional information, refer to Section 100-02. 3. Remove the crankshaft pulley bolt.
2. Using the special tool, install the crankshaft pulley.
4. Using the special tool, remove the crankshaft pulley.
3. Install the bolt and washer. Tighten the bolt in four stages: Stage 1: Tighten to 90 Nm (66 lb-ft). Stage 2: Loosen one full turn. Stage 3: Tighten to 50 Nm (37 lb-ft). Stage 4: Tighten an additional 85-95 degrees.
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01/2003 2003.0 BA Falcon
303-01c-24
Engine — V8 (4V)
303-01c-24
IN-VEHICLE REPAIR (Continued) 4. Lower the vehicle. 5. Install the drive belt. For additional information, refer to Section 303-05.
Crankshaft Front Oil Seal Special Tool(s)
Installation 1. Apply silicone gasket sealant to outer perimeter surface of crankshaft front seal. 2. Lubricate the engine front cover and the crankshaft front oil seal inner lip with clean engine oil.
Installer, Crankshaft Front Oil Seal 303-635
Installer, Front Cover Oil Seal 303-335 (T88T-6701-A)
Remover, Crankshaft Front Oil Seal 303-107 (T74P-6700-A)
Item 1 2
Description Lubricate with engine oil Seal with silicone gasket sealant
3. Using the special tools, install the crankshaft front oil seal into the engine front cover.
Materials SAE 5W-20 Premium WSS-M2C910-A2 Synthetic Blend Motor Oil 10W-30GF2 Engine Oil orequivalent Removal 1. Remove the crankshaft pulley. For additional information, refer to Crankshaft Pulley in this section. 2. Using the special tool, remove the crankshaft front oil seal. 4. Install the crankshaft pulley. For additional information, refer to Crankshaft Pulley in this section.
Engine Front Cover Materials Metal Surface Cleaner F4AZ-19A536-RA or equivalent Silicone Gasket and Sealant F7AZ-19554-EA or LOCTITE 5900 or equivalent 10W-30GF2 Engine Oil or equivalent G89777 en
WSE-M5B392-A WSE-M4G323-A4
WSS-M2C910-A2 01/2003 2003.0 BA Falcon
303-01c-25
Engine — V8 (4V)
303-01c-25
IN-VEHICLE REPAIR (Continued) Removal 1. Remove the left and right valve cover (6582). For additional information, refer to Valve Cover—LH and Valve Cover—RH in this section. 2. Remove the water pump pulley. 1. Remove the four bolts. 2. Remove the water pump pulley.
7. Drain the engine oil.
8. Remove the four front sump bolts (as shown).
3. Remove the crankshaft pulley. For additional information, refer to Crankshaft Pulley in this section. 4. Remove the Power Steering (P/S) bolts and position the power steering pump aside.
9. Remove the crankshaft front oil seal. For additional information, refer to Crankshaft Front Oil Seal in this section. 10. Disconnect the camshaft position (CMP) sensor.
5. Remove A/C Compressor. 6. Disconnect the crankshaft position (CKP) sensor.
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01/2003 2003.0 BA Falcon
303-01c-26
Engine — V8 (4V)
303-01c-26
IN-VEHICLE REPAIR (Continued) 11. Remove the bolt and the belt idler pulley (8678).
2. Position the engine front cover and install the bolts and the studs in three stages: Stage 1: Tighten numbers one through five to 25 Nm (18 lb-ft). Stage 2: Tighten numbers six and seven to 50 Nm (37 lb-ft). Stage 3: Tighten numbers 11 through 15 to 25 Nm (18 lb-ft).
12. Remove the engine front cover, bolts, studs, and the gaskets. Clean and inspect the front cover and oil pan sealing surfaces.
Installation NOTE: If the front cover and gasket are not secured within four minutes, the sealant must be removed and the sealing surface cleaned with metal surface cleaner. 1. Apply silicone gasket and sealant in the locations shown.
Item 1 2 3 4 5 6 7 8 9 10 11
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Description Bolt, Hex Flange Head Pilot, M8 x 1.25 x 50 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 50 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 50 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 50 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 50 Stud, Hex-Head Pilot, M10 x 1.5 x 30 Stud, Hex-Head Pilot, M10 x 1.5 x 30 Bolt, Hex-Head Flange, M8 x 1.25 x 50 Bolt, Hex-Head Flange, M8 x 1.25 x 50 Bolt, Hex-Head Flange, M8 x 1.25 x 50 M8 x 1.25 x 53 01/2003 2003.0 BA Falcon
303-01c-27
Engine — V8 (4V)
303-01c-27
IN-VEHICLE REPAIR (Continued) Item 12 13 14 15
Description M8 x 1.25 x 53 Bolt Hex Shoulder Pilot, M8 x 1.25 x 65 Stud Hex Shoulder Pilot, M8 x 1.25 x 65 M8 x 1.25 x 27 Bolt Hex Shoulder Pilot, M8 x 1.25 x 65
7. Install the crankshaft front oil seal. For additional information, refer to Crankshaft Front Oil Seal in this section. 8. Install the drain plug.
3. Install the belt idler and the bolt.
9. Connect the CKP sensor.
4. Connect the CMP sensor.
10. Refit A/C compressor. 11. Position the power steering pump and install the bolts. 5. Raise the vehicle. 6. Tighten the sump bolts in three stages: Stage 1: Tighten to 2 Nm (18 lb-in). Stage 2: Tighten to 20 Nm (15 lb-ft). Stage 3: Tighten an additional 60 degrees.
12. Install the crankshaft pulley. For additional information, refer to Crankshaft Pulley in this section.
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01/2003 2003.0 BA Falcon
303-01c-28 IN-VEHICLE REPAIR (Continued)
Engine — V8 (4V)
13. Install the water pump pulley and install the bolts.
303-01c-28
2. Remove the crankshaft sensor ring from the crankshaft.
14. Install the left and right valve cover. For additional information, refer to Valve Cover—LH and Valve 3. Using the crankshaft holding special tool, position Cover—RH in this section. the crankshaft as shown. This will set the crankshaft. Keyway facing the top 15. Refill the engine crankcase with clean engine oil. of engine. All pistons will now be away from top of the stroke Timing Drive Components and will ensure piston and valves cannot clash. Special Tool(s) Alignment Plate, Camshaft 303-445 (T93P-6256-A)
CAUTION: Unless otherwise instructed, at no time when the timing chains are removed and the cylinder heads are installed is the crankshaft or the camshaft to be rotated. Severe piston and valve damage will occur.
Holding Tool, Crankshaft 303-448 (T93P-6303-A)
Removal CAUTION: Since the engine is not free-wheeling, if the crankshaft or the camshafts are moved in any manner during removal and installation, the crankshaft and the camshafts must be re-synchronized. 1. Remove the engine front cover. For additional information, refer to Engine Front Cover in this section.
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4. Install the camshaft alignment special tool.
01/2003 2003.0 BA Falcon
303-01c-29
Engine — V8 (4V)
303-01c-29
IN-VEHICLE REPAIR (Continued) 5. This will ensure that all valves are set in a position 8. Remove the bolts and the timing chain guides. to remove any concern for valve and piston clash. CAUTION: The bolts are different lengths 6. Remove the two bolts, the timing chain tensioner and must be returned to their original location. and tensioner arm. NOTE: LH shown; RH similar. NOTE: LH shown; RH similar.
7. Remove the LH and RH timing chains and the crankshaft sprockets. Remove the special holding tool from the crankshaft. Remove the timing chains from the camshaft sprockets. Remove the right and left timing chains and the crankshaft sprocket from the crankshaft. CAUTION: Unless otherwise instructed, at no time when the timing chains are removed and the cylinder heads are installed is the crankshaft or the camshaft to be rotated. Severe piston and valve damage will occur. CAUTION: Do not remove the special tool from the camshafts.
Installation 1. Compress the tensioner plunger, using the edge of a soft-jawed vise. CAUTION: Timing chain procedures must be followed exactly or damage to the pistons or valves will result.
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01/2003 2003.0 BA Falcon
303-01c-30
Engine — V8 (4V)
303-01c-30
IN-VEHICLE REPAIR (Continued) 2. Install a thin rod into the hole in the tensioner housing to hold the ratchet assembly. Remove the tensioner from the vise.
4. Install the timing chain guides.
3. If the copper links are not visible, mark two links on one end and one link on the other end, and use as timing marks. NOTE: There are 61 links in the timing chain.
5. Remove the camshaft alignment special tool.
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01/2003 2003.0 BA Falcon
303-01c-31
Engine — V8 (4V)
303-01c-31
IN-VEHICLE REPAIR (Continued) 6. Rotate the LH camshaft sprocket clockwise until the timing mark is approximately at the 1 o’clock position. Rotate the RH camshaft timing sprocket clokwise until the timing mark is approximately in the 11 o’clock position.
8. Install the LH timing chain onto the Camshaft (exhaust) sprocket, with the timing dot on the sprocket located between the two marked (copper) links.
WARNING: Do not rotate camshafts other than the directions stated.
9. Install the chain on the crankshaft sprocket inner set with the marked (copper) link aligned with the timing sprocket dot. 7. Position the crankshaft so that the keyway is at the 12 o’clock position (top). CAUTION: Unless otherwise instructed, at no time when the timing chains are removed and the cylinder heads are installed is the crankshaft or the camshaft to be rotated or severe piston and valve damage can occur. CAUTION: Rotate the crankshaft counter-clockwise only. Do not rotate past the position shown or sever piston and valve damage can occur. NOTE: With the keyway at the 12 o’clock position, all pistons will be away from the top of 10. Position the crankshaft sprocket onto the stroke. crankshaft. The crankshaft should not need turning. If it does, inspect the timing and start again. 11. Position the LH tensioner arm and tensioner and install the bolts.
12. Remove the pull-key rod from the tensioner housing. G89780 en
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Engine — V8 (4V)
303-01c-32
IN-VEHICLE REPAIR (Continued) 13. Rotate the crankshaft counter-clockwise so that the keyway is at approximately 11 o’clock. The timing dot should line up with a circular moulding behind the sprocket (on the oil pump, as shown). CAUTION: Rotate the crankshaft counter-clockwise only. Do not rotate past the position shown or sever piston and valve damage can occur.
19. Position the crankshaft sensor ring on the crankshaft.
14. Install the RH timing chain onto the Camshaft (exhaust) sprocket, with the timing dot on the sprocket located between the two marked (copper) links. 15. Install the chain on the crankshaft sprocket outer set with the marked (copper) link aligned with the timing sprocket dot. 16. Position the RH tensioner arm and tensioner and install the bolts. NOTE: Torque as for LH tensioner.
20. Install the engine front cover. For additional information, refer to Engine Front Cover in this section.
17. Remove the pull-key rod from the tensioner housing. 18. (Optional) Using the special tool, rotate the crankshaft counter-clockwise and check the alignments of the timing dots and marked links. RH cam sprocket timing dot/links should be at approximately 11 o’clock, LH cam sprocket timing dot/links should be at approximately 1 o’clock and the crankshaft sprocket timing dot/links should be at approximately 6 o’clock (bottom). CAUTION: The tensioner arms may need to be moved to take any slack after the check as the chains may be loosened.
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01/2003 2003.0 BA Falcon
303-01c-33
Engine — V8 (4V)
303-01c-33
IN-VEHICLE REPAIR (Continued)
Valve — Springs, Retainer and Valve Stem Seal Special Tool(s) Compressor, Valve Spring 303-452 (T93P-6565-AR)
4. Use compressed air in the cylinder to hold both valves in position. CAUTION: If air pressure has forced the piston to the bottom of the cylinder any loss of air pressure will allow the valve to fall into the cylinder. If air pressure must be removed support the valve prior to removal.
Installer, Valve Stem Oil Seal 303-383 (T91P-6571-A)
Compressor, Valve Spring 303-567 (T97P-6565-AH)
5. Install the special tool between the valve spring coils to protect the intake valve stem seal from damage.
Spacer, Valve Spring Compressor 303-382 (T91P-6565-AH)
Removal CAUTION: Mark all valve component positions. Reused valve components must be installed in their original locations. 1. Remove the roller followers. For additional information, refer to Roller Followers in this section. 2. Remove the spark plugs. For additional information, refer to Section 303-07B. 3. Position the piston of the cylinder being serviced at the bottom of the stroke.
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6. Using the special tool, compress the intake valve spring. Remove the intake valve spring retainer keys.
01/2003 2003.0 BA Falcon
303-01c-34
Engine — V8 (4V)
303-01c-34
IN-VEHICLE REPAIR (Continued) 7. Remove the special tool, the valve spring retainer, Installation the valve spring and the valve stem seal. 1. Using the special tools, install the new intake NOTE: Valve stem seals should be visually valve stem seals. Repeat this step to install all inspected if new seals are not installed. necessary intake valve stem seals. 8. Repeat above three steps to remove all necessary intake valve spring assemblies. 9. Install the special tool between the valve spring coils to protect the exhaust valve stem seal from damage.
10. Using the special tool, compress the exhaust valve spring. Remove the exhaust valve spring retainer keys.
11. Remove the valve spring retainer keys, the valve spring retainer, the valve spring and the valve stem seal. NOTE: Valve stem seals should be visually inspected if new seals are not installed.
2. Using the same special tools, install the new exhaust valve stem seals. Repeat this step to install all necessary exhaust valve stem seals. 3. Install the special tool between the valve spring coils to protect the intake valve stem seal from damage.
4. Position the intake valve spring and the spring retainer over the intake valve stem and valve seal. 5. Using the special tool, compress the intake valve spring. Install the intake valve spring retainer keys.
12. Repeat above three steps to remove all necessary exhaust valve spring assemblies.
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01/2003 2003.0 BA Falcon
303-01c-35
Engine — V8 (4V)
303-01c-35
IN-VEHICLE REPAIR (Continued) 6. Repeat above three steps to install all necessary intake valve spring assemblies. 7. Install the special tool between the valve spring coils to protect the exhaust valve stem seal from damage.
8. Position the exhaust valve spring and the spring retainer over the exhaust valve stem and valve seal. 9. Using the special tool, compress the exhaust valve spring. Install the exhaust valve spring retainer keys.
2. Remove the 16 hydraulic lash adjusters.
3. Inspect the roller followers. For additional information, refer to Section 303-00. Installation 1. To install, reverse the removal procedure.
Roller Followers Special Tool(s) Compressor, Valve Spring 303-452 (T93P-6565-AR)
Compressor, Valve Spring 303-567 (T97P-6565-AH)
10. Repeat above three steps to install all necessary exhaust valve spring assemblies. 11. Remove the compressed air hose from the cylinder. 12. Install the spark plugs. For additional information, refer to Section 303-07B. 13. Install the roller followers. For additional information, refer to Roller Followers in this section.
Hydraulic Lash Adjusters
Removal CAUTION: Mark roller follower positions. Reused roller followers must be installed in their original locations. 1. Remove the left and right valve cover. For additional information, refer to Valve Cover—LH and Valve Cover—RH in this section. 2. Position the piston of the cylinder being repaired at the bottom of the stroke and the camshaft lobe at the base circle.
Removal 1. Remove the roller followers. For additional information, refer to Roller Followers in this section.
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01/2003 2003.0 BA Falcon
303-01c-36
Engine — V8 (4V)
303-01c-36
IN-VEHICLE REPAIR (Continued) 3. Using the special tool, compress the intake valve spring and remove the roller follower.
Removal 1. Remove the roller followers. For additional information, refer to Roller Followers in this section. 2. Remove the LH timing chain for the LH side and both timing chains for the RH side. For additional information, refer to Timing Drive Components in this section. 3. Install the special tool.
4. Using the special tool, compress the exhaust valve spring and remove the roller follower.
4. Remove the exhaust camshaft sprocket and the intake camshaft bolt, washer and spacer.
5. Repeat above three steps to remove all the necessary roller followers. Inspect the roller finger followers and camshafts. For additional information, refer to Section 303-00. 6. To install, reverse the removal procedure.
Camshaft 5. Remove the special tool.
Special Tool(s) Holding Tool, Camshaft 303-446 (T93P-6256-AHR)
Materials 10W-30 GF2 Engine Oil or equivalent
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WSS-M2C910-A2
01/2003 2003.0 BA Falcon
303-01c-37
Engine — V8 (4V)
303-01c-37
IN-VEHICLE REPAIR (Continued) 6. Compress the tensioner and install a lock pin.
7. Remove the timing chain, the sprocket, and intake camshaft sprocket spacer.
10. Mark cach camshaft for identification purposes. 8. Remove the bolts. NOTE: LH shown; RH similar.
9. Remove the bolts and the camshaft bearing cap assemblies. CAUTION: The outer bolts on the outer cam bearing cap (exhaust) are longer and must be returned to the same location or engine damage may occur. NOTE: Identify the camshaft to cylinder head location. Caps are not interchangeable.
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01/2003 2003.0 BA Falcon
303-01c-38
Engine — V8 (4V)
303-01c-38
IN-VEHICLE REPAIR (Continued) 11. Remove the camshafts. CAUTION: It is vital for camshafts to be marked before removal as each one is different and must be re-installed inti its original position. NOTE: Each camshaft has its part number stamped on its shaft.
Installation 1. Install the camshafts. Lubricate the camshafts with clean engine oil. NOTE: LH shown; RH similar.
NOTE: All 4 camshafts are different.
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01/2003 2003.0 BA Falcon
303-01c-39
Engine — V8 (4V)
303-01c-39
IN-VEHICLE REPAIR (Continued) 2. Install the camshaft bearing cap assemblies.
4. Install the camshaft sprockets and the chain as an assembly. CAUTION: Timing marks must be at 12 o’clock and indexed at 6 o’clock.
5. Remove the lockpin from the chain tensioner.
6. Install the special tool.
3. Install the bolts.
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01/2003 2003.0 BA Falcon
303-01c-40
Engine — V8 (4V)
303-01c-40
IN-VEHICLE REPAIR (Continued) 7. Tighten the exhaust camshaft sprocket and the intake camshaft bolt washer and spacer in two stages: Stage 1: Tighten to 40 Nm (30 lb-ft). Tighten an additional 90 degrees.
2. Install engine in vehicle. For additional information, refer to Engine Installation in this section.
Oil Filter Adapter Removal 1. Raise and support the vehicle. For additional information, refer to Section 100-02. 2. Drain the cooling system. For additional information, refer to Section 303-03. 3. Remove the oil filter.
8. Remove the special tool. 9. Install the left timing chain for the left side or both timing chains for the right side. For additional information, refer to Timing Drive Components in this section. 10. Install the roller followers. For additional information, refer to Roller Followers in this section.
4. Disconnect the oil pressure sensor.
Exhaust Manifold — LH Removal NOTE: LH shown; RH similar. 1. Remove engine from vehicle. For additional information, refer to removal of Engine in this section. 2. Remove the exhaust manifold. Remove the eight nuts. Remove the exhaust manifold and discard gasket. Installation 1. To install, reverse the removal procedure. Install a new gasket.
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5. Remove the oil pressure sender.
01/2003 2003.0 BA Falcon
303-01c-41
Engine — V8 (4V)
303-01c-41
IN-VEHICLE REPAIR (Continued) 6. Disconnect the radiator lower hose.
Oil Pressure Sender Materials Pipe Sealant with Teflon® D8AZ-19554-A or equivalent
WSK-M2G350-A2 and ESR-M18P7-A
Removal and Installation 1. Raise and support the vehicle. For additional information, refer to Section 100-02. 2. Disconnect the oil pressure sender electrical connector.
7. Remove the four bolts and the filter adapter. Discard the gasket.
3. Remove the oil pressure sender.
4. To install, reverse the removal procedure. NOTE: If reusing the sender, clean the threads and coat the oil pressure sensor threads with pipe sealant. 8. To install, reverse the removal procedure. NOTE: Install a new oil filter adapter gasket.
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01/2003 2003.0 BA Falcon
303-01c-42
Engine — V8 (4V)
303-01c-42
IN-VEHICLE REPAIR (Continued)
Oil Level Indicator and Tube Removal and Installation 1. Remove the oil level indicator. 2. Remove the bolt.
3. Remove the oil level indicator tube. Install a new O-ring seal.
4. To install, reverse the removal procedure.
Oil Pan Special Tool(s)
Materials 10W-30 GF2 Engine Oil or equivalent
WSS-M2C910-A2
Removal 1. Remove alternator, refer to Section 414-02.
2. Install the special tool.
3. Raise and support the vehicle. For additional information, refer to Section 100-02. 4. Remove through bolts from the engine mount bracket and chassis. 5. Drain the engine oil.
3-Bar Engine Support 303-F073
Materials Metal Surface Cleaner F4AZ-19A536-RA or equivalent Silicone Gasket and Sealant F7AZ-19554-EA or LOCTITE 5900 or equivalent G89788 en
WSE-M5B392-A WSE-M4G323-A4 6. Lower the vehicle.
01/2003 2003.0 BA Falcon
303-01c-43
Engine — V8 (4V)
303-01c-43
IN-VEHICLE REPAIR (Continued) 7. Raise the engine 63.5 mm (2.5 inch).
8. Raise the vehicle. 9. Remove the bolts, oil pan and gasket. Inspect the oil pan gasket for damage. NOTE: Be careful when removing oil pan gasket. It is re-usable if not damaged.
Installation 1. Clean the mating surfaces. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all traces of old sealant. 2. Apply silicone gasket and sealant at the rear oil seal retainer-to-cylinder block sealing surface. NOTE: If the oil pan and the oil pan gasket are not secured within four minutes, the sealant must be removed and the sealing area cleaned with metal surface cleaner. Allow to dry until there is no sign of wetness, or four minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage.
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3. Apply silicone gasket and sealant at the front cover-to-cylinder block sealing surface. NOTE: If the oil pan and the oil pan gasket are not secured within four minutes, the sealant must be removed and the sealing area cleaned with metal surface cleaner. Allow to dry until there is no sign of wetness, or four minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage.
4. Install the oil pan gasket and the oil pan and loosely install the 16 bolts.
01/2003 2003.0 BA Falcon
303-01c-44
Engine — V8 (4V)
303-01c-44
IN-VEHICLE REPAIR (Continued) 5. Tighten the bolts in three stages, in the sequence shown. Stage 1: Tighten to 2 Nm (18 lb-in). Stage 2: Tighten to 20 Nm (15 lb-ft). Stage 3: Tighten an additional 60 degrees.
8. Raise the vehicle. 9. Install through bolt to the engine mount bracket and chassis.
10. Lower the vehicle. 11. Install the alternator. For additional information, refer to Section 414-02. 12. Install the lower intake manifold. For additional information, refer to Intake Manifold—Upper. 13. Refill the engine crankcase with clean engine oil.
Oil Pump Screen and Pickup Tube Materials 10W-30 GF2 engine oil or equivalent
6. Lower the vehicle. 7. Lower the engine. Remove the special tool.
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WSS-M2C910-A2
Removal 1. Remove the oil pan. For additional information, refer to Oil Pan in this section. 2. Remove the three (A) bolts and the (B) oil pump screen cover and tube.
01/2003 2003.0 BA Falcon
303-01c-45
Engine — V8 (4V)
303-01c-45
IN-VEHICLE REPAIR (Continued) Installation 1. Clean and inspect the mating surfaces. Inspect the O-ring seal. 2. Install the oil pump screen cover and tube and install the bolts.
Installation 1. Position the flexplate and install the bolts in the sequence shown.
CAUTION: Make sure the O-ring is in place and not damaged. A missing or damaged O-ring can cause foam in the lubrication system, low oil pressure and severe engine damage. NOTE: Clean and inspect the mating surfaces and install a new O-ring. Lubricate with clean engine oil. 3. Install the oil pan. For additional information, refer to Oil Pan Installation in this section.
Flexplate Removal 1. Remove the transmission. For additional information, refer to Section 307-01A. 2. Remove the bolts and the flexplate.
2. Install the transmission. For additional information, refer to Section 307-01.
Crankshaft Rear Oil Seal Special Tool(s) Installer, Crankshaft Rear Oil Seal 303-518 (T95P-6701-DH)
Remover, Crankshaft Rear Oil Seal 303-519 (T95P-6701-EH)
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Engine — V8 (4V)
303-01c-46
IN-VEHICLE REPAIR (Continued) Special Tool(s) Installer, Crankshaft Rear Oil Seal 303-516 (T95P-6701-BH)
3. Using the special tools, remove the crankshaft rear oil seal.
Remover, Crankshaft Rear Oil Slinger 303-514 (T95P-6701-AH)
Installer, Crankshaft Rear Oil Slinger 303-517 (T95P-6701-CH)
Installation 1. Using the special tool, install the crankshaft rear oil seal.
Impact Slide Hammer 100-001 (T50T-100-A)
Removal 1. Remove the flexplate. For additional information, refer to Flexplate in this section. 2. Using the special tools, remove the crankshaft oil slinger.
2. Using the special tools, install the crankshaft oil slinger.
3. Install the flexplate. For additional information, refer to Flexplate in this section.
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Engine — V8 (4V)
303-01c-47
IN-VEHICLE REPAIR (Continued)
Engine Mounts — RH
2. Install the special tool.
Special Tool(s) 3-Bar Engine Support 303-F073
Removal 1. Install the special tool. 3. Raise and support the vehicle. For additional information, refer to Section 100-02. 4. Remove the through bolt.
2. Raise and support the vehicle. For additional information, refer to Section 100-02. 3. Remove the engine mount bracket through bolt. 4. Remove crossmember. 5. Remove engine mount & bracket assembly from the engine. 6. Remove engine mount heat shield. 7. Remove the engine mount. Installation 1. To install, reverse the removal procedure.
5. Lower the vehicle. 6. Raise the engine 63.5 mm (2.5 inches).
Engine Mounts — LH Special Tool(s) 3-Bar Engine Support 303-F073
Removal 1. Remove the lower intake manifold. For additional information, refer to Intake Manifold—Upper in this section.
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7. Remove the engine mount from the vehicle. Installation 1. To install, reverse the removal procedure.
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303-01c-48
Engine — V8 (4V)
303-01c-48
REMOVAL
Engine Special Tool(s) Modular Engine Lifting Bar 303-F047 (014-00073)
Holding Wrench, Fan Pulley 303-239 (T84T-6312-C) 6. Drain coolant from engine at tap left hand lower corner. 7. Disconnect the lower radiator hose from the radiator and the engine. Wrench, Fan Clutch Hub Nut 303-240 (T84T-6312-D)
Removal 1. Disconnect lower pivot hood struts. 2. Tie hood back. 3. Remove the radiator upper hose from the engine. 4. Remove the fan shroud. 1. Remove the screws. 2. Lift and remove the fan pack, out of the vehicle.
8. Disconnect the surge tank hose from the radiator. 1. Release the clamp. 2. Slide the hose off the radiator fitting. 9. Remove the surge tank from vehicle. 1. Disconnect vent and supply hoses from surge tank. 2. Remove surge tank from vehicle.
5. Disconnect the transmission fluid cooler fittings. 1. Disconnect the upper transmission fluid cooler fitting. 2. Disconnect the lower transmission fluid cooler fitting. NOTE: To avoid disturbing the transmission oil cooler fittings, use a support spanner when releasing cooling lines. G89795 en
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Engine — V8 (4V)
303-01c-49
REMOVAL (Continued) 10. Remove the radiator. 24. Disconnect fuel lines using special tool, as outlined in Section 310-00. 1. Remove the bolts. 2. Remove the upper radiator support brackets. 25. Disconnect the power steering pressure (PSP) sensor. 3. Remove bolts attaching condensor to radiator. 26. Remove the bolts and position the power steering 4. Lift the radiator off the radiator mounting pump out of the way. insulators. 5. Remove the radiator mounting insulators.
11. Remove the accessory drive belt. For additional information, refer to Section 303-05. 12. Disconnect the alternator electrical connectors. 13. Disconnect battery and alternator cables from RH Relay box. 14. Remove PCM, refer to Section 303-14-104. 15. Disconnect the wiring harness (PCM ‘A’ connector & 24 pin connector) from vehicle. 16. Disconnect transmission wiring harness from transmission. 17. Disconnect hego sensor wiring plugs. Refer to chapter Section 303-14-106 for more information. 18. Remove the ground strap retaining bolt. 27. Disconnect the starter motor electrical connections. 1. Remove the two nuts. 2. Remove the battery cable. 3. Remove the starter solenoid wire.
19. 20. 21. 22. 23.
Disconnect the lower radiator hose. Disconnect the heater hoses from rear of engine. Disconnect brake booster vacuum hose. Disconnect purge valve connection. Disconnect air intake to throttle body and remove entire air cleaner assembly.
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Engine — V8 (4V)
303-01c-50
REMOVAL (Continued) 28. Remove the nut and the starter motor ground cable.
31. Disconnect the A/C compressor electrical connector.
29. Remove the three bolts and the starter motor.
32. Remove the bolts and the A/C compressor. NOTE: Do not degas, position A/C compressor out of the way.
30. Disconnect the crankshaft position (CKP) sensor. 33. Remove nut holding exhaust heatshield and discard, then remove heatshield. 34. Disconnect the pipes at the exhaust manifolds. NOTE: If studs are removed from exhaust manifolds during disassembly, then discard studs and nut and replace with new parts. 35. Remove the through bolt from the LH engine mount.
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Engine — V8 (4V)
303-01c-51
REMOVAL (Continued) 36. Remove the through bolt from the RH motor mount.
37. Remove the plate bolts and the inspection cover.
39. Remove the five bolts from the transmission.
40. Lower the vehicle. 41. Install rear lifting hook and front lifting hook. 42. Support the transmission with a floor jack and a block of wood. 43. Remove the engine from the vehicle.
38. Remove the four nuts from the torque converter and discard (Auto tran only). NOTE: Gain access to the nuts by turning the crank dampener counterclockwise.
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Engine — V8 (4V)
303-01c-52
DISASSEMBLY Special Tool(s)
Engine Special Tool(s) Remover, Crankshaft Rear Oil Seal 303-519 (T95P-6701-EH)
Remover, Crankshaft Rear Oil Slinger 303-514 (T95P-6701-AH)
Compressor, Valve Spring (Exhaust Side) 303-567 (T97P-6565-AH)
Compressor, Valve Spring (Intake Side) 303-452 (T93P-6565-AR)
Cylinder Ridge Reamer 303-016 (T64L-6011-EA) Impact Slide Hammer 100-001 (T50T-100-A)
Lift Bracket Set, Engine 303-DS086 (D93P-6001-A)
Disassembly NOTE: The crankshaft rear oil seal slinger and the oil seal retainer plate must be removed before mounting the engine on the engine stand. 1. Remove the bolts and the flywheel ring gear.
Remover, Crankshaft Vibration Damper 303-009 (T58P-6316-D)
Installer, Connecting Rod 303-442 (T93P-6136-A)
Remover, Crankshaft Front Oil Seal 303-107 (T74P-6700-A)
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Engine — V8 (4V)
303-01c-53
DISASSEMBLY (Continued) 2. Using the special tools, remove the rear oil slinger.
3. Using the special tools, remove the rear main seal.
4. Lower the engine onto the wooden blocks. 5. Remove the LH exhaust manifold. 1. Remove the eight bolts. 2. Remove the manifold and discard the gasket. 6. Remove the stud and the oil level indicator and tube.
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7. Install the lifting bracket special tools on the LH and RH sides of the engine. NOTE: LH shown, RH similar.
8. Mount the engine on a work stand.
9. Drain oil, remove filter. Remove the bolts and the oil pan. Clean and inspect the sealing surfaces. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all traces of old sealant.
01/2003 2003.0 BA Falcon
303-01c-54
Engine — V8 (4V)
303-01c-54
DISASSEMBLY (Continued) 10. Remove the bolts and the rear seal retainer plate. 13. Remove the cylinder block drain plugs, and drain the coolant in a suitable container. Clean and inspect the sealing surfaces. NOTE: LH shown, RH similar. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all traces of old sealant.
14. Disconnect the oil pressure sender.
11. Remove the special tools from the LH and RH sides of the engine. NOTE: LH shown, RH similar.
15. Remove the bolts and the LH ignition coil cover.
12. Remove the RH and LH engine mounts. NOTE: LH shown, RH similar.
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Engine — V8 (4V)
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DISASSEMBLY (Continued) 16. Disconnect the ignition coils.
19. Remove the bolts and the RH ignition coil cover.
17. Remove the ignition coils.
20. Disconnect the ignition coils.
18. Disconnect the camshaft position (CMP) sensor.
21. Remove the ignition coils.
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Engine — V8 (4V)
303-01c-56
DISASSEMBLY (Continued) 22. Remove the heater return tube and heater supply 24. Remove the water pump pulley. tubes. 1. Remove the bolts. 2. Remove the pulley.
23. Remove the Heater supply tube.
25. Remove the water pump bolts.
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Engine — V8 (4V)
303-01c-57
DISASSEMBLY (Continued) 26. Remove the water pump. Clean and inspect the sealing surfaces.
29. Using the special tool, remove the front crank seal.
CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all traces of old sealant.
30. Remove the bolt and the belt idler pulley.
27. Remove the crankshaft pulley bolt.
31. Remove the eight spark plugs. NOTE: LH shown, RH similar.
28. Using the special tool, remove the crankshaft damper.
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01/2003 2003.0 BA Falcon
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Engine — V8 (4V)
303-01c-58
DISASSEMBLY (Continued) 32. Remove the bolts, studs and the valve covers. Remove the gaskets. Clean and inspect the sealing surfaces. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all traces of old sealant. NOTE: LH shown, RH similar.
34. Remove the crankshaft sensor ring from the crankshaft. CAUTION: Since the engine is not free-wheeling, if the crankshaft (6303) or the camshafts (6250) are moved in any manner during removal and installation, the crankshaft and the camshafts must be re-synchronized.
35. Position the piston at the bottom of the stroke and the camshaft lobes at the base circle. 36. Using the special tool, compress the intake valve springs and remove the roller followers. 33. Remove the studs, bolts, and the engine front cover. Remove the gaskets, clean and inspect the sealing surfaces. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all traces of old sealant.
37. Remove the two bolts, the timing chain tensioner (6L266) and tensioner arm (6L255). NOTE: LH shown, RH similar.
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Engine — V8 (4V)
303-01c-59
DISASSEMBLY (Continued) 38. Remove the LH and RH timing chains and the crankshaft sprocket. Remove the timing chains from the camshaft sprockets. Remove the right and left timing chains and the crankshaft sprocket from the crankshaft. NOTE: LH shown, RH similar.
39. Remove the bolts and the timing chain guides.
40. Remove the RH and RH exhaust manifolds. 1. Remove the eight bolts. 2. Remove the exhaust manifold and gasket. NOTE: RH manifold same as LH manifold.
Item 1 2
Description Nut x 8 RH manifold
CAUTION: The bolts are different lengths 41. Remove the bolts from the RH and LH cylinder and must be returned to their original location. head and remove the cylinder heads. NOTE: RH shown, LH similar. Discard the bolts.
42. Remove and discard head gaskets. Clean and inspect the cylinder block and the head sealing surfaces. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all traces of old sealant.
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Engine — V8 (4V)
303-01c-60
DISASSEMBLY (Continued) 45. Before removing pistons, inspect the top of the cylinder bores. If necessary, remove the ridge or carbon deposits from each cylinder using a Cylinder Ridge Reamer, following manufacturer’s instructions.
43. Remove the bolts and remove the oil pump screen cover and tube and the spacer.
46. Remove the bolts and the connecting rod caps for pistons number 1 and 6. CAUTION: Do not stamp the top of pistons. This may cause ring land damage. NOTE: Connecting rods and rod caps should be numbered to keep the correct orientation.
44. Remove the bolts and remove the oil pump. Remove the gasket. Clean and inspect the sealing surfaces. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all traces of old sealant. 47. Discard the bolts. NOTE: Carefully tap connecting rod bolts out. Avoid damaging the rod cap. 48. Install the Connecting Rod Guides and push the pistons number 1 and 6 through the top of the cylinder block (6010). CAUTION: Do not scratch the cylinder walls or crankshaft journals with the connecting rod. NOTE: Connecting rod guides shown uninstalled for clarity.
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Engine — V8 (4V)
303-01c-61
DISASSEMBLY (Continued) 50. Remove the crankshaft main bearing caps. 1. Remove and discard the side bolts. 2. Remove and discard the main bearing cap bolts. 3. Remove the dowel pins. NOTE: Crankshaft not shown for clarity.
49. To remove pistons 3 and 5, 4 and 7, 2 and 8, turn crankshaft 90 degrees and repeat the previous steps.
51. Remove the crankshaft, the crankshaft thrust washer, and the crankshaft upper main bearings from the cylinder block.
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Engine — V8 (4V)
303-01c-62
DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES
Piston Materials SAE 5W-20 Premium WSS-M2C153-H Synthetic Blend Motor Oil XO-5W20-QSP or equivalent
4. Clean and inspect the piston and connecting rod. For additional information, refer to Section 303-00. Assembly 1. Position the connecting rod in the piston. NOTE: Connecting rod must be installed into piston with identification markings toward front.
Disassembly 1. Remove the clips. NOTE: Connecting rods and rod caps are a matched set and cannot be interchanged.
2. Remove the piston pin from the piston and connecting rod assembly.
2. Lubricate the piston pin and pin bore with clean engine oil.
3. Remove the connecting rod from the piston.
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Engine — V8 (4V)
303-01c-63
DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES (Continued) 3. Install the piston pin in the piston and connecting rod assembly.
Special Tool(s) Installer, Valve Stem Oil Seal 303-383 (T91P-6571-A)
Compressor Spacer, Valve Spring 303-382 (T91P-6565-AH)
4. Install the piston pin retaining clips in the piston.
Disassembly 1. Install the special tool. CAUTION: Before disassembly begins, mark the valve position on the face of each valve being removed. The valves must be installed in their original positions.
Cylinder Head RH and LH Special Tool(s) Compressor, Valve Spring 303-567 (T97P-6565-AH) 2. Remove the exhaust camshaft sprocket and the intake camshaft bolt, washer and spacer.
Compressor, Valve Spring 303-452 (T93P-6565-AR)
Holding Tool, Camshaft 303-446 (T93P-6256-AHR)
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01/2003 2003.0 BA Falcon
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Engine — V8 (4V)
303-01c-64
DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES (Continued) 3. Compress the tensioner and install a lock pin.
6. Remove the head tensioners.
4. Remove the special tool.
7. Using the special tool, compress the intake valve spring and remove the roller follower. Repeat this step for all necessary intake valve roller followers.
5. Remove the timing chain and the camshaft sprocket.
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8. Using the special tool, compress the exhaust valve spring and remove the roller follower. Repeat this step for all necessary exhaust valve roller followers.
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303-01c-65
Engine — V8 (4V)
303-01c-65
DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES (Continued) 9. Install the special tool between the valve spring coils to protect the intake valve stem seal from damage.
14. Using the special tool, compress the exhaust valve spring. Remove the exhaust valve spring retainer keys.
10. Using the special tool, compress the intake valve spring. Remove the intake valve spring retainer keys.
15. Remove the special tool, the valve spring retainer, the valve spring and the valve stem seal. NOTE: Valve stem seals should be visually inspected if new seals are not installed. 16. Repeat above three steps to remove all necessary exhaust valve spring assemblies.
11. Remove the special tool, the valve spring retainer, the valve spring and the valve stem seal. NOTE: Valve stem seals should be visually inspected if new seals are not installed. 12. Repeat above three steps to remove all necessary intake valve spring assemblies. 13. Install the special tool between the valve spring coils to protect the exhaust valve stem seal from damage.
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01/2003 2003.0 BA Falcon
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Engine — V8 (4V)
303-01c-66
DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES (Continued) 17. Remove the bolts and the camshaft bearing cap assemblies. CAUTION: The outer bolts on the outer cam bearing cap (exhaust) are longer and must be returned to the same location or engine damage can occur. NOTE: Identify the camshaft-to-cylinder head location. Caps are not interchangeable.
18. Remove the camshafts. CAUTION: It is vital for camshafts to be marked before removal as each one is different and must be re-installed into its original position. NOTE: Each camshaft has its part number stamped its shaft.
19. Remove the hydraulic lash adjusters.
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Engine — V8 (4V)
303-01c-67
DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES (Continued) Assembly 1. Install the hydraulic lash adjusters.
3. Install the camshaft bearing cap assemblies.
2. Install the head camshafts. NOTE: LH shown, RH similar.
4. Using the special tools, install the new intake valve stem seals. Repeat this step to install all necessary intake valve stem seals.
5. Using the special tools, install the new exhaust valve stem seals. Repeat this step to install all necessary exhaust valve stem seals.
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01/2003 2003.0 BA Falcon
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Engine — V8 (4V)
303-01c-68
DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES (Continued) 6. Install the special tool between the valve spring coils to protect the intake valve stem seal from damage.
7. Position the intake valve spring and the spring retainer over the intake valve stem and the valve seal. 8. Using the special tool, compress the intake valve spring. Install the intake valve spring retainer keys.
9. Repeat above three steps to install all necessary intake valve spring assemblies. 10. Install the special tool between the valve spring coil to protect the exhaust valve stem seal from damage.
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11. Position the exhaust valve spring and the spring retainer over the exhaust valve stem and the valve seal. 12. Using the special tool, compress the exhaust valve spring. Install the exhaust valve spring retainer keys.
13. Repeat above three steps to install all necessary exhaust valve spring assemblies. 14. Using the special tool, compress the intake valve spring and install the roller follower. Repeat this step for all necessary intake valve roller followers.
15. Using the special tool, compress the exhaust valve spring and install the roller follower. Repeat this step for all necessary exhaust valve roller followers.
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Engine — V8 (4V)
303-01c-69
DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES (Continued) 16. Install the head tensioners.
19. Tighten the exhaust camshaft sprocket and the intake camshaft bolts washers and spacer in two stages: Stage 1: Tighten to 40 Nm (30 lb-ft). Stage 2: Tighten an additional 90 degrees.
17. Install the camshaft sprockets and the chain as an assembly. CAUTION: Timing marks must be at 12 o’clock and indexed at 6 o’clock.
20. Remove the special tool.
18. Install the special tool.
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Engine — V8 (4V)
303-01c-70
ASSEMBLY Special Tool(s)
Engine
Installer, Front Cover Oil Seal 303-335 (T88T-6701-A)
Special Tool(s) Installer, Crankshaft Rear Oil Seal 303-518 (T95P-6701-DH)
Installer, Crankshaft Rear Oil Seal 303-516 (T95P-6701-BH)
Installer, Crankshaft Rear Oil Seal 303-517 (T95P-6701-CH)
Compressor, Piston Ring 303-D032 (D81L-6002-C) or equivalent
Modular Engine Lift Bracket 303-F047 (014-00073) or equivalent
Alignment Plate, Camshaft 303-445 (T93P-6256-A) Lifting Bracket Set, Engine 303-DS086 (D93P-6001-A)
Installer, Connecting Rod 303-442 (T93P-6136-A)
Installer, Crankshaft Front Oil Seal 303-635
Compressor, Valve Spring (Exhaust Side) 303-567 (T97P-6565-AH)
Compressor, Valve Spring (Intake Side) 303-452 (T93P-6565-AR)
Holding Tool, Crankshaft 303-448 (T93P-6303-A) Installer, Crankshaft Vibration Damper 303-102 (T74P-6316-B)
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Engine — V8 (4V)
303-01c-71
ASSEMBLY (Continued) Materials Metal Surface Cleaner F4AZ-19A536-RA or equivalent Silicone Gasket and Sealant F7AZ-19554-EA or LOCTITE 5900 or equivalent 10W-30 GF2 engine Oil or equivalent
WSE-M5B392-A WSE-M4G323-A4
WSS-M2C910-A2
Assembly 1. Read the first character code information on the cylinder block face and record the information.
Item 1 2 3 4
Description Cylinder block identification Cylinder bore grade Cylinder block serial number Cylinder block front face
2. Read the first character on the No. 7 crankshaft counterweight and note it. NOTE: Crank pistons, and rods come in three grades.
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Engine — V8 (4V)
303-01c-72
ASSEMBLY (Continued) 3. Using the data recorded in the previous two steps, cross-reference using the chart to obtain bearing grade.
4. Lubricate the crankshaft main bearings with clean 5. Install the crankshaft onto the upper main engine oil and install into the cylinder block. Install bearings. the crankshaft main bearings into the main NOTE: Do not install the upper thrust bearings bearing caps. until the crankshaft is installed. NOTE: Before assembling the cylinder block, all sealing surfaces must be free from chips, dirt, paint and foreign material. Also, make sure the coolant and oil passages are clear.
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Engine — V8 (4V)
303-01c-73
ASSEMBLY (Continued) 6. Push the crankshaft rearward and install the upper crankshaft thrust washer at the back of the No. 5 main boss. Ensuring locating lug fits into block recess. CAUTION: Make sure the side of the thrust washer with three 5-mm wide oil grooves faces the crankshaft thrust surface.
9. Install the crankshaft lower main bearings into the main bearing caps. Locate the main bearing cap on the cylinder block and tap into place using a plastic or deadblow hammer.
7. Push the crankshaft forward and install the front crankshaft upper thrust washer at the front of the No. 5 main boss. CAUTION: Make sure the side of the thrust washer with three 5-mm wide oil grooves faces the crankshaft thrust surface.
8. Install the lower crankshaft thrust washer to the back side of the No. 5 main bearing cap, with the oil grooves facing the crankshaft surface. CAUTION: Make sure the side of the thrust washer with three 5-mm wide oil grooves faces the rear of the engine. NOTE: To aid in assembly apply petroleum jelly to the back of the crankshaft thrust washer.
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Engine — V8 (4V)
303-01c-74
ASSEMBLY (Continued) 10. Install the main bearing cap dowel pins so the flat 11. Install and tighten the new bolts in two stages: sides face the crankshaft. Stage 1: Tighten to 40 Nm (30 lb-ft). NOTE: Crankshaft not shown for clarity. Stage 2: Tighten an additional 90 degrees. NOTE: Crankshaft not shown for clarity.
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Engine — V8 (4V)
303-01c-75
ASSEMBLY (Continued) 12. Install and tighten the new cross-mounted bolts in 14. Using the special tools, install the No. 1 and No. 6 two stages: piston and connecting rod assemblies. Stage 1: Tighten to 30 Nm (22 lb-ft). Lubricate the piston and ring with clean engine oil. Stage 2: Tighten an additional 90 degrees. Lubricate the rod bearings with clean engine NOTE: Crankshaft not shown for clarity. oil. CAUTION: Do not scratch the cylinder walls or crankshaft journals with the connecting rod. NOTE: Make sure the piston arrow is facing forward.
15. Seat the connecting rods on the crankshaft journals and remove the special tools.
13. Prepare the connecting rod and caps. Insert the bolts in the rod cap. Insert the upper and lower rod bearings into the rod and cap. NOTE: Verify the connecting rods and rod caps for correct orientation. NOTE: Carefully tap the connecting rod bolts in. Avoid damaging the connecting rod.
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Engine — V8 (4V)
303-01c-76
ASSEMBLY (Continued) 16. Install the rod bearing caps and tighten the bolts in three stages: Stage 1: Tighten to 25 Nm (18 lb-ft). Stage 2: Tighten to 45 Nm (30 lb-ft). Stage 3: Tighten an additional 90 degrees.
19. Install and tighten the oil pump screen and cover spacer.
CAUTION: The rod bearing caps must keep the same orientation as marked during disassembly. NOTE: The rod bearing cap bolts are torque-to-yield. Install new bolts each time repaired.
20. Install the oil pump screen cover and tube, and the bolts. CAUTION: Make sure the O-ring is in place and not damaged. A missing or damaged O-ring can cause foam in the lubrication system, low oil pressure and severe engine damage. NOTE: Clean and inspect the mating surfaces and install a new O-ring. Lubricate with clean engine oil. 17. Install the piston connecting rod assemblies 3 and 5, 4 and 7, 2 and 8, by turning the crankshaft 90 degrees and repeating the previous steps. 18. Position the oil pump and gasket and install the bolts in the sequence shown.
21. Install the cylinder head gaskets.
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Engine — V8 (4V)
303-01c-77
ASSEMBLY (Continued) 22. Install the LH and the RH cylinder heads. Loosely 24. Install the LH and RH exhaust manifold gaskets install the new bolts. and the exhaust manifold. Tighten the nuts in the sequence shown.
25. Compress the tensioner plunger, using the edge of a soft-jawed vise. CAUTION: Timing chain procedures must be followed exactly or damage to the pistons or valves can result.
23. Tighten the LH and RH bolts in three stages, in the sequence shown. Stage 1: Tighten to 40 Nm (30 lb-ft). Stage 2: Tighten an additional 90 degrees. Stage 3: Tighten an additional 90 degrees. 26. Install a paper clip into the hose in the tensioner housing to hold the ratchet assembly. Remove the tensioner from the vise.
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Engine — V8 (4V)
303-01c-78
ASSEMBLY (Continued) 27. If the copper links are not visible, mark two links on one end and one link on the other end, and use as timing marks. NOTE: There are 61 links in the timing chain.
28. Install the timing chain guides.
29. Rotate the LH camshaft sprocket until the timing mark is approximately at the 12 o’clock position. Rotate the RH camshaft timing sprocket until the timing mark is approximately in the 11 o’clock position.
30. Install the special tools on the LH and RH cylinder heads. NOTE: LH shown, RH similar.
31. Using the special tool, position the crankshaft.
32. Remove the special tool.
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Engine — V8 (4V)
303-01c-79
ASSEMBLY (Continued) 33. Install the crankshaft sprocket with the timing mark facing outward.
34. Install the LH and RH timing chains onto the crankshaft and camshaft sprockets. Align the two copper (marked) links with the timing mark on the camshaft sprocket. Align the one copper-colored link with the timing mark on the crankshaft sprocket.
36. Remove the paper clip.
37. Verify the camshaft and crankshaft sprocket to copper link alignment.
38. Remove the special tools from the LH and RH cylinder heads. NOTE: LH shown, RH similar. 35. Position the tensioner arms and tensioners, and install the bolts. NOTE: LH shown, RH similar.
39. Position the piston at the bottom of the stroke and camshaft lobes at the base circle. 40. Repeat the previous steps to install all roller followers.
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Engine — V8 (4V)
303-01c-80
ASSEMBLY (Continued) 41. Position the crankshaft sensor ring on the crankshaft.
42. Apply silicone gasket sealant in the locations shown.
Item 1 43. Position the engine front cover and install the bolts and the studs in three stages: Stage 1: Tighten numbers one through five to 25 Nm (18 lb-ft). Stage 2: Tighten numbers six and seven to 50 Nm (37 lb-ft). Stage 3: Tighten numbers 11 through 15 to 25 Nm (18 lb-ft).
2 3 4 5 6 7 8 9 10 11 12 13 14 15
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Description Bolt, Hex Flange Head Pilot, M8 x 1.25 x 50 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 50 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 50 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 50 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 50 Stud, Hex-Head Pilot, M10 x 1.5 x 30 Stud, Hex-Head Pilot, M10 x 1.5 x 30 Bolt, Hex-Head Flange, M8 x 1.25 x 50 Bolt, Hex-Head Flange, M8 x 1.25 x 50 Bolt, Hex-Head Flange, M8 x 1.25 x 50 Stud, Hex Shoulder Pilot, M8 x 1.25 x 65 M8 x 1.25 x 27 Stud, Hex Shoulder Pilot, M8 x 1.25 x 65 M8 x 1.25 x 27 Bolt, Hex Shoulder Pilot, M8 x 1.25 x 65 Stud, Hex Shoulder Pilot, M8 x 1.25 x 65 M8 x 1.25 x 27 Bolt, Hex Shoulder Pilot, M8 x 1.25 x 65
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Engine — V8 (4V)
303-01c-81
ASSEMBLY (Continued) 44. Apply silicone gasket sealant in the locations shown.
46. Install the eight spark plugs. NOTE: LH shown, RH similar.
45. Install the valve covers, the bolts, and the studs. 1. Install the gaskets. 2. Install the valve covers. NOTE: LH shown, RH similar.
47. Install the bolt and the belt idler pulley.
48. Using the special tools, install the front crank seal.
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Engine — V8 (4V)
303-01c-82
ASSEMBLY (Continued) 49. Apply silicone gasket and sealant to the Woodruff 52. Install the water pump. key slot on the crankshaft pulley. Inspect and lube the water pump O-ring seal NOTE: The crankshaft pulley must be installed before installation. within four minutes after applying the silicone.
50. Using the special tool, install the crankshaft pulley.
53. Install the four bolts.
51. Install the bolt and washer. Tighten the bolt in four stages: Stage 1: Tighten to 90 Nm (66 lb-ft). Stage 2: Loosen one full turn. Stage 3: Tighten to 50 Nm (37 lb-ft). Stage 4: Tighten an additional 90 degrees.
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Engine — V8 (4V)
303-01c-83
ASSEMBLY (Continued) 54. Install the water pump pulley and the bolts.
57. Connect the RH ignition coils.
58. Install the RH ignition coil cover.
55. Install the heater return tube and the heater supply tubes. Inspect and lube the O-ring seals. 56. Install the RH ignition coils.
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59. Connect the camshaft position (CMP) sensor.
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Engine — V8 (4V)
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ASSEMBLY (Continued) 60. Install the LH ignition coils.
63. Connect the oil pressure sender.
61. Connect the LH ignition coils.
64. Install the cylinder block drain plugs. NOTE: LH shown, RH similar.
62. Install the bolts and the LH ignition coil cover. 65. Install the left and right engine mounts. NOTE: RH shown, LH similar.
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Engine — V8 (4V)
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ASSEMBLY (Continued) 66. Install the lifting bracket special tool. NOTE: LH shown, RH similar.
67. Remove the engine from the work stand.
69. Install the rear oil seal retainer and loosely install the six bolts.
70. Tighten the bolts in the sequence shown.
71. Apply silicone gasket and sealant at the crankshaft rearseal retainer-to-cylinder block sealing surface. NOTE: If the oil pan and the oil pan gasket are not secured within four minutes, the sealant must be removed and the sealing area cleaned with metal surface cleaner. Allow to dry until there is no sign of wetness, or four minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage.
68. Apply a 4 mm (0.16 in) bead of silicone gasket and sealant around the rear oil seal retainer sealing surface. NOTE: If the rear crankshaft seal retaining plate is not secured within four minutes, the sealant must be removed and the sealing area cleaned with metal surface cleaner. Allow to dry until there is no sign of wetness, or four minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage. NOTE: The silicone must be applied on the groove along the retainer plate. G89799 en
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Engine — V8 (4V)
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ASSEMBLY (Continued) 72. Apply silicone gasket and sealant at the engine front cover-to-cylinder block sealing surface. NOTE: If the oil pan and the oil pan gasket are not secured within four minutes, the sealant must be removed and the sealing area cleaned with metal surface cleaner. Allow to dry until there is no sign of wetness, or four minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage.
74. Tighten the bolts in three stages, in the sequence shown. Stage 1: Tighten to 2 Nm (18 lb-in). Stage 2: Tighten to 20 Nm (15 lb-ft). Stage 3: Tighten an additional 60 degrees.
73. Install the oil pan gasket and the oil pan and loosely install the 16 bolts.
75. Lower the engine onto wooden blocks. 76. Remove the special tool.
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Engine — V8 (4V)
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ASSEMBLY (Continued) 77. Install the oil level indicator and tube, and the stud.
80. Using the special tool, install the crankshaft rear oil seal.
78. Install the LH exhaust manifold and gaskets. Tighten the bolts in the sequence shown.
81. Using the special tool, install the crankshaft oil slinger.
79. Install the special tool and raise the engine.
82. Install the spacer plate.
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Engine — V8 (4V)
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ASSEMBLY (Continued) 83. Install the bolts and the flywheel.
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Engine — V8 (4V)
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INSTALLATION 6. Install the five bolts to the bell housing.
Engine Materials 10W-30 GF2 Engine Oil or equivalent
WSS-M2C910-A2
Installation 1. Support the transmission with a floor jack and a block of wood. 2. Install the engine in the vehicle. 3. Remove the special tool.
7. Install the oil filter.
4. Raise the vehicle. For additional information, refer to Section 100-02. 5. Position the transmission level indicator tube and install the bolt. 8. Install four new nuts to the torque converter (Auto trans only). NOTE: Gain access to the nuts by turning the crank dampener counterclockwise.
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Engine — V8 (4V)
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INSTALLATION (Continued) 9. Install the plug (Auto trans only).
12. Install the bolt to the LH engine motor mount.
10. Install the inspection cover and the bolts.
13. Install the starter motor and three bolts.
11. Install the bolt to the RH engine motor mount.
14. Connect the cable and install the motor nut.
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Engine — V8 (4V)
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INSTALLATION (Continued) 15. Connect the starter motor electrical connectors. 1. Position the starter solenoid wire. 2. Position the battery cable. 3. Install the nuts.
19. Install heatshield with new nut on lower stud, to specified torque.
20. Install the A/C compressor and bolts. 16. Install the starter motor solenoid terminal cover.
21. Connect the A/C compressor electrical connector. 17. Install the RH exhaust manifold studs. 18. Connect the exhaust pipes to the exhaust manifolds and torque nuts to specification.
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Engine — V8 (4V)
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INSTALLATION (Continued) 22. Connect the crankshaft position sensor.
23. Position the power steering pump and install the bolts.
24. 25. 26. 27. 28. 29.
Connect the power steering pressure sensor. Lower the vehicle. Connect the lower radiator hose. Install the stud and reposition the A/C muffler. Install battery into vehicle. Connect the heater hoses to rear of engine.
33. Install the two bolts retaining the transmission to the engine.
34. Connect the transmission wiring harness to transmission.
35. Connect wiring harness (PCM ‘A’ connector and 24 pin connector) to vehicle. 36. Install the alternator and alternator bracket.
30. Install surge tank into vehicle. 31. Connect vent and supply hoses to surge tank. 32. Connect the surge tank return hose.
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Engine — V8 (4V)
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INSTALLATION (Continued) 37. Connect the alternator electrical connectors.
42. Install the surge tank hose to the radiator. 1. Release the clamp. 2. Slide the hose onto the radiator fitting.
38. Connect battery and alternator cables to RH relay box. 39. Install the accessory drive belt. For additional 43. Connect the lower radiator hose and the upper information, refer to Section 303-05. radiator hose. 40. Install the intake manifold. For additional 44. Connect the transmission fluid cooler fittings. information, refer to Intake Manifold—Upper in 1. Connect the lower transmission fluid cooler this section. fitting. 41. Install the radiator. 2. Connect the upper transmission fluid cooler 1. Install the radiator mounting insulators. fitting. 2. Position the radiator on the radiator mounting NOTE: To avoid disturbing the transmission insulators. oil cooler fittings, use a support hammer when tightening fuel lines. 3. Position the brackets. 4. Install the bolts.
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Engine — V8 (4V)
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INSTALLATION (Continued) 45. Install the fan shroud. 1. Install the fan blade and fan shroud, as a unit, in the vehicle. 2. Install the screws.
46. Recharge the A/C system. For additional information, refer to Section 412-00. 47. Fill the engine with oil. 48. Fill the engine cooling system. For additional information, refer to Section 303-03.
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Engine Cooling
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SECTION : 303-03 Engine Cooling VEHICLE APPLICATION : 2003.0 BA Falcon CONTENTS
PAGE
SPECIFICATIONS Specifications ........................................................................................................................303-03-2 DESCRIPTION AND OPERATION Engine Cooling ......................................................................................................................303-03-3 Radiator ................................................................................................................................303-03-3 Electric Fans ........................................................................................................................303-03-3 Water Pump .........................................................................................................................303-03-3 Cooling System ....................................................................................................................303-03-3 Cooling Maintenance ...........................................................................................................303-03-3 DIAGNOSIS AND TESTING Engine Cooling ......................................................................................................................303-03-5 Inspection and Verification ...................................................................................................303-03-5 Symptom Chart ....................................................................................................................303-03-5 Tests ....................................................................................................................................303-03-6 Pressure Test .......................................................................................................................303-03-8 Supply Tank Cap Pressure Test ..........................................................................................303-03-8 Thermostat Test ...................................................................................................................303-03-8 Coolant System ....................................................................................................................303-03-8 Cooling Fan Self Test - All Models ......................................................................................303-03-8 GENERAL PROCEDURES Coolant Level Check .............................................................................................................303-03-9 Cooling Color Inspection .......................................................................................................303-03-9 Adjusting Anti — Freeze Protection Level ..........................................................................303-03-10 Anti — Freeze Replacement ...............................................................................................303-03-10 Draining and Filling the Cooling System .............................................................................303-03-10 Radiator Cleaning ...............................................................................................................303-03-10 REMOVAL AND INSTALLATION Thermostat ..........................................................................................................................303-03-12 Thermostat Housing — 8 Cylinder ......................................................................................303-03-12 Thermostat Housing — 6 Cylinder ......................................................................................303-03-12 Water Pump — 6 Cylinder ...................................................................................................303-03-13 Water Pump — V8 ...............................................................................................................303-03-14 Radiator ..............................................................................................................................303-03-14 Fan ......................................................................................................................................303-03-16 Radiator Hose .....................................................................................................................303-03-16 Coolant Supply Tank ...........................................................................................................303-03-16
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Engine Cooling
303-03-2
SPECIFICATIONS General Specifications Description Fan Speeds Passenger Side Driver Side
Specification 1400, 2300 RPM @ 12.0V 1400, 2300 RPM @ 12.0V 160 W
Fan Motor Rating Coolant Capacities 6 Cylinder Engine 12.5 litres 8 Cylinder Engine 15 litres Anti-Freeze All Engines Motorcraft R132/R133 Radiator Cleaner All Engines Motorcraft R1-5 Radiator Cap Pressure (Supply Tank) All Engines 120 kPa Thermostat 6 Cylinder Starts to open 89° - 93°C Fully open 103° - 106°C Minimum travel of capsule from fully closed position: 7.1 mm 8 Cylinder Starts to open 87°C-91°C Fully Open 105°C Coolant Additive Level of Additive Volume Protection Specification of Additive AntiMES33% corrosion MN121-C (5.3 & (Motorcraft litre) antiR1-52) freeze to minimum temp. of -16°C AntiMES50% (8 corrosion MN121-C litre) & (Motorcraft antiR1-52) freeze to minimum temp. of -37°C
Volume of Water 67% (10.7 litre)
Specific Gravity 1.050 1.042 1.034 1.026 1.016
Approximate % of Anti-Freeze (by volume) 30 25 20 15 10
Remains Solidfies at Fluid to (C°) (C°) -16 -13 -9 -7 -4
Torque Specifications - 6 & 8 Cylinder Description Water outlet housing Radiator support bracket Radiator hose clamps Transmission oil cooler tube nuts Fan shroud asy screw to radiator Water pump I6 Water pump V8 Water pump pully V8
-39 -29 -19 -14 -8 Nm 21 10 5 20 6 20 25 25
Service Interval 3 Years 100,000 km
50% (8 4 Years litre) 120,000 km
Anti-Freeze Concentration Specific Approximate Remains Solidfies at Gravity % of Fluid to (C°) (C°) Anti-Freeze (by volume) 1.080 50 -37 -58 1.065 40 -25 -45 G97830 en
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Engine Cooling
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DESCRIPTION AND OPERATION
Engine Cooling
Water Pump
Radiator
A centrifugal-type water pump is mounted on the front of the cylinder block. A vane-type impeller supplies coolant through centrifugal action to the water pump oitlet port. If the pump is found to be faulty remove and discard as it is of a sealed unit type which cannot be repaired.
The radiators are of the tube and fin-core type with the tubes arranged for horizontal coolant flow. Two header tanks, one at each end of the core provide uniform distribution of the coolant to the tubes. The radiator outlet port is connected to the water pump inlet port. The radiator inlet port is connected to the coolant outlet housing of the engine, thereby permitting coolant circulation through the radiator when the thermostat is open. Midway down the right hand side radiator header tank is the coolant supply tank feed port, this connects the cooling system with the supply tank. The supply tank provides a chamber to accommodate the expansion of the coolant as engine temperature increases. A small port is located at the top of the right hand side tank. It is connected to the top of the supply tank. This port aids the self purging of air from the cooling system. An oil cooler is located in the radiator outlet header-tank to cool transmission fluid for automatic transmission vehicles. A draincock is located at the bottom of the left hand side tank. The coolant supply tank cap incorporates a 120 kPa (18 psi) pressure relief valve and vacuum valve. For routine coolant level inspections the tank provides a quick visual method for determining the coolant level without removing the tanks cap. Should the coolant level exceed the capacity of the header tank it is discharged out the overflow channel. The header should not be overfilled. With the engine cold the level of coolant in the supply tank should between the max and min lines on the supply tank.
Electric Fans The vehicle is fitted with dual electric fans controlled by three relays linked to the PCM module. During service operations, ensure that fan is not rotated in a direction opposing normal operation as this may damage the motor (refer to arrow on fan blade). Two operating modes are used (excluding OFF) depending on the status of the three relays (determined by the PCM module). The different operating modes provide different cooling capabilities. Refer to Wiring Diagrams section for a schematic of the Fan Control System. CAUTION: When the ignition is in the ON position the fans may start without warning.
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Cooling System The cooling system operates as follows: Coolant flows through the radiator tubes and is cooled by air passing over the cooling fins assisted by the radiator electric fans. Coolant expands as the temperature and pressure rise in the system. When the limiting system working pressure is reached, the pressure relief valve in the supply cap is lifted from its seat and allows coolant to flow through the supply tank overflow channel. The supply tank cap has a rubber seal on the underside to prevent leakage. When the system temperature and pressure drop, the coolant contracts in volume and the pressure in the radiator is reduced. WARNING: Never remove the supply tank cap under any conditions while the engine is operating. Failure to follow these instructions could result in damage to the cooling system or engine and/or personal injury. To avoid having scalding hot coolant or steam blow out of the supply tank, use extreme care when removing the supply tank cap from a hot supply tank. Wait until the engine has cooled, try squeezing the upper radiator hose to determine if the system is still under pressure. Then wrap a thick cloth around the supply tank cap and turn it slowly. Step back while the pressure is released from the cooling system. When certain all the pressure has been released, turn the supply tank cap (still with a cloth), and remove it. WARNING: The engine radiator electric fans may come on at any time without warning. Disconnect battery ground cable before servicing - this will clear diagnostic trouble codes and adaptive learning. The vehicle must then be driven for 30 mins and idled for 15 mins to relearn. (suggest using a 9 volt memory minder in the cigar lighter to retain keep alive memory).
Cooling Maintenance Correct coolant level is essential for maximum circulation and adequate cooling. In addition, for the cooling system to perform its function it must receive proper care. This includes maintaining corrosion 01/2003 2003.0 BA Falcon
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Engine Cooling
303-03-4
DESCRIPTION AND OPERATION (Continued) protection, keeping radiator fins clean, and periodic inspection of the cooling system for leakage. Use care when removing the supply tank to avoid injury from escaping steam or hot water. To prevent the build up of rust, sludge and other foreign material in the cooling system, add the specified Corrosion Inhibitor at the intervals specified. If it is found necessary to remove build up of foreign material from the cylinder block or radiator owing to neglect of adding an inhibitor, use the specified radiator cleaner. Removal of such material restores cooling efficiency and avoids over-heating. In severe cases where cleaning solvents will not properly clean the cooling system for efficient operation, it will be necessary to use the pressure flushing method. Various types of flushing equipment are available. If pressure flushing is used, make sure the cylinder head bolts are properly tightened to prevent possible water leakage into the cylinders. NOTE: Always remove the thermostat prior to pressure flushing the engine.
in toxic amounts on repeated or prolonged skin contact. To promote the safe handling of coolant the following precautions should be adhered to: Maintain adequate ventilation and do not inhale vapours. Must never be taken internally. If accidentally swallowed seek medical advice immediately. Avoid skin contact. In the event of accidental spillage onto the skin, wash off as soon as possible. If clothing is splashed it should be removed and washed to avoid prolonged skin contact. Avoid spillage on vehicle paint work. Wash off immediately with water.
When pressure flushing the engine or radiator, flush in the reverse direction to normal water flow. A pulsating or reversed direction of flushing water will loosen sediment more quickly than a steady flow in the normal direction of coolant flow. The pressure applied to the radiator must not exceed the supply tank cap relief pressure. The coolant is water plus corrosion inhibitor and Ethylene Glycol antifreeze (Motorcraft R1-33) Refer to specifications. CAUTION: Motorcraft R1-33 is not compatible with soluble oil or soluble oil based additives, or leak-stop additives. Do not use these other additives in the vehicle’s cooling system. If any of these other additives have been added to the coolant, the system must be drained and cleaned with Motorcraft radiator cleaner R1-5 and then thoroughly reverse flushed before refilling with clean water and the specified quantity of Motorcraft R1-33. Refer to “DRAINING AND FILLING THE COOLING SYSTEM” in this part. WARNING: Do not remove the coolant supply cap when the engine is hot. Allow the engine to cool before removing the cap. Even then use extreme care when removing the cap; wrap a thick cloth around the cap and turn it slowly. Step back while pressure is released from the cooling system. When sure that all pressure has been released, using the cloth, remove the cap. WARNING: Motorcraft R1-33 Anti-Freeze/Anti-Boil Concentrate contains ethylene glycol and/or other constituents which are toxic if taken internally and can be absorbed G97831 en
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DIAGNOSIS AND TESTING
Engine Cooling
Visual Inspection Chart Mechanical Electrical Radiator Cap/Cooling System Pressure Tester Damaged hoses. Circuitry Available Commercially E 9353 Loose/damaged hose open/shorted. (Litchfield Tools) clamps. Damaged fan control Damaged thermostat. relays Constant Tension Clamp Tool Damaged head Damaged radiator Drive Belt gaskets. electric motor, fan Available Commercially E 9353 Damaged water blade and fan shroud (Litchfield Tools) pump. assembly. Damaged radiator. Damaged or faulty Inspection and Verification Damaged supply tank PCM. Damaged heater core. Open circuit in FAN 2 1. Verify the concern by operating the engine cooling motor. system to duplicate the concern. Special Tool(s)
2. Inspect to determine if one of the following mechanical or electrical concerns apply:
3. If the concern(s) remains after the inspection, determine the symptom(s) and proceed to the following Symptom Chart.
Symptom Chart Condition
Source
Action
Loss of Engine Coolant
Damaged radiator. Damaged water pump. Loose/damaged radiator hoses. Loose/damaged heater hoses. Damaged heater core. Damaged engine gaskets. Damaged supply tank. Demaged cap relief valve. Demaged drain cock.
Go to Test A.
Engine Overheats
Damaged thermostat. Damaged water pump. Internal engine coolant leak. Cooling fans inoperative. Radiator coolant flow obstruction (internal) Radiator air flow obstruction (external fins) Heater core blocked. Openings or grille blocked. Damaged or faulty PCM. Airlock in system
Go to Test B.
Engine Does Not Reach Normal Operating Temperature
Damaged thermostat. Cooling fans, PCM fault. Low engine coolant.
Go to Test C.
Water pump leaking
Gasket (leak at pump/block interface)
CHECK bolt torques. Perform pressure test both statically and dynamically and visually confirm leak. REPLACE water pump if necessary.
O-Ring (leak at heater tube)
Perform pressure test both statically and dynamically and visually confirm leak. REPLACE O-Ring.
Weep hole
A small amount of weep through this hole is considered normal and acceptable. Perform pressure test both statically and dynamically and visually confirm leak. REPLACE water pump if necessary.
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Engine Cooling
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DIAGNOSIS AND TESTING (Continued) Tests TEST A : LOSS OF COOLANT
A1
Test Step CHECK COOLANT LEVEL NOTE: If engine is hot, allow engine to cool down before proceeding. Check coolant level coolant supply tank. Is coolant level OK?
A2
A3
A4
A5
A6
CHECK FOR VISIBLE LEAKAGE Engine coolant has an added dye colour that makes the coolant an excellent leak detector. Check entire cooling system for visible leakage. Is there visible leakage? CHECK SUPPLY TANK CAP Using a Radiator/Heater Core Pressure Tester test radiator cap as outlined in this section. Did supply tank cap test OK? CHECK COOLANT FOR INTERNAL LEAKAGE Visually inspect coolant in radiator and coolant supply tank for signs of transmission or engine oil. Is oil evident in coolant?
CHECK ENGINE AND TRANSMISSION FOR COOLANT Remove oil level indicator from engine and transmission. Carefully inspect oil level indicator for evidence of coolant. Is coolant evident?
Result/Action to Take Yes Go to A2 No REFILL coolant. Go to A2 Yes Rectify leak. RETEST system. No Go to A3 Yes Go to A4 No REPLACE damaged supply tank cap. RETEST system. Yes If engine oil is evident, Go to Section 308-03. If transmission oil is evident, Go to Section 307-01 or Section 308-03. No Go to A5 Yes If coolant is in engine, Go to Section 303-00. If coolant is in transmission, Go to Section 307-01 or Section 308-03. No Go to A6
PRESSURE TEST COOLING SYSTEM Yes Rectify leak. RETEST system. Using a Radiator/Heater Core Pressure Tester conduct a No pressure test. Cooling system is operational at this Check for any signs of visible leakage. time. Is there leakage? RETEST system.
NOTE: Check inside vehicle for possible heater core leakage.
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Engine Cooling
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DIAGNOSIS AND TESTING (Continued) TEST B : ENGINE OVERHEATS
B1
Test Step CHECK COOLANT LEVEL NOTE: If engine is hot, allow engine to cool down before proceeding.
B2
B3
B4
B5
B6
Result/Action to Take Yes Go to B2 No REFILL coolant. Go to A
Remove supply tank cap and check coolant level at supply tank. Is coolant level OK? CHECK COOLANT CONDITION Check coolant for contaminants such as rust or corrosion. Yes Also check for fluid discoloration. Go to B3 Is coolant condition OK? No FRETEST system.LUSH system. CHECK FOR AIRFLOW OBSTRUCTION Visually inspect A/C condenser core and radiator core for Yes obstructions such as leaves or bugs. REMOVE obstruction and Is there any obstruction? CLEAN A/C condenser core and radiator. RETEST system. No Go to B4 CHECK HEATER CORE OPERATION Yes Install supply tank cap. As engine starts to warm up, feel the inlet and outlet Go to B5 heater water hoses. They should feel the same after three No or four minutes. TURN engine OFF before it Is outlet heater water hose the same temperature as overheats. SERVICE heater core. the inlet heater water hose? RETEST system. CHECK WATER THERMOSTAT OPERATION Yes Allow engine to run for 10 minutes. Feel the inlet and outlet heater water hoses and the REPLACE water thermostat. underside of the upper radiator hose. RETEST system. Are the upper radiator hose and heater water hoses No cold? Leave engine RUNNING. Go to B6 CHECK COOLING FAN Refer to Cooling Fan Self Test in this section.
TEST C : ENGINE DOES NOT REACH NORMAL OPERATING TEMPERATURE C1
Test Step CHECK ENGINE TEMPERATURE Start engine and allow to RUN for 15 minutes. Feel inlet and outlet heater water hoses and underside of upper radiator hose. Are upper radiator hose and heater water hoses cold?
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Result/Action to Take Yes REPLACE water thermostat. RETEST system. No CHECK coolant temperature gauge for correct operation.
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Engine Cooling
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DIAGNOSIS AND TESTING (Continued) Pressure Test
foreign material between the gasket and cap body. Refer to supply tank Cap Cleaning and It is recommended that a cooling system pressure test Inspection. Rinse supply tank cap in clean water. gauge be used to properly test the system for: NOTE: The supply tank cap used on this system is Blown or leaking cooling system sealing gaskets. unique; replace only with the proper supply tank cap. Internal or external coolant leakage. 2. Replenish the engine coolant at the supply tank. Pressure cap malfunction. 3. Install the supply tank cap. Many types of pressure gauges are available for use. Cooling Fan Self Test - All Models Therefore, it is recommended that the gauge manufacturer’s instructions be followed when The cooling fan motors and circuits are tested during performing the test. a PCM KOEO TEST. Refer to Section 303-14 NOTE: Never exceed the rated pressure indicated on Powertrain Control Module. the pressure cap when performing the pressure test. Fan Relay 1 Relay 2 Relay 3 Fan 1 Fan 2 Speed Supply Tank Cap Pressure Test OFF OFF OFF OFF OFF OFF 1. Remove the supply tank cap. LO ON OFF OFF LOW LOW 2. Use water to clean the cap seal and the vacuum HI ON ON ON HIGH HIGH relief valve. 3. Install the cap on a pressure test unit following the manufacturer’s directions. 4. Slowly depress the plunger of the test unit pump until the highest reading is achieved on the gauge. 5. This reading should be within the specification for the cap being tested. 6. Repeat the test several times. If the gauge reading is not within specification replace the cap.
Thermostat Test Thermostat Removed Remove the thermostat and immerse it in boiling water. Remove when open and place a .05 mm feeler gauge in the throat of the thermostat and allow the thermostat to cool and clamp on the feeler gauge. Suspend a thermometer into a container of cool water and heat the water. Suspend the thermostat by the feeler gauge into the container of warming water. When the thermostat opens and drops off the feeler gauge, note the temperature. Refer to Specifications in this section for the operating temperatures and opening dimensions. If the problem being investigated is insufficient heat, the thermostat should be checked for leakage. This may be done by holding the thermostat up to a lighted background. Slight leakage of light at one or two locations on the perimeter of the valve may be detected. This should be considered normal.
Coolant System In the event no engine coolant is observed in the supply tank, or when a coolant level change does not occur, check the system as follows: 1. With the engine cold, remove the supply tank cap, and inspect the filler neck sealing gasket for G97832 en
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Engine Cooling
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GENERAL PROCEDURES
Coolant Level Check The coolant level is maintained by a coolant supply tank located on the right hand fender apron just ahead of the suspension tower. If there is no coolant visible in the supply tank the procedure quoted under ‘DRAINING AND FILLING THE COOLING SYSTEM’ must be used. Do not remove coolant supply tanks pressure cap for routine coolant level inspections. The coolant supply tank provides a quick visual method for determining the coolant level without removing the pressure gap. With the engine cold, the level of the coolant supply tank should be between the MIN and MAX lines on its side wall. WARNING: Do not attempt to remove the supply tank cap under any circumstances while the engine is operating or while the engine is hot. To do so might lead to damage to the cooling system and the engine and could result in serious personal injury from hot coolant or steam blowout. Switch off the engine and wait until it has cooled. Use extreme care when removing the cap and wrap a thick cloth around the cap and turn it slowly. Step back while the pressure is released from the cooling system. When you are sure all the pressure has been released – still with a cloth – turn cap and remove it. NOTE: The level of the coolant in the supply tank should only be checked when the engine is cold. Remove the supply tank cap. Fill the supply tank to the FULL/MAX mark with specified coolant. Refit the supply tank cap correctly (fully tighten by hand). NOTE: If the coolant tank requires topping up to maintain the correct level of coolant, the complete cooling system should be checked without delay. NOTE: When topping up the cooling system a mixture of clean drinkable water and Motorcraft R1-33 inhibitor should be used. Adding water only will dilute the inhibitor and reduce its effectiveness. Refer to specifications.
Cooling Color Inspection CAUTION: Check the coolant level, engine oil and transmission fluid, top off the coolant if needed, if there is engine coolant in the engine oil or transmission fluid the cause must be corrected and oil/fluid changed or major component damage may occur. The initial factory coolant fill is a 33% by volume mixture of glycol-based anti-freeze/ant-corrosion inhibitors in water, meeting Ford specification
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ESE-M97B44-A / WSS-M97B51-A1. Ford R1-33 meets this specification and is green in colour. 1. Inspect the coolant color: If Engine Coolant R-33 or equivalent meeting Ford specification ESE-M97B44-A has a clear, light green or blue color, this indicates higher water content than required. Dark brown could indicate unauthorized stopleak may have been used. Flush the system and refill with the correct mixture of water and Premium Engine Coolant. A light or reddish brown color indicates that rust may be present in the cooling system. An iridescent sheen on top of the coolant could indicate a trace of oil is entering the system. For additional information on engine diagnosis, refer to Diagnosis in this section. A milky brown color may indicate that either engine oil or transmission fluid is entering the cooling system. If transmission fluid is suspected the cause may be a leaky radiator, pressure test the cooling system. For additional information, refer to component tests in this section. If engine oil is suspected the cause of the leak may be internal to the engine. For additional information on engine diagnosis, refer to Diagnosis in this section. If transmission fluid is contaminated with engine coolant the cause may be a leaky radiator, pressure test the system. For additional information, refer to the component tests in this section. 2. If engine coolant appearance is good, test the engine coolant range with the battery and antifreeze tester: Maximum range is 50/50. Minimum range is 33/67. 3. Adjust coolant range and level if necessary: If coolant is low, add specified coolant mixture only. If the engine coolant tests to weak, add straight engine coolant concentrate until the readings are within acceptable levels. If the engine coolant tests strong, remove some of the engine coolant and add water until the readings are within acceptable levels. NOTE: Use only clean drinkable water In the engine cooling system. It is strongly recommended that in areas of heavily mineralised water (e.g. bore water), only non-mineralised water (e.g. rain water) is used. Mineral deposits on cooling surfaces will reduce the effectiveness of an engine cooling system and lead to engine overheating.
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Engine Cooling
303-03-10
GENERAL PROCEDURES (Continued)
Adjusting Anti — Freeze Protection Level NOTE: All vehicles are factory supplied with 33% concentration of R1-33 anti-freeze, which provides protection to -16 C. The specific gravity of the coolant should be checked at the recommended service intervals and the concentration adjusted by adding either, anti-freeze alone, a mixture of anti-freeze and water or water alone, depending on whether the specific gravity is low, correct or high. The specific gravity is checked using an anti-freeze tests hydrometer with the coolant cold. Example: Checking a 50-50 concentration of Motorcraft R1-33 anti-freeze (1.080 coolant specific gravity). If the hydrometer reading is 1.080 or greater, no adjustment is necessary. If the reading is less than 1.080, add R1-33 to the cooling system at the rate of 1 litre for each 0.012 S.G. increase required (e.g. 1.068 to 1.080).
2. Place a suitable container below the radiator draincock. The front bumper “lower air deflector” has a drainage aperture adjacent to the radiator draincock and doesn’t need removal. Open the draincock or remove lower radiator hose and allow to drain. Close the radiator draincock when finished. To Refill 1. Refit the lower radiator hose or drain plug. 2. Add the specified amount of anti-freeze to the coolant supply tank. 3. Fill the system with clean water to the “ADD/MIN” mark on the supply tank. NOTE: CAPACITY: Includes heater and coolant pressure bottle. Most service refills are about 80 percent of capacity listed. This is because not all coolant is drained the cooling system.
4. Install the cap one turn only or depress and turn until fully locked. 5. Set the heater control to ‘HOT’(for an Automatic NOTE: Draw of sufficient coolant to allow for the Climate Control system set the temperature to addition of the required quantity of R-133. 32°C). NOTE: The heater control doesn’t require setting Anti — Freeze Replacement to hot as the heater core is constantly flowing coolant. NOTE: The cooling system should be drained, flushed with clean water and refilled with water and 6. Start the engine and run it at 2000 rpm for 10 anti-freeze according to the recommendations given in minutes to open the thermostat and purge air from the Specifications section of this Section. the system. Vehicles must be refilled using specified quantities of 7. Top up the supply tank to the “FULL/MAX” mark. R1-33 in the cooling system. 8. Replace the cap. 9. Refit the lower air deflector. This procedure must Draining and Filling the Cooling be followed to ensure correct system System performance. Draining
Radiator Cleaning
WARNING: To avoid personal injury, do not unscrew the coolant pressure relief cap while engine is operating or hot. The cooling system is under pressure; steam and hot liquid can come out forcefully when the cap is loosened slightly. Failure to follow these instructions may result in personal injury.
Condition of driving - Town, City and Casual Driving 1. Loosen the top two radiator mounting brackets. NOTE: Cleaning of the radiator exterior is important to obtain maximum radiator efficiency and cooling performance.
2. Tilt the radiator and fan assembly rearwards from CAUTION: The coolant must be recovered in the top. a suitable, clean container for reuse. If the coolant 3. Use air pressure line to clear the debris then is contaminated it must be recycled or disposed wash by using a hose (pressure cleaning is too of correctly. aggressive) between radiator and condenser. Do NOTE: About 80% of coolant capacity can be not point the nozzle near the radiator and recovered with the engine in the vehicle. Dirty, rusty condenser fins as this may damage them. or contaminated coolant requires replacement. 4. Reposition radiator. Refer to the Radiator 1. Release the pressure in the cooling system by removal/installation in this section for additional slowly turning the pressure relief cap one half turn information. counterclockwise. When the pressure is released, Condition of driving - Outback, Dirt and Field remove the pressure relief cap. G97834 en
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Engine Cooling
303-03-11
GENERAL PROCEDURES (Continued) Driving 1. Remove the radiator as described in the Radiator removal in this section. 2. Use air pressure line to clear the debris then wash by using a hose (pressure cleaning is too aggressive) between radiator and condenser. Do not point the nozzle near the radiator and condenser fins as this may damage them. 3. Reinstall the radiator as described in the Radiator removal in this section. 4. Top up the coolant and transmission oil per specifications.
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Engine Cooling
303-03-12
REMOVAL AND INSTALLATION
Thermostat Removal and Installation 1. Partially drain the engine coolant so that the coolant level is below the thermostat. For additional information refer to Cooling System Draining Filling and Bleeding in this section. 2. Remove the two bolts and separate the water outlet adapter from the thermostat housing and slide (with hoses attached) to one side. 6 Cylinder
Item 1 2 3 4
Description Bolt Housing Thermostat Conn water outlet
8 Cylinder
6. Refill and bleed the cooling system as previously described in this section. NOTE: On thermostats that have a bleeder valve, the thermostat should be positioned with bleeder valve at the 12 o’clock position as viewed from front of engine.
Thermostat Housing — 8 Cylinder Removal and Installation NOTE: The 5.4-3V V8 thermostat housing is located at the coolant cross over manifold between the cylinder heads. 1. Disconnect the battery. For additional information refer to Electrical system section. 2. Remove the drive belt as previously described in this section. 3. Remove the alternator. For additional information refer to Electrical system section. 4. Drain the engine coolant as previously described in this section. 5. Remove the Thermostat as previously described in this section. 6. Remove the two bolts securing the coolant manifold to the LHS cylinder head. 7. Remove the bolt securing the coolant manifold to the RHS cylinder head. 8. Remove the inlet manifold bolt clamping the coolant manifold and loosen the adjacent inlet manifold bolts to allow removal of coolant manifold. 9. Clean and inspect the gasket. 10. Fitting a new gasket/s requires inlet manifold removal. For additional information refer to Fuel system section. 11. Clean and inspect the sealing surfaces. To install, reverse the removal procedure. 12. Refill and bleed the cooling system as previously described in this section. NOTE: All hardware must be correctly installed and torqued to specification.
Thermostat Housing — 6 Cylinder
Item 1 2 3
Description Bolt Thermostat Housing
Removal and Installation 1. Remove the thermostat. For additional information, refer to Thermostat in this section. 2. Remove the bolt and clamp that holds the heater tube to the housing. Remove the bolt holding the heater tube on the inlet manifold. Withdraw the heater tube from the thermostat housing.
3. Remove the thermostat and the O-ring seal. 4. Clean and inspect the sealing surfaces. 5. To install reverse the removal procedure.
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Engine Cooling
303-03-13
REMOVAL AND INSTALLATION (Continued) 3. Remove the two bolts and separate the thermostat housing from the cylinder head.
Item 1 2 3 4 5 6 7
3. Remove the water pump from the cylinder block being careful not to damage the heater pipe. This pipe is a slide fit with an ‘O’ ring seal.
Description Bolt O-ring Seal Bolt Housing Thermostat Conn Water outlet
4. Clean and inspect the sealing surfaces after removing all traces of gasket material. 5. Fit a new gasket and O-ring. 6. To install, reverse the removal instructions. 7. Refill and bleed the cooling system as previously described in this section.
Water Pump — 6 Cylinder Special Tool(s) Installer Power Steering Pump Pulley (6 & 8 Cylinder) 416-D001 (A7005)
Remover Power Steering Pump Pulley (6 & 8 Cylinder) 888-000 (A7185)
Removal 1. Drain the cooling system as described in Section 303-03a. 2. Remove the accessory drive belt.
G97847 en
4. If necessary, the water pump pulley can be removed using 888-000. Installation NOTE: If necessary, install the water pump pulley before installing the water pump, using 416-D001. 1. Clean the heater outlet pipe and the matching opening in the water pump. Lubricate a new ‘O’ ring seal and install on the heater pipe. 2. Clean the pump and cylinder block mating surfaces and install a new gasket coated with water resistant sealer. 3. Position the water pump on the cylinder block and heater pipe. Install the bolts and lock washers. 4. Refit the lower radiator hose. 5. Install the drive belt, refer to Section 303-03a. 6. Fill the cooling system as described in Section 303-03a. NOTE: All hardware must be correctly installed and torqued to specification.
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Engine Cooling
303-03-14
REMOVAL AND INSTALLATION (Continued)
Water Pump — V8 Removal 1. Drain the engine coolant. For additional information, refer to General Procedures in this section. 2. Loosen the coolant pump pulley bolts.
CAUTION: Do not rotate the coolant pump housing once installed in the engine. Damage the O-Ring seal can occur, causing the coolant pump to leak. NOTE: Install a new O-Ring seal and lubricate with the same clean engine coolant that is present in the system. Do not mix coolant types. Installation 1. To install, reverse the removal procedure.
Radiator Removal 1. Drain the cooling system as described in General Procedures Section. Disconnect the upper and lower radiator hoses. 2. Disconnect the coolant supply hose from the side of the radiator and the bleed hose from the top of the radiator. 3. Remove the accessory drive belt. For additional information, refer to Section 303-05. 4. Remove the bolts and the coolant pump pulley.
5. Remove the four bolts and the coolant pump.
6 Cylinder
Item 1 2 3
Description Hose assy. Upper Hose assy. Bleed Hose to engine vent
6. If necessary wipe the coolant pump mounting surface with a soft cloth.
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Engine Cooling
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REMOVAL AND INSTALLATION (Continued) 8 Cylinder
Item 1 2 3 3.
4. 5. 6. 7.
9. Remove the screws securing the fan shroud and fans to the top of the radiator, lift the shroud from the clips on the bottom of the radiator and lay it back.
Description Hose assy. to bleed Hose assy. Upper Hose assy. Radiator overflow
10. Remove the radiator upper mounting brackets and carefully lift the radiator from the vehicle. Installation On vehicles equipped with automatic transmission 1. Locate the radiator in the vehicle and install the disconnect the oil cooler lines at the radiator by upper support brackets. unscrewing the AF 17mm fittings and plug to 2. Locate the fan shroud in the brackets on the guard against contamination entry. bottom of the radiator and install the two securing Remove the air cleaner intake duct. screws at the top of the shroud. Remove the grille. 3. Connect the upper and lower hoses and the XR6 Turbo vehicles: remove intercooler (see coolant supply hose. Connect the bleed hose to 303-04b for procedure). the radiator. Remove the 4 bolts holding the A/C condenser 4. Connect the electrical connections to the fans. and wire or cable tie the condenser to the top 5. Remove the support cable tie/wire from the top crossmember. condensor and install the 4 A/C condensor mounting bolts 6. Install the air cleaner intake duct. 7. XR6 Turbo vehicles: install intercooler (see 303-04b for procedure). 8. Connect the oil cooler lines (auto only) do not over tighten the fittings as this will demage the oil cooler. 9. Install air cleaner intake duct. 10. Install the grille. 11. Fill the cooling system as described in General Procedures Section.
8. Disconnect the electrical connections to the fans.
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Engine Cooling
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REMOVAL AND INSTALLATION (Continued)
Fan Removal 1. Remove fan and shroud from vehicle.
3. Insert a new ‘C’ Spring Clip. Do not re-use the old clip. 4. Rotate fan (in the direction of normal operation) to ensure it rotates freely. 5. Install fan and shroud assembly into vehicle.
Radiator Hose Removal and Installation NOTE: Radiator hoses should be replaced whenever they become cracked, rotted or have a tendency to collapse, See Draining and Filling the Cooling System.
Item 1 2 3 4
Description Condensor assy. Radiator assy. Motor and Fan assy. Screw and washer assy.
2. Lay the assembly flat. 3. Remove and discard the ‘C’ Spring Clip by gently sliding sideways. 4. Gently prise drive plate from cavity. 5. Remove fan.
1. Drain radiator: then loosen the clamps at each end of hose to be removed. Slide hose off radiator connection and the cylinder head water outlet or water pump connection. 2. Position the clamps and hoses as shown in the applicable installation in this chapter. Tighten clamps. 3. Fill coolant supply tank to the “FULL/MAX” mark. 4. Fill and bleed the cooling system as described in Draining and Filling the Cooling System in this section. NOTE: The hose clamps initial factory fit make use of a torque limiting cap that’s drive shears off once the torque valve is reached. For service remove the cap body by prying off to reveal the hand tool drive feature. Install the hose clamps as close as possible to the bead on the inlet and outlet pipes. Use only Ford approved hoses and clamps when replacement is necessary. Clamps with a “ bow spring‘‘ show improved resistance to compression set of the rubber hoses
Coolant Supply Tank Removal 1. Remove supply tank cap and loosen radiator drain tap and drain cooling system until no coolant remains in the supply tank. 2. Remove the bleed tubes found on upper surface of supply tank. Item 1 2 3 4 5 6
Description Shroud Fan Drive plate ‘C’ Spring clip Screw Motor
Installation 1. Place fan on spindle. 2. Install drive plate ensuring locating peg fits into hole correctly. G97842 en
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REMOVAL AND INSTALLATION (Continued) 6 Cylinder
Item 1 2 3
Description Hose assy. Upper Hose assy. Bleed Hose to engine vent
8 Cylinder
Item 1 2 3
3. Remove the two bolts which retain the supply tank to the vehicle and release the leg to the RH suspension tower.
Item 1 2
Description Supply tank cap Screw
4. Remove coolant feed hose on side surface of supply tank. Installation 1. Remove supply tank cap. 2. Position coolant feed hose onto supply tank. 3. Position supply tank in vehicle and tighten coolant feed hose. 4. Attach supply tank to vehicle using the locating leg and two attaching screws. 5. Attach bleed tubes to the top of the supply tank. 6. Fill the supply tank with coolant as described in General Procedures Section.
Description Hose assy. to bleed Hose assy. Upper Hose assy. Radiator overflow
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Fuel Charging and Controls — Turbocharger
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SECTION : 303-04b Fuel Charging and Controls — Turbocharger VEHICLE APPLICATION : 2003.0 BA Falcon CONTENTS
PAGE
SPECIFICATIONS Specifications .......................................................................................................................303-04b-2 DESCRIPTION AND OPERATION Turbocharger ........................................................................................................................303-04b-3 Boost Control .....................................................................................................................303-04b-3 Charge Air Cooler (Intercooler) ..........................................................................................303-04b-4 Heatshielding .....................................................................................................................303-04b-5 DIAGNOSIS AND TESTING Turbocharger ........................................................................................................................303-04b-6 Inspection and Verification .................................................................................................303-04b-6 Symptom Chart ..................................................................................................................303-04b-6 Pinpoint Tests ....................................................................................................................303-04b-7 REMOVAL AND INSTALLATION Turbocharger ......................................................................................................................303-04b-16 Boost Pressure Sensor ......................................................................................................303-04b-20 Wastegate Control Solenoid (WCS) .................................................................................303-04b-21 Charge Air Cooler (Intercooler) ..........................................................................................303-04b-21
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Fuel Charging and Controls — Turbocharger
303-04b-2
SPECIFICATIONS NOTE:Oil threads with engine oil. NOTE:Do not oil threads that require thread sealant or thread locker. Torque Specifications (Turbocharger) Description Nm Exhaust Manifold to Cylinder Head 27 Heat Shield to Exhaust Manifold (M8 20 Bolt, 2 places) Turbocharger to Exhaust Manifold Stud 27 Nut 55 Dump-Pipe to Turbocharger Stud 15 Nut 25 Pencil Brace to Dump-Pipe 25 HEGO Sensor to Dump-Pipe 25 Oil Return Pipe to Turbocharger 20 Oil Return Pipe to Sump 20 Water Supply Tube to Turbocharger 45 Water Return Tube to Turbocharger 45 Oil Supply Tube to Turbocharger 20 Oil Supply Tube to Nut & Filter 20 Assembly Oil Supply Nut & Filter Assembly to 20 Cylinder Block Torque Specifications (Intercooler & Ducting) Description Nm Studs to cushion connectors 15 Cushion connector to intercooler 15 15 Nuts holding brackets to cushion 20 connectors Mounting brackets to front cross 25 member Screw hose clamps on air ducting 2 pipes & hoses Under headlight duct retaining screw 8 Boost pressure sensor screw 2 Wastegate solenoid bracket retaining 8 screw Cross-over duct nuts 9
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DESCRIPTION AND OPERATION
Turbocharger Applicable to the XR6 Turbo model only
Item Description 1 Coolant Supply Line 2 Oil Supply Line 3 Oil Outlet Line 4 Coolant Outlet Line The turbocharger consists of two elements, a turbine and a compressor both installed on a single shaft and contained within housings. The turbocharger bearings are supplied oil from the engine via the oil supply tube. This is returned to the oil pan via the oil return pipe. The turbocharger housing also receives coolant from the engine cooling system, to assist with turbocharger cooling. The turbine element of the turbocharger is mounted on the exhaust manifold and uses the energy of the exhaust gas to drive the compressor. The compressor feeds air to the engine via the intercooler.
Item 1 2 2
Description Exhaust manifold Turbine side of turbo Compressor side of turbo
Boost Control The turbocharger is governed by means of a wastegate valve. The wastegate valve diverts some of the exhaust gas past the turbine and therefore regulates the speed of the turbine. The wastegate valve is controlled by a pressure operated actuator. The actuator incorporates a diaphragm, and uses G99921 en
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Fuel Charging and Controls — Turbocharger
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DESCRIPTION AND OPERATION (Continued) regulated air pressure to control the wastegate. This The PCM uses the BPS output voltage to control actuator is preset during manufacture and must not be boost pressure, dependent upon engine load, tampered with. temperature and RPM. The control system increases engine intake pressure by diverting excess pressure away from the wastegate actuator through the Wastegate Solenoid Valve. The solenoid valve is controlled by the PCM’s TURBO output.
The air pressure to the actuator diaphragm is regulated by use of a Boost Pressure Sensor (BPS) and a Wastegate Control Solenoid (WCS). The Boost Pressure Sensor is located on the aluminium duct beneath the driver’s side headlight. The Wastegate Control Solenoid is mounted underneath the fuse box.
Item Description 1 Wastgate Control Solenoid 2 Boost Pressure Sensor The BPS measures the absolute pressure of the pre-throttle intake system for cruise control and wastegate control strategy. The pressure sensing element in the BPS employs a Piezo resistive sensor that outputs a voltage proportional to absolute pressure. BPS Specification Absolute Pressure (kPa) Signal 10 50 100 150 200 G99921 en
CONNECTIONS AT PCM Pin C2 Boost Pressure Sensor (BPS) Signal Pin C28 BPS Signal Return (SIGRTN) Pin C21 TURBO Pin B45 Vehicle Reference Voltage (VREF) Intake air pressure is further controlled by a blow-off valve, which dumps excess pressure into the low pressure side of the intake system when the throttle is closed. The blow-off valve is actuated by intake manifold pressure, via a rubber hose from the intake manifold. The blow-off valve is situated in the Cross-Over Duct on top of the engine.
Charge Air Cooler (Intercooler) The Charge Air Cooler (CAC) is an air-to-air cooler. The compressed air from the turbocharger flows through the cooler, and is cooled by outside air flowing over the vanes of the CAC. The lower temperature of the charge air increases its density, so giving improved engine efficiency and power. The CAC is mounted in front of the radiator with four rubber isolated mounts.
Voltage (V) 0.3 1.0 1.9 2.8 3.7 01/2003 2003.0 BA Falcon
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Fuel Charging and Controls — Turbocharger
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DESCRIPTION AND OPERATION (Continued)
Heatshielding Two heatshields cover the exhaust manifold and the turbocharger, to protect surrounding engine bay components from heat damage. A heatshield is also fitted over the engine mount under the turbocharger, to protect the mount from radiated heat.
Item 1 2 3
Description Rear exhaust manifold heatshield Front exhaust manifold heatshield Engine mount heatshield
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DIAGNOSIS AND TESTING Visual Inspection Chart Mechanical Electrical Inspection and Verification Oil leak(s) Wiring harness Air cleaner element Electrical connector(s) NOTE: It is normal for a small amount of combustion Air cleaner outlet pipe PCM gas to pass into the crankcase. These ’blow-by’ Air cleaner intake pipe Boost Pressure gases are scavenged into the air intake system Turbocharger oil Sensor through the positive crankcase ventilation (PCV) supply or oil return Wastegate Control system. tube Solenoid Some engine oil, in the form of a vapour is carried into Turbocharger coolant the air intake system with the blow-by gases (this supply or return tube engine oil also contributes to valve seat durability). Wastegate valve and This means that oil will collect inside the air intake actuator components and the turbocharger. This is not an Turbocharger indication that the turbocharger oil seal has failed. The housings turbocharger oil seal will not fail unless the bearings Turbocharger rotor fail first, which will cause the turbocharger to become blades noisy or seize. Charge Air Cooler Ducting to and from Do not install a new turbocharger due to oil inside the the Charge Air Cooler turbocharger or the air intake components. If a leak is detected in the oil supply or return tubes or 3. If an obvious cause for an observed or reported connections, locate and rectify the source. Do not concern is found, correct the cause (if possible) install a new turbocharger due to an oil leak. before proceeding to the next step. 1. Verify the customer concern. 4. If the cause is not visually evident, verify the 2. Visually inspect for the following obvious signs of symptom and refer to Symptom Chart. mechanical and electrical damage:
Turbocharger
or renewed.
Symptom Chart NOTE: The wastegate actuator diaphragm unit is a fixed part of the turbocharger and cannot be adjusted Condition
Source
Action
Blue smoke with excessive turbocharger noise
Turbocharger compressor rubbing on housing walls. Turbocharger turbine rubbing on housing walls. Turbocharger bearings and oil seal(s) damaged.
Go to PinPoint Test A.
Excessive turbocharger noise without blue smoke
Turbocharger oil supply tube blocked or damaged.
Go to PinPoint Test A.
Blue smoke without excessive turbocharger noise
Turbocharger oil return tube blocked or damaged.
Go to PinPoint Test B.
Poor engine performance
Wastegate control valve vacuum line(s).
CHECK all vacuum line(s) are installed and no signs of air leaks are present. REPAIR as necessary.
Unauthorized adjustment of the wastegate control valve actuator rod.
The turbocharger boost pressure is factory set and must not be adjusted. CHECK that the wastegate actuator valve and rod have not been tampered with. If there is evidence of tampering, INSTALL a new turbocharger. REFER to Removal and Installation Turbocharger
Wastegate valve actuator rod.
CHECK the wastegate valve actuator rod moves freely. If the wastegate valve actuator rod does not move freely. CHECK for signs of damage or signs of foreign material. REPAIR as necessary. Go to PinPoint Test C
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DIAGNOSIS AND TESTING (Continued) Pinpoint Tests PINPOINT TEST A : NOISY TURBOCHARGER WITH BLACK OR BLUE EXHAUST SMOKE Test Step A1
Result / Action to Take
INSPECT THE TURBOCHARGER COMPRESSOR VANES FOR DAMAGE Disconnect the fresh air supply duct from the turbocharger. Inspect the compressor rotor vanes for damage.
Yes
Go to A2
No
Go to A3
Is there visible damage to the rotor vanes?
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DIAGNOSIS AND TESTING (Continued) Test Step A2
Result / Action to Take
CHECK FOR FOREIGN MATERIAL IN THE INTAKE AIR SYSTEM COMPONENTS Check the intake air system components for signs of foreign material.
Yes
CLEAN the intake air system components. INSTALL a new turbocharger. REFER to Removal and Installation Turbocharger.
No
Go to A4
Are there any signs of foreign material?
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DIAGNOSIS AND TESTING (Continued) Test Step A3
Result / Action to Take
CHECK THE TURBOCHARGER BEARINGS FOR EXCESSIVE MOVEMENT NOTE: A small amount of movement in the bearings is normal. Make sure the turbocharger rotor spins freely within the housing. While slowly turning the rotor assembly by hand, push the shaft radially and axially.
Yes
Go to A4
No
INSTALL a new turbocharger. REFER to Removal and Installation Turbocharger. TEST the system for normal operation.
Does the rotor spin freely within the housing?
A4
CHECK THE TURBOCHARGER OIL SUPPLY TUBE FOR BLOCKAGE NOTE: New sealing washers should be installed when refitting the oil
Yes
Attach a small piece of known good hose to the oil supply tube and gently blow down the hose.
INSTALL a new turbocharger oil supply pipe and/or banjo bolt. INSTALL a new turbocharger. REFER to Removal and Installation Turbocharger TEST the system for normal operation.
INSPECT the banjo bolt and turbo oil gallery for signs of blockage or oil clotting.
No
pipe.
Disconnect the oil supply tube from the turbocharger.
Go to A5
Are there any signs of blockage?
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DIAGNOSIS AND TESTING (Continued) Test Step A5
Result / Action to Take
INSPECT THE TURBOCHARGER TURBINE VANES FOR DAMAGE Remove the exhaust pipe and the dump-pipe from the turbocharger. Inspect the turbine vanes for damage.
Yes
INSTALL a new turbocharger. REFER to Removal and Installation - Turbocharger. SOURCE and rectify the cause of the damage to the turbine blades. TEST the system for normal operation.
No
Go to A1
Are there any signs of damage?
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Fuel Charging and Controls — Turbocharger
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DIAGNOSIS AND TESTING (Continued) PINPOINT TEST B : BLUE EXHAUST SMOKE WITHOUT EXCESSIVE TURBOCHARGER NOISE Test Step B1
Result / Action to Take
CHECK THE TURBOCHARGER OIL RETURN PIPE NOTE: New sealing gaskets should be installed when refitting the oil return pipe. Disconnect the turbocharger oil return tube from the turbocharger and from the engine sump Remove the turbocharger oil return tube. Check the turbocharger oil return tube for a blockage or signs of damage.
Yes
Go to Symptom Chart in this section for further blue smoke diagnostics.
No
INSTALL a new turbocharger oil return tube. INSTALL a new turbocharger. REFER to Removal and Installation Turbocharger. TEST the system for normal operation.
Is the turbocharger oil return tube OK?
PINPOINT TEST C : POOR ENGINE PERFORMANCE Test Step C1
Result / Action to Take
CHECK THE WASTEGATE ACTUATOR CONTROL HOSE Remove the wastegate actuator control hose.
Yes
INSTALL a new wastegate actuator control Check that the hose has no cracks or holes, and that it is not blocked. hose. TEST the system for normal operation.
No
Go to C2
Is the hose damaged?
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DIAGNOSIS AND TESTING (Continued) Test Step C2
Result / Action to Take
CHECK THE WASTEGATE ACTUATOR DIAPHRAGM FOR LEAKS NOTE: The wastegate control actuator is factory set and must not be adjusted or modified. If the wastegate control actuator is not operating correctly, the complete turbocharger assembly must be replaced. Connect one end of the wastegate actuator control hose to the wastegate actuator. Connect the other end of the wastegate control actuator hose to a hand pressure pump.
Yes
Go to C3
No
INSTALL a new turbocharger. REFER to Removal and Installation Turbocharger TEST the system for normal operation.
Using the hand pressure pump apply 35-45 kPa to the wastegate actuator.
Item 1 2
Description Wastgate Actuator Rod Wastgate Actuator Control Hose
Does the wastegate actuator rod move and hold its new position until the pressure is released?
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DIAGNOSIS AND TESTING (Continued) Test Step C3
Result / Action to Take
CHECK THE WASTEGATE CONTROL SOLENOID NOTE: The wastegate control solenoid is factory set and must not be
adjusted.
NOTE: If a fault develops in the turbo wastegate control system, a standby function is carried out. The wastegate solenoid is forced fully open (0% duty cycle) allowing minimum mechanical boost to be delivered. If the boost pressure is still higher than desired, torque-limiting by cylinder cut-out will occur. The appropriate trouble code will be logged in memory for retrieval during Self Test mode.
Yes
REPLACE the wastegate control solenoid. REFER to Removal and Installation - Wastegate Control Solenoid. TEST the solenoid.
No
Go to C4
Connect a WDS tester to the diagnostic connector. Check for Diagnostic Trouble Codes at: - Key-On-Engine-Off (KOEO) - Key-On-Engine-Running (KOER) - Engine Running (cont)
DTC
P1227
TEST MODE KOEO, KOER, Cont Cont
P1228
Cont
P0243
CONDITION Wastegate Solenoid Circuit Malfunction Wastegate Control System Failed - Wastegate Closed (Over Pressure) Wastegate Control System Failed - Wastegate Open (Under Pressure)
Is the solenoid operation faulty?
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DIAGNOSIS AND TESTING (Continued) Test Step C4
Result / Action to Take
CHECK THE BOOST PRESSURE SENSOR NOTE: The Failure Mode Effects Management (FMEM) strategy will, in most cases, ensure reasonable operation of the vehicle in the event of a BPS failure. If the BPS signal is not within the normal operating range, the PCM will substitute a default value for pre-throttle absolute pressure and use MAP for boost control. The appropriate trouble code will be logged in memory for retrieval during Self Test mode. Connect a WDS tester to the diagnostic connector.
Yes
REPLACE the boost pressure sensor. REFER to Removal and Installation - Boost Pressure Sensor. TEST the sensor.
No
Go to C5
Check the Parameter Identification (PID) value of the BPS. At Key-On-Engine-Off (KOEO) the value should be between 1.8 - 2.2 Volts.
Is the PID value within the specified limits?
C5
CHECK THE BOOST PRESSURE NOTE: The boost pressure is factory set and must not be adjusted. Start and run the engine until normal operating temperature is achieved. Connect a WDS tester to the diagnostic connector. Run the engine at idle and observe the Parameter Identification (PID) value of the BPS. The value should be between 1.8 - 1.9 Volts (this equates to 0.5 bar of boost).
Yes
Go to C6
No
REPLACE the boost pressure sensor. REFER to Removal and Installation - Boost Pressure Sensor. TEST the sensor.
Is the PID value within the specified limits?
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Fuel Charging and Controls — Turbocharger
303-04b-15
DIAGNOSIS AND TESTING (Continued) Test Step C6
Result / Action to Take
CHECK THE CHARGE AIR COOLER AND DUCTING Remove the air ducting that runs to and from the charge air cooler. REFER to Removal and Installation - Charge Air Cooler. Inspect the components for cracks, leaks or blockages. Remove the charge air cooler. REFER to Removal and Installation Charge Air Cooler. Inspect the cooler for cracks, leaks or blockages.
Yes
Unblock or replace components as required. REFER to Removal and Installation - Charge Air Cooler. TEST the system for normal operation.
No
TEST the fuel system. REFER to Section 310-00.
Are any blocked or damaged components evident?
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Fuel Charging and Controls — Turbocharger
303-04b-16
REMOVAL AND INSTALLATION
Turbocharger Removal All vehicles 1. Disconnect the battery ground cable. For additional information, refer to Section 414-01. 2. Remove the fresh air duct from the turbocharger. 1. Unscrew the hose clamps. 2. Remove the pipe.
3. Detach the charge air cooler intake duct from the turbocharger. 1. Unscrew the hose clamp. 2. Remove the duct.
5. Disconnect the water inlet tube from the turbocharger. 1. Discard the sealing washers. 6. Disconnect the water outlet tube from the turbocharger. 1. Discard the sealing washers.
Item 1 2
Description Water Inlet Water Outlet
7. Disconnect the oil supply tube from the turbocharger. 1. Discard the sealing washers. 8. Disconnect the oil return tube from the turbocharger. 1. Discard the gasket.
4. Disconnect the HEGO sensor wiring connector at the chassis rail. Item 1 2
G99923 en
Description Oil supply line Oil return line
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Fuel Charging and Controls — Turbocharger
303-04b-17
REMOVAL AND INSTALLATION (Continued) 9. Remove the exhaust manifold and turbocharger 13. Remove the exhaust manifold, turbocharger and heatshields. dump-pipe as a complete assembly. 1. Remove the 5 exhaust manifold and heat 1. Discard exhaust manifold gasket. shield retaining bolts from the cylinder head. 2. Remove the two heat shield retaining screws. 3. Remove the two heat shields.
10. Disconnect the exhaust catalyst pipe from the dump-pipe. 11. Disconnect the turbocharger from the H-Brace. 1. Remove and discard the two lower turbocharger nuts to disconnect the H-Brace.
14. Inspect the condition of the engine mount heatshield. 1. Replace if damaged. 15. Inspect the condition of the H-Brace. 1. Replace if damaged. 16. Remove the Dump-Pipe. 1. Remove and discard the five retaining nuts. 2. Discard the gasket. 3. Inspect the threads on the studs. Replace if damaged.
12. Remove the remaining exhaust manifold retaining bolts from the engine.
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Fuel Charging and Controls — Turbocharger
303-04b-18
REMOVAL AND INSTALLATION (Continued) 17. Remove the turbocharger from the exhaust manifold. 1. Remove and discard the two remaining nuts. 2. Inspect the threads on the studs. Replace if damaged.
Installation All vehicles NOTE: Install a new exhaust manifold gasket. NOTE: Install a new dump-pipe gasket. NOTE: Install a new oil return line gasket.
2. Refit the dump-pipe to the turbocharger. 1. Install a new dump-pipe gasket. 2. Use new stainless steel studs if necessary. 3. Use new copper coated nuts. 4. Torque nuts to specifications.
3. Install the exhaust manifold, turbocharger and dump-pipe assembly. 1. Install a new manifold gasket. 2. First, fit the bottom two turbocharger mounting studs into the H-Brace holes, then lower the manifold onto the head.
NOTE: Install new oil supply line sealing washers (x2). NOTE: Install new coolant supply line gaskets (x2). NOTE: Install new coolant return line gaskets (x2). 1. Refit the turbocharger onto the exhaust manifold. 1. Use new stainless steel studs if necessary 2. Fit the upper two nuts only at this stage. 3. Use new copper coated nuts. 4. Torque nuts to specifications. NOTE: There is no gasket between the exhaust manifold and turbocharger. 3. Install the manifold mounting bolts, leaving out the four bolts that mount the heat shields and the one bolt that mounts the pencil brace.
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Fuel Charging and Controls — Turbocharger
303-04b-19
REMOVAL AND INSTALLATION (Continued) 4. Fit the two remaining copper nuts to the 7. Connect the oil return tube to the turbocharger. turbocharger mounting studs. 1. Install a new oil return line gasket. 5. Fit the pencil brace to the dump-pipe and 2. Use Loctite Thread Sealer or equivalent on exhaust manifold bolts. 6. Torque all the bolts to specification. 4. Install the heat shielding to the turbocharger. 1. Fit the remaining exhaust manifold bolts with the heatshields. 2. Fit one of the heat shield retaining screws into the dump-pipe. 3. Fit the other heat shield retaining screw into the manifold. 4. Torque all the hardware to specification.
Item 1 2
5. Reconnect the HEGO sensor wiring. 6. Connect the exhaust catalyst to dump-pipe. 1. Use new studs if necessary. 2. Use new catalyst pipe nuts. 3. Torque nuts to specifications.
G99923 en
Description Oil supply line Oil return line
8. Connect the coolant outlet tube to the turbocharger. 1. Install a new coolant outlet line sealing washers. 2. Use Loctite Thread Sealer or equivalent on bolts.
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Fuel Charging and Controls — Turbocharger
303-04b-20
REMOVAL AND INSTALLATION (Continued) 9. Connect the coolant inlet lines to the turbocharger. 1. Install a new coolant inlet line sealing washers. 2. Use Loctite Thread Sealer or equivalent on bolts.
10. Connect the charge air cooler intake pipe. CAUTION: Make sure that the inside of the charge air cooler intake pipe is clean and free from any residue as this will reduce the installation grip of the pipe to the charge air cooler. Failure to follow this instruction may result in engine damage. 1. Install the pipe to the turbocharger. 2. Refit the two hose clamps and tighten to specification.
11. Install the fresh air inlet duct to the turbocharger. 1. Install the pipe duct. 2. Tighten the hose clamps to specification.
12. Connect the battery ground cable. For additional information, refer to Section 414-01. 13. Start engine and check all connections for oil/water/air leaks.
Boost Pressure Sensor Removal 1. Disconnect the wire harness from the BPS connector. 2. Undo the retaining bolt. 3. Gently pull the sensor out vertically from the aluminium duct.
Installation 1. Push the new BPS into the aluminium duct. 2. Refit the retaining bolt and tighten.
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Fuel Charging and Controls — Turbocharger
303-04b-21
REMOVAL AND INSTALLATION (Continued) 3. Reconnect the harness to the BPS.
5. Reconnect the harness to the WCS.
Charge Air Cooler (Intercooler)
Wastegate Control Solenoid (WCS) Removal 1. Disconnect the wire harness from the WCS connector. 2. Disconnect the hose that runs from the turbocharger compressor to the WCS. 3. Disconnect the hose that runs from the WCS to the wastegate actuator on the turbocharger. 4. Undo the retaining bolt. 5. Withdraw the Wastegate Control Solenoid.
Item 1 2 3 4
Description Hose WCS to turbo compressor WCS electrical connection Hose turbocharger actuator to WCS Wastgate control solenoid (WCS)
Installation 1. Fit the Wastegate Control Solenoid into position. 2. Refit the retaining bolt and tighten. 3. Connect the hose that runs from the WCS to the wastegate actuator on the turbocharger. 4. Connect the hose that runs from the turbocharger compressor to the WCS.
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Removal 1. Remove bumper and grill, Refer Section 501-19 of this workshop manual. 2. Remove horns, Refer Section 413-06 of this workshop manual. 3. Remove RH headlamp, Refer Section 417-01 of this workshop manual 4. Undo the clamps and disconnect the tube that runs from the top of the intercooler to the under headlamp duct. 5. Undo the clamps and disconnect the tube that runs from the turbocharger to the intercooler. 6. Remove the nuts holding the intercooler to the passenger side mounting bracket 7. Remove the nuts holding the driver’s side mounting bracket to the crossmember and remove the bracket and the intercooler together. 8. Remove the nuts holding the RH bracket to the intercooler. 9. Remove the cushion connectors from the intercooler ends. 10. Remove the wiring harness from the under headlamp duct. 11. Undo the bolt retaining the earth wire and under headlamp duct to the body. 12. Remove the duct from under the battery tray by twisting and removing at the same time.
Item 1 2 3 4 5 6
Description Cool air to intake manifold Cool air duct and BPS TURBO to intercooler Cool air hose from intercooler Intercooler Intercooler mounting bracket
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Fuel Charging and Controls — Turbocharger
303-04b-22
REMOVAL AND INSTALLATION (Continued) Installation 1. Installation is the reversal of the removal procedure. 2. Check all connections to ensure there are no airleaks.
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Single Fuel LPG
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SECTION : 303-04c Single Fuel LPG VEHICLE APPLICATION : 2003.0 BA Falcon CONTENTS
PAGE
SPECIFICATIONS Specifications .......................................................................................................................303-04c-3 DESCRIPTION AND OPERATION Single Fuel LPG ...................................................................................................................303-04c-4 Introduction .........................................................................................................................303-04c-4 Licensing Requirements ....................................................................................................303-04c-5 Important Safety Notice .....................................................................................................303-04c-5 Notes, Cautions and Warnings ..........................................................................................303-04c-6 Vehicle Identification ..........................................................................................................303-04c-7 Description .........................................................................................................................303-04c-8 LPG System Major Components ......................................................................................303-04c-11 Converter ..........................................................................................................................303-04c-13 Engine Servicing Requirements .......................................................................................303-04c-16 Scheduled Maintenance ...................................................................................................303-04c-17 DIAGNOSIS AND TESTING Single Fuel LPG .................................................................................................................303-04c-20 Inspection and Verification ...............................................................................................303-04c-20 Symptom Charts ...............................................................................................................303-04c-23 Connector Circuit Reference ............................................................................................303-04c-26 REMOVAL AND INSTALLATION Primary Service ..................................................................................................................303-04c-29 LPG Filter ...........................................................................................................................303-04c-29 Tank Assembly ...................................................................................................................303-04c-29 Pressure Decanting ............................................................................................................303-04c-29 Tank Decanting ..................................................................................................................303-04c-30 Tank — Ute ........................................................................................................................303-04c-30 Tank — Wagon ..................................................................................................................303-04c-32 Tank — Sedan ...................................................................................................................303-04c-33 Fuel Gauge and Float Assembly ........................................................................................303-04c-34 Automatic Fill Limiter ..........................................................................................................303-04c-34 Service Valve (With Relief Valve on Ute and Wagon) .......................................................303-04c-35 Fuel Filler Valve .................................................................................................................303-04c-35 Pressure Relief Valve .........................................................................................................303-04c-36 Fuel Filler Hose ..................................................................................................................303-04c-36 LPG Fuel Delivery System Hose .......................................................................................303-04c-36 Bundy Tube Connection .....................................................................................................303-04c-37 Converter Including Filter Lockoff & Solenoid ....................................................................303-04c-38 Filter ...................................................................................................................................303-04c-39 Main/Idle/Prime Lockoff Solenoids .....................................................................................303-04c-39 Converter Assembly ...........................................................................................................303-04c-39
01/2003 2003.0 BA Falcon
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Single Fuel LPG
303-04c-2
(Continued) Throttle Body ......................................................................................................................303-04c-40 DISASSEMBLY AND ASSEMBLY Converter with integral Filter/Lock Off ″ Solenoid ..............................................................303-04c-41 Converter ............................................................................................................................303-04c-41 Idle Jet ................................................................................................................................303-04c-45
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Single Fuel LPG
303-04c-3
SPECIFICATIONS General Specifications Description Fuel Tank
Specification Manufactured by APA Industries
Capacity Ute Sedan Wagon Fuel sender
92 Litres usable 93 Litres usable 116 Litres usable 40 - 250 ohms. Normal Working Range Pressure relief valves Relief Pressure - 2.55 on tanks MPa Pressure relief valve Relief Pressure - 3.10 (hydrostatic) on service MPa lineService line Bundy-tube - Preformed 5/16 " and 3/8 " diameter with Flexible pressure hose to the fill line. Converter assembly VIALLE - F5 Type (Special) Idle Jet 0.8mm diameter Throttle body and mixer LPG Fuel (38mm I.D.) assembly Spark plugs - Iridium K 20 SR 11 Long Life Gap 1.1 ± - 0.05mm Torque Specifications Description Flared connections - All Converted bracket to spring tower Filler valve plate to bracket fuel tank neck Primary/Lock Off to Converter Idle solenoid to converter Converter to mounting bracket Tank to chassis mounting bolts Service valve to tank AFL to tank 5Nm LPG Gauge (AXIOM) to tank Converter outlet retainer Electrical connector bracket on converter lock offs Inlet union to converter Filter bowl Fuel Tank Neck to Body Converter Torque settings Nut (73) Bolt water pipes (not shown) Second stage lever screws (37) G86720 en
Description Second stage section bolts (76) Second stage spring cap (51) First stage lever screws (24) First stage cover screw (68) Idle section bolts (76) Support plate screw (5) M5 cover nuts (1) Inlet lockoff assembly (stem) (15) Screw stepper motor (not shown) Filter lockoff assembly (15) Filter bowl screws (65) Idle plug (17) Sludge drain plugs (79) Balance plug (19)
Nm 4-5 12-15 1.5-2.5 1.5-2.5 4-5 2-2.5 4-6 16-17 4-5 22-24 4-6 3-6 5-7 10-15
Nm 35-38 17-23 8-12 10-12 10-12 4-8 80 5 5 4-8 4-8 plus Loctite 262 15-20 21-29 Refer to Section 310-00. 1.5-2.5 4-5 1.5-2.5 01/2003 2003.0 BA Falcon
303-04c-4
Single Fuel LPG
303-04c-4
DESCRIPTION AND OPERATION fitment on these vehicles may comprimise safe vehicle operation, reduce the life of certain engine components and result in non-compliance with Introduction emission regulations. Ford does not warrant or This Repair Manual has been prepared to provide take responsibility for any defect caused by or service information relating to the option of a specially attributed to fitment of LPG to a petrol vehicle. developed VIALLE LPG system for the Ford BA The manual is intended for use by only Falcon Sedan, Wagon and Ute. registered/licensed technicians operating in It should be recognized that the information contained approved specialist gas workshops. All specialist in this manual applies only to the BA Falcon LPG work shops should be in possession of, and option supplied by Ford and does not apply to other technicians completely familiar with the installations made to Ford Falcon vehicles. requirements of Australian and New Zealand Standards Publications AS/NZS 1425 - 1999 (or Aftermarket Fitment of LPG later) AND AS 2746 -1999 (or later), which cover the SAA automotive LP Gas Code and SAA Gas CAUTION: Only BA Series vehicles factory Vehicles Work Shop Codes respectively. built with E-Gas are designed and tested by Ford Available from: Motor Company to run on LPG. Petrol BA Series vehicles are not compatible with LPG fitment. LPG Standards Australia Australian Sales 1300 65 46 46 Telephone International Services 1300 65 46 46 Update Services 1300 65 46 46 Customer Service Center: Facsimile All Sales 1300 65 49 49 E-Mail Address
[email protected] 24 hour internet advice www.standards.com.au Internet Address available at Address: — 1 The Crescent Homebush NSW 2140 P.O. Box 1055, Strathfield NSW 2135 — (02) 9746 4700 Administration and Phone: Head Office: Fax: — (02) 9746 8450 Telephone — (02) 9746 4732 — (02) 9746 4123 Technical Advisory Facsimile Services: E-Mail Address —
[email protected] Telephone — (02) 9746 4784 Facsimile — (02) 9746 2950 Seminar Services: E-Mail Address — seminars @standards.com.au Telephone — (02) 9746 4748 Information Center: Address 232 St. Pauls Terrace, P.O. Queensland: Box 290, Spring Hill 4000 Address Suite 2, 237 Elizabeth Street, Tasmania: North Hobart 7000 Address 19-25 Raglan Street, South Victoria: Melbourne 3205 Branches at: Address 1274 Hay Street, West Perth Western Australia: 6005 South Australia: 63 Greenhill Road, Wayville 5034
Single Fuel LPG
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Single Fuel LPG
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DESCRIPTION AND OPERATION (Continued) Northern Territory (Agency): Australian Capitol Territory: Standards New Zealand Address: Telephone: Facsimile: Customer Services: Information Services: E-Mail: Web Site:
Address
Territory Construction Association 191 Stuart Highway Parap 0820 Shop 5, Level 4, The Boulevard, Canberra 2601
Address
Level 10, Radio New Zealand House, 155 The Terrace, Wellington 6001 (Private Bag 2439, Wellington 6020) (04) 498 5990 (04) 498 5994 (04) 498 5991 (04) 498 5992
[email protected] www.standards.co.nz
Licensing Requirements
any purchaser thereof.
There are some variations relating to the obligations of businesses regarding licensing of technicians and registration of premises in different states/territories and it is recommended that specific details of requirements for your location be checked with the relevant Licensing Authority. The various Authorities and their locations are listed below. The specifications referred to in this publication were in effect at the time this publication was approved for printing. However, Ford Motor Company of Australia Limited reserve the right, subject to the laws of any state or territory and the regulations of any competent authority which may be applicable at the time, at its discretion and without notice, to change the specifications of the products referred to herein at any time and without incurring any liability whatsoever to
Important Safety Notice Appropriate service methods and proper repair procedures are essential for the safe, reliable operation of all motor vehicles as well as the personal safety of the individual doing the work. This manual provides general directions for accomplishing service and repair work with tested, effective techniques. Following them will help assure reliability. There are numerous variations in procedures, techniques, tools, and parts for servicing vehicles, as well as in the skill of the individual doing the work. This manual cannot possibly anticipate all such variations and provide advice or cautions as to each. Accordingly, anyone who departs from the instructions provided in this manual must first establish that there is no compromise to personal safety nor the vehicle integrity by the choice of methods, tools or parts.
State
Vehicle installation regulator
Vehicle registration
Installer licensing
A.C.T.
Manager, Technical Operations Dept of Urban ServicesDickson ACT 2602
-
W.A.
Regulatory Services (Licensing Branch) Office of Energy 20 Southport St. Leederville WA 6007
Manager, Technical Operations Transport Regulation Dept Dept of Urban Services Manager - Technical Vehicle Engineering & Safety Branch Police Licensing Authority 22 Mount St. Perth WA 6000
N.S.W.
N.T.
G86721 en
Workarea licensing -
Manager Regulatory Services Office of Energy 20 Southport St. Leederville WA 6007 Chief Inspector, Dangerous Manager, Automotive Manager, Technical Goods Chemical Safety Unit Engineering Operations Services Motor Work Cover NSW Locked Vehicle Standards Section Vehicle Repair Bag 10 Clarence Street NSW Roads & Traffic Authority 260 Industry Council 239 2000 Elizabeth St. Surry Hills NSW Great North Road 2010 Five Dock NSW 2046 Manager, Dept of Transport & Manager Motor Vehicle Works Work Health Authority Registry Department of DARWIN NT 0800 Transport DARWIN NT 0800
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Single Fuel LPG
303-04c-6
DESCRIPTION AND OPERATION (Continued) State QLD.
S.A.
TAS.
VIC.
Vehicle installation regulator
Vehicle registration
Workarea licensing Chief Inspector, Gas & Manager, Motor Vehicle Chief Inspector Gas & Petroleum Dept of Mines & Registration Branch Petroleum Dept of Energy 61 Mary St. Brisbane Queensland Department of Mines & Energy 61 QLD 4000 Transport Brisbane QLD 4000 Mary St. Brisbane QLD 4000 Manager, Dangerous Manager, Vehicle Operations Substances Branch Dept for Section Dept of Transport Industrial Affairs 45 Pirie St. Kateena St. Regency Park Adelaide SA 5000 SA 5010 Manager, Chemical Safety Registrar of Motor Vehicles Manager, Chemical Section Industry Safety & Department of Transport Safety Section Mines 30 Gordons Hill Rd. GPO Box 936J Hobart Tas Industry Safety & Rosney Park Tas 7018 7001 Mines 30 Gordons Hill Rd. Rosney Park Tas 7018 Manager, Chemical Manager, Vehicle Safety Chairman, Technology Health & Safety Road Safety Division VIC Automotive Division Victorian Work Cover Roads 60 Denmark Street Alternative Fuels Authority World Trade Centre Kew Vic 3101 Registration Board Melbourne Vic 3000 464 St. Kilda Road Melbourne Vic 3004
Notes, Cautions and Warnings As you read through the procedures, you will come across NOTES, CAUTIONS, and WARNINGS. Each one is there for a specific purpose. NOTES give you added information that will help you to complete a particular procedure. CAUTIONS are given to prevent you from making an error that could damage the vehicle. WARNINGS remind you to be especially careful in those areas where carelessness can cause personal injury. The following list contains some general WARNINGS that you should follow when you work on a vehicle. Always wear safety glasses for eye protection. Use safety stands whenever a procedure requires you to be under the vehicle. Be sure that the ignition switch is always in the OFF position, unless otherwise required by the procedure. Set the parking brake when working on the vehicle. If you have an automatic transmission, set it in PARK unless instructed otherwise for a specific operation. Place wood blocks (100mm x 100mm or larger) to the front and rear surfaces of the tyres to provide further restraint from inadvertent vehicle movement. Operate the engine only in a well-ventilated area to avoid the danger of carbon monoxide. Keep yourself and your clothing away from moving parts, when the engine is running, especially the fan and belts. G86721 en
Installer licensing
To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, and muffler. Where procedures can be conducted without electrical power, disconnect the battery earth lead. Do not smoke while working on the vehicle. To avoid injury, always remove rings, watches, loose hanging jewellery, and loose clothing before beginning to work on a vehicle. Tie long hair securely behind the head. Where the nature of the work will require an LPG equipped vehicle to remain in the workshop overnight or for longer periods, the service valve should be turned off.
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Single Fuel LPG
303-04c-7
DESCRIPTION AND OPERATION (Continued) Vehicle Identification
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Single Fuel LPG
303-04c-8
DESCRIPTION AND OPERATION (Continued) Sedan and Wagon
Ute
Sedan
Ute
Wagon
Description The LPG fuel option utilises a VIALLE LPG system specifically engineered to suit the Ford 4 Litre engine. The LPG control system is fully integrated into the vehicles Power Control Module (PCM). Sedan and wagon units have two cylinders that are joined together through a manifold to form 1 storage tank that uses single filler hose. The tank has Automatic Fill Limiter (AFL), a non-return valve, a Service valve (incorporating an electric solenoid-activated Lock Off), and a fuel gauge with a
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Single Fuel LPG
303-04c-9
DESCRIPTION AND OPERATION (Continued) sender unit. The sender unit gives normal operation of the fuel gauge mounted in the instrument cluster . The Ute has two cylinders that form two separate tanks and uses a single filler hose. Each tank has Automatic Fill Limiter (AFL), a non-return valve, a Service valve (incorporating an electric solenoid-activated Lock Off), and a fuel gauge with a sender unit. The sender unit gives normal operation of the fuel gauge mounted in the instrument cluster. The liquid line has a hydrostatic valve on the Ute. Also for all variants included in the system is a second Filter/Lock Off, Converter Unit and a Gas/Air Mixer, which is in the engine throttle body with a filtered air supply through the vehicle’s special for LPG air cleaner.
state changes to a gas and in so doing, expands approximately 270 times its original liquid volume. This property results in a fuel that combines the compactness of a liquid for storage and combustion properties of a gas when mixed with air. Pressure vs. Temperature At 20°C LPG must be stored at approximately 750 kPa to remain as a liquid. This pressure is used to push LPG through the fuel line to the engine bay to the converter - a Fuel Filter and Lock Off is installed prior to the Converter. The pressure inside the fuel tanks varies with ambient temperature, as ambient temperature increases to 40°C the vapour pressure increases to approximately 1280 kPa
Operating Principles Liquid Petroleum Gas (LPG) is a hydrocarbon fuel similar to petrol and consists primarily of Propane and Butane. The mix will vary by location and source. For reasons of safety an additive is introduced to LPG that produces a strong odour to aid in leak detection. LPG is heavier than air, and will settle in low areas such as service bay pits, etc. Any leaks will not readily be dispersed and extreme care must be taken to prevent ignition of the gas if a leak does occur. LPG boils between -40°C and -9°C depending on actual mixture of propane and butane (at atmospheric pressure) and therefore must be pressurised to approximately 750 kPa to maintain it in a liquid state. When subjected to atmospheric pressure the liquid
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Single Fuel LPG
303-04c-10
DESCRIPTION AND OPERATION (Continued)
Item 1 2 3 4 5 6 7 8
Description LPG Liquid Line Coolant Hoses Cooler Temp. LPG Spark Plugs LPG Vacuum Tree Fuse & Relay Electronic Throttle Body with LPG Venturi Unique PCV Hose Air Cleaner with Paper Element, Coil Spring Clips and a Balance Hose Tube and Connector
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Item 9 10 11 12 13 14 15 16 17 18
Description LPG Intake Manifold 10.7:1 Compression Ratio Pistons Green Rocker Cover Spark Plug Cover with LPG Clip Balance Hose Vapour Hose LPG Oil Cap Designating 15W 40 Oil LPG Converter Converter Bracket Exhaust Manifold Heat Shield
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Single Fuel LPG
303-04c-11
DESCRIPTION AND OPERATION (Continued) LPG System Major Components
Sedan
Fuel Tank The LPG fuel tanks are thick walled steel cylinders built to safety standards. They are mounted to the chassis. NOTE: The tanks are heat treated in manufacture and must not be welded or treated in any way during installation or servicing. Sedan
Item 1 2 3
Description Pressure relief valve Fuel contents gauge with sender unit AFL (Automatic Fill Limiter)
Supply fuel to the engine through pick up filter and lock off. Sedan Item 1 2 3 4 5
Description Valve pad (see AUS00139) Cylinders Service valve Stone shield Service line
Sedan
Measure fuel level. Relieve excess vapour pressure should it rise to a high level. Variant
Each tank has four openings that are used to: Fill the tank with LPG and stop the fill when the tank has reached 80% of total capacity (AFL).
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80% of Total Capacity (AFL) Sedan 93 litres of LPG Wagon 116 litres of LPG Ute 92 litres of LPG Each tank has the following components: Automatic Fill Limiter, which incorporates a non-return valve. Service valve incorporating an electric solenoid actuated shut off valve. Fuel contents gauge with sender unit. Pressure relief valve.
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Single Fuel LPG
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DESCRIPTION AND OPERATION (Continued) Automatic Fill Limiter
UTE - Through each of the wheel arches (2 valves to shut off supply) . The system incorporates an Automatic Fill Limiter WAGON - From underneath the vehicle between (AFL), which prevents the tank being filled with liquid the rear axle and the front cylinder. beyond 80% of the tank volume. The 20% vapour The excess flow valve will automatically close to a space is necessary to allow for expansion of the liquid trickle and shut off the supply of liquid if an that occurs as temperature increases. The AFL abnormally high flow rate occurs. This may occur if incorporates a non-return valve. the fuel supply line is ruptured or damaged. The Variant Tank Capacity 80% of Total service valve incorporates a pipe that extends to the (100%) Capacity (AFL) bottom of the tank to ensure that only liquid LPG is Sedan 115 litres 93 litres of LPG withdrawn and directed to the converter. Wagon 145 litres 116 litres of Pressure Relief Valves/Hydrostatic Valve LPG Ute 114 litres 92 litres of LPG A pressure relief valve is located on each tank and on the service line Hydrostatic Valve located: Service Valve and Solenoid Operated Shut UTE only - near the bottom of the firewall. Off Valve Should the pressure at the relief valve(s) on the tank(s) reach approximately 2.55MPa, the valve will The Service Valve consists of a solenoid operated, open and discharge excess pressure to the normally closed shut off valve, a manual-isolating atmosphere. The Hydrostatic Valve on the liquid valve and, an excess flow valve. service line performs the same function but at The solenoid operated shut off valve is energised only 3.10MPa. Once the pressure reduces below that when the vehicle is starting or the vehicle’s engine is pressure the valve will close automatically. During running. When the valve is de-energised, it prevents normal operating and under normal ambient the flow of LPG from the tank. conditions there is no reason for the relief valve to Wagon & Ute
operate. NOTE: The pressure relief valves are NOT a serviceable item.
Fuel Contents Gauge Each LPG tank fuel gauge/sender unit has a float similar to a petrol gauge unit. (i.e. it will float up and down with the liquid level in the tank.) The fuel gauge will indicate FULL when the LPG liquid level is at 80% of each tank capacity. The LPG tank sender is interfaced with the vehicle dash mounted fuel gauge and indicates total amount of fuel.
Fill Valve Item Description 1 Service valve 2 Service line 3 Solenoid operated shut off valve 4 Fuel contents gauge with sender unit 5 AFL (Automatic Fill Limiter) The manual isolating valves enable the liquid supply to the converter to be shut off in the event of an accident or during servicing. These can be accessed from various regions depending on the variant. SEDAN - From underneath the vehicle in the stone plate service cut out (between the two cylinders).
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The fill valve consists of a valve with a soft seat and a soft housing. The fill valve is connected to the AFL mounted on the tank by a flexible pressure hose.
Fuel Line and Filter Lock Off The fuel line is made of Bundy tubing and transports liquid LPG from both tanks to the Filter/Lock Off Valve. This valve is integral with the converter and incorporates a filter and a magnet to prevent foreign particles interfering with the operation of the Lock Off Valve. The Filter/Lock Off is a safety device designed to prevent the flow of liquid to the converter when the engine is not running or cranking. They are controlled electronically by the PCM when the engine is running. If the engine stalls or the ignition is left switched ON,
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Single Fuel LPG
303-04c-13
DESCRIPTION AND OPERATION (Continued) the PCM will switch OFF the supply of LPG automatically.
Converter
coolant to prevent the converter from freezing as the vaporising gas draws heat from the atmosphere. The converter is located in the engine bay and is attached by a bracket to the right hand spring tower.
The converter is a two-stage pressure regulator, which incorporates a heat exchanger, prime circuit and idle circuit. The heat exchanger uses engine
Item 1 2 3 4 5 6 7 8 9 10 11 12 13
Description Stepper Motor Prime Solenoid Prime Hose Mount Bracket Coolant Outlet Coolant Inlet Inlet Gas Lock Off Solenoid Liquid Gas Inlet Filter & Magnet Drain Plugs Idle Solenoid Balance Hose Fitting Vapour Line Fitting
First Stage Liquid enters the converter at tank pressure (approximately between 750-1280 kPa). It is then reduced to a pressure of approximately 36 kPa (5.5 psi) in the primary chamber. If the pressure drops G86721 en
below 35 kPa the primary valve opens. If the pressure is above 35 kPa the valve closes. This action maintains primary pressure at the correct level. As the liquid enters the primary chamber and the pressure drops it boils and a change of state to gas occurs. A large amount of heat energy (latent heat of vaporisation) is absorbed during this change of state and it is therefore necessary to pass hot engine coolant through a jacket in the converter body to prevent the converter from freezing up. NOTE: If the converter freezes at any time during its life, it may be damaged internally. This will affect the vehicles driveability and continued safe operation. A registered LPG technician should inspect/repair the converter. Regular maintenance of the cooling system, coolant level and anti-freeze is very important to ensure correct operation of converter. From the primary chamber the vapour moves through two different paths: The idle circuit and the secondary valve.
01/2003 2003.0 BA Falcon
303-04c-14
Single Fuel LPG
303-04c-14
DESCRIPTION AND OPERATION (Continued) Second Stage
central bore via the sensitive diaphragm. This stabilises the pressure in the central bore and stops Second stage LPG flow is controlled by a secondary the secondary valve from opening more. As the valve. The force needed to overcome the secondary secondary valve is partially open, vapour also leaves spring pressure and therefore control the flow, is the primary chamber through the secondary valve. acquired from the flow amplifier system within the idle As the engine speed increases, the pressure through circuit and from the engine vacuum signal present in the gas/air mixer reduces which in turn reduces the the secondary stage. The idle circuit, which pressure in the secondary chamber. As the secondary incorporates the flow amplifier, remains open for as chamber pressure reduces, the sensitive diaphragm long as the engine is running. Flow through this restricts the flow of vapour to the central bore. This section is stopped by the idle solenoid when the causes the central bore pressure to drop further, and engine stops turning. Note that, at idle the LPG vapour is supplied through both the idle circuit and the therefore, open the secondary valve more. As the secondary valve releases more vapour, the secondary valve. pressure in the secondary chamber is increased and Prime Valve the sensitive diaphragm allows more vapour into the central bore. Once the pressures are balanced the A prime solenoid is incorporated to permit primary secondary valve reaches an equilibrium point and pressure LPG to go directly to the engine via the steady state flow is maintained. stepper motor housing during starting. The stepper motor does not directly control this initial primary Air Cleaner pressure gas flow. The prime circuit is fed LPG from The air cleaner is unique on this LPG vehicle. It the idle circuit. includes a pipe to fit the balance hose to and also has Heat Shield unique springs, which allow the pressure of backfire to escape. The exhaust manifold heat shield has an extension that protects the bottom of the converter and liquid Ram Air Balance Hose service line. The System includes a Ram air balance hose connected between the converter and the air cleaner base. The purpose of the Ram air balance is to provide the converter with the correct pressure levels inside the intake system, as the pressure levels will vary away from atmospheric due to the positive Ram air effect built up in front of the vehicle at highway speeds. The varying pressure levels have an influence on the positioning of the sensitive diaphragm within the converter and ultimately the Ram air balance assists in ensuring that the converter is supplying gas to the engine in quantities suitable to the current and varying operating requirements.
Stepper Motor The stepper motor is bolted directly to the converter at the vapour outlet and is connected to the mixer by a Liquid LPG flows from the tank through the converter vapour hose. The stepper motor is a bipolar unit with lock off and up to the primary valve. As the liquid LPG two independently controlled coils. The rotational motion of the motor is converted to a linear pintle passes through the primary valve, the pressure is movement via a screw drive. In normal operation the reduced to 35 kPa and the liquid vaporises as it pintle extends and retracts as commanded by the passes through the primary chamber. From the PCM. This trims the flow of LPG vapour to the engine primary chamber the vapour either passes through allowing closed loop EGO (Exhaust Gas Oxygen) the idle circuit or the secondary valve. The prime content control. valve is fitted to the converter for starting. LPG at primary pressure flows from the idle circuit to the Fuel Gauge and Instrument Cluster prime valve lock off only while the idle solenoid is energised. The LPG fuel level signal from the sender is sent The idle vapour passes through the idle jet to the flow directly to the instrument cluster. The fuel gauge will amplifier and then into the secondary chamber. As the show the total amount of fuel in the cylinders. The PCM transmits the fuel usage to the cluster, to be vapour passes through the flow amplifier, it draws used in the ’Range’ calculation, over the CAN line. vapour out of the central bore. The pressure in the central bore is reduced and the secondary valve is opened. At the same time vapour is leaking into the
Operation Summary
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01/2003 2003.0 BA Falcon
303-04c-15
Single Fuel LPG
303-04c-15
DESCRIPTION AND OPERATION (Continued) Pin C26
Label GSCC
C27
GSCD
C7
GCO
C21
PRIME
Function Stepper motor coil connection C Stepper motor coil connection D Solenoid relay trigger (grounding signal) LPG Prime Solenoid
Solenoid Operation
LPG Solenoid Valves The LPG system has number of solenoid valves depending on the variant: SEDAN has four solenoid valves - one tank lock off, an engine-bay lock off, an idle circuit solenoid and a prime solenoid. WAGON has four solenoid valves - one tank lock off, an engine-bay lock off, an idle circuit solenoid and a prime solenoid. UTE has five solenoid valves - two tank lock offs, an engine-bay lock off, an idle circuit solenoid and a prime solenoid. All of the solenoids are controlled by the PCM. All solenoids, except the prime, are switched together by a relay and fuse mounted near the PCM.
Three solenoids valves on the sedan and wagon and four solenoid valves on the Ute, as mentioned above, are energized continuously whenever LPG operation is required. The engine must be running before the valves will open. The valves are de-energised when ignition is turned off or the engine stops. The prime solenoid is operated independently of the other solenoids by the EEC in most starting conditions.
Stepper Motor Operation The main LPG control is performed by the stepper motor. The pintle moves back and forth over a range of 255 steps to trim the LPG flow. A step position of 255 is fully closed and 0 is fully open. Normal operation is in the range of 100 to 200 steps. The New Generation Star Tester (NGS) or WDS can monitor and log the stepper motor step position.
Reset Procedure
The stepper motor is reset by the EEC during starting to initialise the pintle position. The pintle ramps Wiring Loom towards the fully open position and continues pushing The wiring connects circuits at the LPG tank, into the seat for a number of steps to guarantee that converter, PCM and fuse panel. The PCM therefore the motor is in a known open position. The motor then performs all of the control functions. The extends to a normal operating position. When coolant solenoid-switching relay and fuse are directly mounted temperature (ECT) is below 20°C and engine off time to the harness near the PCM. For protection, the relay is between 1 to 10 minutes, the stepper motor will is covered by a moulded sheathe. The wiring open fully to determine its zero position and then diagrams and connector pinouts are detailed in the close immediately. the stepper motor will then slowly wiring schematic section (section 9). open to its normal operating position. This is to protect against the possibility of rich starting under these PCM conditions. The PCM has direct control of the LPG stepper motor Open Loop Operation and switches four LPG solenoids via a relay. The PCM also controls the prime solenoid. The PCM has The open loop stepper motor position is determined also been specially calibrated to control the ignition within the PCM based on several operating and transmission systems when running on LPG. This parameters. This is calculated from engine and inlet ensures that the vehicle is operating at peak air temperatures and A/C status. The engine operates performance and efficiency. in open loop in similar situations to petrol: Post start - 20 to 45 seconds depending on LPG related PCM pins temperature. Pin Label Function Wide-open throttle C24 GSCA Stepper motor coil The adaptive learn system also adds a learnt step connection A position offset. C25 GSCB Stepper motor coil connection B
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01/2003 2003.0 BA Falcon
303-04c-16
Single Fuel LPG
303-04c-16
DESCRIPTION AND OPERATION (Continued) Closed Loop Operation
Vehicle Backfire Information
During closed loop operation the stepper motor is driven open and closed. The HEGO (Heated Exhaust Gas Oxygen) sensor detects rich or lean air fuel ratios. While the HEGO is reading a rich signal, the motor ramps closed and the step position increases. When lean, the motor ramps open and the step position decreases.
In the event of backfire, stop and inspect the vehicle for damage in the form of cracked or split intake components, dislodged components such as air cleaner upper or manifold nipple caps, etc. Note that in extreme cases, backfire can damage the PCV valve or MAP sensor rendering the vehicle undriveable. Backfires are caused by poor ignition system condition or an over-lean air/fuel ratio.
Starting During engine start, the prime solenoid pulses open and delivers fuel for a few hundred milliseconds only. The LPG lock-off solenoids are opened as the engine starts to turn and the stepper motor is reset. The prime solenoid operation (on time) is dependant on the engine temperature and the time since the ignition was previously turned off.
Engine Coolant Hoses Coolant hoses are connected to the heat exchanger in the converter to provide heat, which is required for the LPG evaporation process.
Adaptive Learn Strategy The PCM control strategy includes an adaptive learn capability. The system automatically adjusts for vehicle, environmental, and fuel differences as the car ages. The adaptive learn system can be reset by disconnecting the power to the PCM for a few minutes. This is recommended after servicing the LPG converter, engine or changing the air filter.
Positive Crankcase Ventilation System The Crankcase ventilation system is re-routed to the inlet manifold near the throttle body to ensure even air/fuel ratio and therefore maintain a smooth idle.
Vapour Hose This unique vapour hose carries the LPG vapour from the converter to the gas/air mixer.
Gas / Air Mixer
Item 1 2 3
Description Hose from LPG converter to heater Quick connector on hose Hose from engine to LPG converter
Engine Servicing Requirements
There are no special running-in requirements for this The function of the gas/air mixer is two-fold: vehicle. Please refer to the standard running-in Convert intake airflow into a vacuum signal that is requirements in the Owners Manual. detected at the converter. Engine Oil Thoroughly mix air and fuel together. The 15W-40 oil specification is recommended. The combustion products of LPG does not blacken but tends to acidify the engine oil more than petrol does. This problem may be exaggerated when oil change intervals are extended because the oil appears clean to the owner.
Spark Plugs Vehicles operating continuously on LPG require a colder range spark plug than vehicles operating on petrol. The recommended spark plugs for LPG are: Specification: DENSO K20SR11 Gap: 1.1mm
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01/2003 2003.0 BA Falcon
303-04c-17
Single Fuel LPG
303-04c-17
DESCRIPTION AND OPERATION (Continued) Coolant The normal service schedule for the cooling system should be adhered to. For optimum cooling system performance of vehicles running on LPG, the recommended coolant specification is: Motorcraft Rl-32/33 Anti-corrosion/Anti-freeze (33% MIN) and water. This specification provides frost protection to a minimum temperature of -16°C and should be replaced every 3 years/100,000 km (whichever comes first). It is paramount to cooling system efficiency that this is the only coolant used. With the addition of extra components into the cooling system (the LPG Converter), it is imperative that the replacement schedule be strictly adhered to. Should the cooling system be dirty, it is necessary to flush out the converter coolant passages in addition to the engine cooling system.
Scheduled Maintenance All LPG installations must comply with standard AS/NZS 1425-1999 and most states require that any person engaged in the installation and/or repair of LPG vehicles must be registered.
“Repair” means any repair to the vehicle which involves opening the high pressure gas lines to the atmosphere. NOTE: LPG fuel tanks must be removed from the vehicle and be inspected and pressure tested by an authorised tank test centre every 10 years. A plate with the original test date and other information is attached to the tank. Removal of the tank should only be performed by a registered operator. NOTE: Running the vehicle on LPG places a greater demand on the ignition system (as compared to petrol) -Accordingly the ignition system must be maintained in excellent condition. e.g. Replace spark plugs at intervals indicated below, without failure. In addition to the normal vehicle maintenance schedule as set out in the Vehicle Owners Manual the following minimum maintenance schedule should be followed for an LPG equipped vehicle. Some states require the inspection of the LPG system annually coincident with the registration inspection. Where this is not a requirement it is recommended that an annual inspection be performed by an Authorised Ford Dealer or a registered LPG repairer in accordance with the requirements of standard AS/NZS 1425-1999.
Minimum LPG Maintenance Schedule Items High Pressure Leak Check: Converter and lock offs All service line connections Filler valves LPG Tank connections All mounting points for tightness Filter/Lock Off - Inspect Filter Auto fill limiter operation Air Filter Element Spark Plugs Diagnostic Checks Drain Second Stage Bodies Inspect Idle Jet
30
I I I I I F
I I I I
I I I I
I I I I
I I I I
I
R
I I*
R
I
I I I I I F I R
N D I
N D I
N D I
N D I
N D I
N D I
I. Inspection of condition and testing of systems operation. I*. Clean, replace as required. R. Replace. F. Filter/Lock - off - inspect filter replace as necessary (high pressure leak check when replaced) D. Remove plugs and drain converter body N. Diagnostics check to be carried out NOTE: Engine Coolant must be maintained as follows: G86721 en
Maintenance Interval (kmx1000) 45 60 75 90
15
105
120
I I I I
I I I
I R N D I
R N D I
Replace every 3 years/100,000km. When coolant is due for replacement per standard service schedule, flush out original coolant and refill system with R1-32/33 Anti-corrosion/Anti-freeze (33% MIN) and water. NOTE: In severe/unusual (dusty/sandy) conditions the air cleaner element should be checked, cleaned and replaced more frequently to allow correct operation of the vehicle. NOTE: By Australian law tanks must be inspected every 10 years by an authorised LPG tank tester. 01/2003 2003.0 BA Falcon
303-04c-18
Single Fuel LPG
303-04c-18
DESCRIPTION AND OPERATION (Continued) NOTE: The total LPG system must be periodically inspected in accordance with standard AS/NZS 1425-1999.
filter and O-Rings. Refit/replace ensuring the filter is not crimped by the bowl.
Converter Body
LPG Service Procedures
Drain Second Stage Converter Bodies This must only be carried out by registered LPG number plate decals Every time the vehicle is in for service or repair of any technicians. kind, ensure that the red LPG decals are fixed to the Close the service valve. front and rear registration plates on metal plates (in Run the engine until it stalls. the centre), in the diamond orientation. Try to re-start engine several times. NOTE: 1 decal front and rear for sedan and wagon. Prior to opening the high pressure system to 2 decals front and rear for ute. atmosphere, the battery negative lead must be removed and carefully isolated. Auto Fill Limiter (AFL) Every 45,000 km it is necessary to test the operation of the AFL. The tank must be empty to accurately check the operation of the AFL and owners should be encouraged to present the vehicle for service with the tank nearly empty. Instructions to that effect appear in the owners manual. The remaining LPG in the tank will need to be decanted.
LPG Filter Service The filter which is integral with converter requires inspection and replacement (if necessary) after the initial 15,000 km of travel and at 75,000 km intervals thereafter. Always replace ‘O’ rings when replacing filter.
Item 1 2
Description Inlet Filter Bowl Plugs - to drain converter body
LPG Filter Service Procedure This must only be carried out by registered technicians. Close the service valve. Run the engine until it stalls. Try to restart engine several times. Prior to opening the high pressure system to atmosphere, the battery negatlve lead must be removed and carefully isolated. Remove the bowl, G86721 en
Item Description 1 Inlet Filter Bowl 2 Plugs - to drain converter body Despite the filter prior to the converter, sludge will gradually accumulate in the converter body and must be drained at least every 15,000 km to ensure correct converter operation. Ideally this should be performed at the same time as the filter in the filter lock off is replaced and the converter is devoid of gas. There are two hex headed drain plugs located at the base of the converter. Copper washers are installed between the drain plug heads and the converter body to ensure sealing of the chambers. To drain the converter, remove the plugs and allow the sludge to escape – when replacing the plugs install new copper washers. Conduct a leak test after replacing the plugs. This draining process must be conducted while the converter/engine is at running temperature.
Idle Jet Clean idle jet every 15,000 km as indicated in the service schedule. The head of idle jet is a 4 mm thread (Refer to Converter of Disassembly and Assembly in this section for Tool no. 303-689).
01/2003 2003.0 BA Falcon
303-04c-19
Single Fuel LPG
303-04c-19
DESCRIPTION AND OPERATION (Continued) Leak Testing
When a leak free condition has been confirmed, heating, welding or flame cutting can be carried out as long as it is no closer than one metre to a fuel container. The service valve must be closed when a vehicle is to be left overnight in the workshop or when stored for any period of time.
High Pressure Leak Testing A high pressure leak check of the LPG system must be carried out at 15,000 kilometre intervals. The standard AS/NZS 1425-1999 requires that this be carried out at least annually. In most cases this would Tank Testing fall in line with one of the 15,000 km service intervals. An important requirement of the AS/NZS 1425-1999 is Leak Testing Equipment the testing and inspection of the LPG fuel tank. Every The most common method of leak detection is to use ten years, the tank must be removed from the vehicle and tested by an Authorised Container Test Station. a foam test solution. It should be a proprietary leak Once testing is completed and passed, the tank is test solution, specifically formulated for this purpose, stamped with the test date and is ready for another eg. must not cause corrosion of steel lines etc. ten years service. Electronic combustible gas detectors are also Exhaust Relocation regularly used by many Technicians. Refer to the operating instructions supplied with either To provide the extra space required for the gas tanks, method to ensure accuracy and safety when leak the exhaust route has been changed and the muffler testing. pattern modified. This arrangement however, uses similar exhaust mounting locations as on the standard Leak Testing Procedure BA Falcon. The fuel system must contain sufficient LPG liquid to ensure a minimum vapour pressure to 450 kPa, otherwise a leak check will not be valid. Begin by testing: all the tank and filler fittings. service line joints. Where possible run or crank the engine to ensure all components are supplied with liquid LPG. Test all Filter/Lock Off and Converter connections and joints. A large leak can actually blow away the foam solution and not produce any bubbles, this must be carefully monitored. Remember since LPG is heavier than air, test thoroughly below all fittings and components. Where a leak is indicated, remake the joint, using a suitable sealing compound. The sealing compound used must be specifically suitable for LPG applications. CAUTION: Leaking joints with parallel threads and seats are uncommon. If this type of joint leaks, check for correct torque. If the leak persists after re-torquing, the joint must be replaced. Thread sealing compounds should not be used to seal these types of joints.
Welding and Heating The Australian Standard has two requirements regarding welding and heating on or near an LPG vehicle. Until an LPG vehicle has been tested and confirmed leak free, a Zone 1 hazardous area exists up to 3 metres from the perimeter of the vehicle. No welding, heating or flame cutting may be carried out in this area.
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01/2003 2003.0 BA Falcon
303-04c-20
Single Fuel LPG
303-04c-20
DIAGNOSIS AND TESTING solution, specifically formulated for this purpose, eg. not cause corrosion of steel lines, etc. Electronic combustible gas detectors are also regularly used by Inspection and Verification many Technicians. Refer to the operating instructions supplied with either method to ensure accuracy and WARNING: Where testing procedures require safety when leak testing. the handling of LPG of which may result in the release of LPG the following precautions must be Leak testing procedure taken: The fuel system must contain sufficient LPG liquid to Disconnect and safely stow the vehicles ensure a minimum vapour pressure of 450 kPa, battery earth lead. (The lead may require otherwise a leak check will not be valid. reconnection for certain tests involving NOTE: The pressure in the cylinder (tank) is related to electrically operated components.) the temperature of the LPG rather than the liquid The working area and working procedures level. must comply with Australian Standards (AS) 2746. Where possible run the engine to ensure all components are supplied with liquid LPG. When the tank is being filled, the normal precautions applicable to petrol or LPG Begin by testing: service station areas must be observed. i.e. all the tank and filler fittings No smoking and no ignition sources within the service line joints working zone - ignition off and parking brake all filter/lock-off and converter connections and engaged. joints. If for any reason the tank is filled beyond the A large leak can actually blow away the foam solution 80% level, the vehicle can be driven without and not produce any bubbles. This must be carefully stopping the engine for a sufficient distance (approx. 150 km) to consume the excess fuel. monitored. If this is not possible the excess fuel must be Remember since LPG is heavier than air, test removed by de-canting (refer Removal and thoroughly below all fittings and components. Installation) or by one of the methods for fuel Where a leak is indicated, remake the joint, using a unloading as described in Australian suitable sealing compound. The seal compound used Standards (AS) 2746. must be specifically suitable for LPG applications. NOTE: All workshops performing repairs/ maintenance on LPG equipped vehicles should be CAUTION: Leaking joints with parallel registered and in possession of, and technicians threads and seats are uncommon. If this type of familiar with, the contents of standards AS/NZS 1425- joint leaks, check for correct torque. If the leak 1999 and AS 2746. persists after re-torquing, the joint must be replaced. Thread sealing compounds should not Leak Detection Methods be used to seal these types of joints. NOTE: When using a liquid leak detection method, There are several acceptable methods such as: the liquid must be mopped from the cylinder at the Combustible gas detectors completion of the test to prevent corrosion. Trace gas detectors Foam LPG Tank Assembly Total immersion Each tank assembly comprises: Visual inspection The tank shell and valve PAD. Refer to standards AS/NZS 1425-1999 for a complete Automatic fill limiter. description including advantages or disadvantages of Tank gauge. each of the above mentioned leak detection methods. Safety valve. High pressure leak testing Service valve with integral excess flow valve. A high pressure leak check of the LPG system must be carried out at each service. The standard AS/NZS Test 1425-1999 requires that this be carried out at least Pressure test with an inert gas (eg. Nitrogen) in annually. In most cases this would fall in line with one accordance with the following procedure. of the 15,000 kilometre intervals.
Single Fuel LPG
Leak testing equipment The most common method of leak detection is to use a foam test solution. It should be a proprietary leak G86745 en
WARNING: Oxygen must NOT be used for pressurising, furthermore compressed air can be dangerous in association with LPG and a tank 01/2003 2003.0 BA Falcon
303-04c-21
Single Fuel LPG
303-04c-21
DIAGNOSIS AND TESTING (Continued) which has previously contained LPG must be thoroughly purged with Nitrogen if it is intended to use compressed air for pressurising. Close the service valve. Pressurise the container to an internal pressure of 2.3 ± 0.05 MPa. Remove the pressurising attachment. Check all joints between the container and the components for leaks (refer Leak Detection Methods). Check the filler valve and the service valve for leakage through the valve seats. With the valve outlet plugged or capped and the valve opened, check for leaks at the valve stem seal of any valve that is normally open in service. Where a leak is indicated, rectify the fault by replacement or resealing, and retest the area. Testing the Installation The following procedure should be applied after the tank sub assembly has passed the required test and has been installed in the vehicle. WARNING: It is essential that all air be purged from the container before LPG pressure tests commence, and it is more convenient if this purging is carried out before the container is installed. Leak testing of gas system After all connections have been made, the LPG system should be tested for leaks as follows: WARNING: It is important that high propane LPG, (not high butane LPG) be used for this test because it has a relatively high vapour pressure at the lowest temperatures likely to occur in a workshop. The pressure gauge on the LPG supply tank can be taken to represent the container pressure reasonably accurately, and if below 450 kPa, testing should be postponed. Under no circumstances should the container be heated to raise the pressure. Place high propane LPG in the container and ensure that the liquid lines are full of liquid phase LPG. Test all pipe and component connections, including those on remote filling lines, and test the filler valve. Where a leak is indicated, rectify the fault by remaking or replacing the joint, and retest the area.
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Automatic Fill Limiter The accuracy of the shut-off function of the automatic fill limiter should be checked with the vehicle standing on level ground and the tyres correctly inflated in accordance with standard AS/NZS 1425-1999. The container must be emptied of liquid LPG and then filled by a pump meter unit. The pump meter reading at which the AFL cuts off shall be within ± 2% of the maximum permitted filling volume i.e. 80% of the capacity of the container. The capacity must be less than 92 litres for Ute, 93 litres for Sedan and 116 litres for Wagon . NOTE: The accuracy of the contents gauge may be checked at the same time.
Excess Flow Valve To test the function of the excess flow valve in accordance with AS/NZS 1425-1999 follow the steps as listed below: Using compressed air or a gas inert to LPG, pressurise the LPG cylinder to an internal pressure 2.3 MPa as per clause 4.2.2 of AS/NZS 1425-1999. Fully disconnect the service line from the AXIOM solenoid service valve. Fully close the manual hand tap on the AXIOM solenoid service valve. Remove the solenoid coil, solenoid piston sleeve and solenoid piston. Quickly open the manual hand tap on the valve and check that the excess flow valve functions. WARNING: If the service line is to be disconnected, first remove the battery and take steps to ensure that discharging gas does not become a hazard. Manual valve Open and close the manual valve and test around glands and connections for leaks.
Lock Off Solenoids (At Cylinders and Converter) Start the engine. Disconnect the solenoid connector plug at the converter or both solenoid connector plugs on the cylinders (one on each) depending on which solenoid(s) you are testing. When the LPG in the converter and supply lines has been used up the engine should stop. If the engine continues to run it indicates that either the lock off piston is not sealing or the solenoid(s) are inoperative. To test the solenoid electrically a resistance measurement needs to be taken. The correct resistance is: 12.6 Ohms ± 4% at 20°C. 01/2003 2003.0 BA Falcon
303-04c-22
Single Fuel LPG
303-04c-22
DIAGNOSIS AND TESTING (Continued) Fuel Filler Check for damage to the coupling and for the presence of foreign matter, and check that the cap is 6. attached correctly. Check that the sealing washer is in place and in good order. Check that the housing 7. containing the filler valve is soundly attached to the vehicle, and that the remote fill line is not deformed or damaged by twisting resulting from a loose housing or 8. mounting. 9. Water system tests The water circulation system which supplies radiator water to the converter should be pressure tested for leaks, using a conventional radiator pressure testing method.
Converter
1. No air should come out of the prime solenoid. 2. Idle solenoid still energised. Energise the prime solenoid. 1. High pressure air should come out of it. De-Energise prime solenoid high pressure air should stop coming out (returns to idle flow). De-Energise prime and idle solenoids first then de-energise lock off solenoid. Disconnect air supply. Do not shake the converter. 1. Converter should hold pressure for at least 10 minutes. 2. Test pressure retention by gently inserting a blunt object into the central hole of the rear cover. Air will be heard to escape from the vapour outlet. 3. Soap test complete converter for leaks including water inlet and outlet, atmospheric vent fitting and backcover openings when converter does not hold pressure. If converter passes above test, remove hose. Converter is now ready for installation.
Converter freeze-up Converter freezing will occur if insufficient heat is available to support the change of state from liquid LPG to a gas. This can occur if the radiator coolant level is low or there is a restriction of some kind in the 10. converter coolant hoses, or air inlet to radiator. 11. A heat exchanger is included in the converter which is supplied with engine coolant. In the event of freeze up Worldwide Diagnostic System (WDS) Tester occuring, back flush the hoses and heat exchanger The WDS tester can display the stepper motor and check coolant flow to converter. position and LPG fuel level as well as all the usual functions. Should the engine stall or lose power, particularly under hard acceleration, promptly inspect converter Stepper Motor for signs of freezing. Freezing can cause internal leaking and damage within the converter. Stepper Motor Position
Bench Testing Converter
The stepper motor moves in discrete steps from 0 (fully open) to 255 (fully closed). The step rate will 1. Place converter with diaphragms in vertical vary from 250 steps per second to 2 steps per position making sure that the atmospheric vent second. During a reset procedure, the motor is fitting in the front cover is free of obstructions and commanded to step 0 to drive the pintle wide open. It that the converter lock off is energised. should then retract to approximately step 150. In 1. Do not energize idle solenoid. normal operation, the motor should sit in the range of 2. There should be no air coming out the vapour 120-200 steps. During steady state open loop operation, the step position will stay near constant. In outlet or water chamber openings. closed loop, the position will oscillate 10 to 20 steps to 2. Apply air pressure of 6-20 BAR (80-280 psi) to maintain a constant air-fuel ratio. fuel inlet. 3. Energize idle solenoid and inlet gas lock off solenoid. 1. Air should be coming out at vapour outlet. 2. Converter may slightly pulse air at vapour outlet. This is normal. 4. Install a hose to front cover atmospheric vent fitting. 1. Blow on hose with mouth. 2. Air flow should increase each time you blow on hose. 5. Disconnect prime hose.
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Condition Stepper motor reset Closed loop
Step Position 0-150 (APPROX.) ~100-200
High throttle ~60-130 openings Other open loop ~100-160
HEGO output N/A oscillates between rich and lean rich rich or lean
LPG Self Test — KOER The LPG self test checks that the HEGO output responds to movements in the stepper motor. This is performed during the KOER test. The engine must be 01/2003 2003.0 BA Falcon
303-04c-23
Single Fuel LPG
303-04c-23
DIAGNOSIS AND TESTING (Continued) warm before the test is started. The PCM increases the engine speed to approximately 1300 rpm. The stepper motor is ramped towards 180 steps or until the HEGO reads a lean signal. The motor is then ramped towards 50 steps or until the HEGO reads a rich signal. Engine speed may drop slightly and run a little rough during this phase. The engine speed should then drop once. Failure to maintain engine speed or switch to rich and then lean within a specified time will result in a test fault (P1159 - Fuel Stepper Motor Fault). The stepper motor fault can be due to many factors and not just the stepper motor itself.
Stepper Motor Movement Check - Manual This test will establish whether the stepper motor is being correctly driven through its reset procedure. A failure in this test could be due to a problem in the PCM, wiring or the motor itself. LPG Runout Stop engine
Disconnect LPG solenoids in the engine bay. Start engine. Engine will start and stop running shortly afterwards as the residual fuel is used up. Remove Stepper Motor Housing: Undo the two M6 cap screws that secure the stepper motor body to the converter. Leave the stepper motor connected to the housing. Stepper Motor Pintle Movement: Inspect stepper motor pintle and housing for foreign matter or water. Observe pintle through the LPG vapour outlet. Start the engine. The pintle should smoothly extend to fully open the outlet and then go to approximately half of its full travel. The engine should stop running immediately afterwards due to lack of fuel.
Symptom Charts WARNING: Before removal of any valves or fuel gauge, the LPG tank must be emptied. Refer to “Decanting of Tank”, in the Removal and Installation chapter. Service Valve Condition
Source
Action
Foreign matter between valve seat hand tap.
Remove foreign material.
Damaged shaft.
Replace hand tap assembly.
Damaged or worn seal.
Replace seal.
Defective valve.
Replace valve.
Damaged flare connection.
Mishandling.
Replace nipple.
Excess flow valve locked closed on cylinder containing LPG preventing decanting tank.
Defective automatic fill flow valve.
Turn off manual hand tap and wait for valve to unseat. Then replace valve.
Will not shut off.
Leaking valve stem. Excess flow valve not operating/responding too early.
Automatic Fill Limiter (AFL) . Condition
Source
Action
Fills slowly/will not fill.
Damaged automatic fill limiter (AFL).
Confirm with second fill at different bowser on a different day to ensure the issue isn’t related to fuel, temperature or bowser pressure. Replace automatic fill limiter (AFL)
Over/under filling.
Incorrect positioning of float.
Confirm with second fill.
Float defective.
If faulty, replace AFL.
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Single Fuel LPG
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DIAGNOSIS AND TESTING (Continued) Relief Valve Condition
Source
Leaking (Note:This is normal if tank pressure is above 2.5 MPa)
Action
Foreign matter caught between seat.
Replace relief valve.
Defective seat.
Replace relief valve.
Inadequate spring tension.
Replace relief valve.
LPG Gauge & Sender Unit Condition
Source
Inaccurate tank reading.
Remains at empty.
Leaking gas.
Action
Defective sender.
Replace sender.
Misaligned gearing.
Replace float arm.
Defective sender.
Replace sender.
Defective float arm.
Replace float arm.
Wiring fault.
Check and rectify wiring.
Defective gasket.
Replace gasket.
Dash-mounted fuel gauge Condition No indication.
Erratic reading.
Reads full at all times.
Inaccurate reading.
Source
Action
Empty fuel tank.
Refill tank.
Broken/disconnected wire.
Check wiring.
Grounded wire from sender.
Check wiring.
Sender not earthed.
Check earthing connection & PCM
Sender defective.
Replace sender.
Loose connection.
Tighten connection.
Defective sender.
Replace sender.
Short in wiring.
Check wiring.
Defective sender.
Replace sender.
Defective sender or gauge.
Replace defective part.
Receiver incompatible with sender.
Check resistance in ohms.
Functional Diagnosis Condition Probable Cause & Rectification Driveability issues such Replace Ram-Air Balance Tube if as stalling, roughness damaged. Refit if simply dislodged. of operation, flat spots, hesitations, surges, etc. Remove & clear Ram-Air Balance Tube of water, grass, etc. Refit.
Hints / Cautions A small crack or hole in the Balance Tube, often difficult to see, will cause a driveability issue.
Ensure care is taken not to damage Balance Tube during this process (see above). Replace Air Filter if dirty. Ensure Air A dirty Air Filter will cause driveability Cleaner & Springs are installed correctly. issues. Always reset KAM after it is replaced. Clear contaminant/blockage from idle jet. The idle jet plays an important role Refit. throughout the driving range – not just at idle.
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Single Fuel LPG
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DIAGNOSIS AND TESTING (Continued) Condition
Backfiring
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Probable Cause & Rectification Inspect & clean the mesh within the Filter/Lock-off at Converter. Refit.
Hints / Cautions This requires high pressure liquid LPG work and must, therefore, be conducted by a registered technician. Check for leaks in the Intake System A small vacuum leak from the intake between the Air Filter Element and the Manifold or any vacuum assisted Gas-Air Mixer, Intake Manifold or PCV component will lean out the air/fuel System. Rectify all leaks. mixture causing driveability issues. Check condition of PCV Valve. Replace if If the PCV Valve is broken, check the damaged or faulty. Valve Cover for fragments. They will be held within a baffle. If insufficient supply of LPG is making it Prior to working on components to the converter, ensure both Manual associated with high pressure liquid Isolating Valves on each LPG Tank LPG, always run the vehicle with the Service Valve are fully open and the Manual Isolating Valve closed until the condition and security of steel Bundy engine stalls to ensure no LPG remains tubes is satisfactory. Rectify any damage after the Service Valve. or leaks. If there is no fault found externally, the Service Valve and its Strainer or a blockage within the Bundy tubes could be the problem. Replace the Service Valve or clear the blockage as required. Drain contaminant from converter whilst Draining a hot converter will allow those still hot from recent LPG operation. Refit contaminants that solidify when cool to both drain plugs. be drained as well. However, precautions must be taken against burns. Check Secondary Chamber within the Gently pushing on the metal plate in the Converter retains pressure for at least 10 centre of the Secondary Diaphragm minutes after recent LPG operation. If through the hole in the Converter not, recondition or replace converter. outboard shell should result in an Note: Converter-related warranty claims audible release of pressure. The metal require a Ford Prior Approval No. to be plate should move in without issued. notchiness, indicating that the pin behind it isn’t sticking. Contamination, damage or Do not Key On with the Stepper Motor electrical/mechanical fault within Stepper removed from its mounting body. It will Motor leading to Stepper Motor seizure. reset which involves full extension and Replace Stepper Motor. subsequent loss of the Pintle. Wiring or connector damage or fault The NGS has a built in Self Test to between Stepper Motor and PCM leading check fuel control. Stepper Motor to Stepper Motor seizure, reversal of position can also be monitored - most direction or stutter. Rectify wiring or usefully with HEGO voltage. connector problem. PCM not providing correct signals to Swapping PCMs to check for Stepper Motor. Replace PCM. functionality where PATS/BETS is active cannot be done. Check Ignition System components for A slight ignition breakdown under load is function and security. significant with LPG. Rectify problem with Ignition System. A lean mixture increases the likelihood Check spark plug specification, gap and of a backfire with a poor Ignition condition. Ensure COILS are in good System, but is not the true cause of the condition. problem.
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Single Fuel LPG
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DIAGNOSIS AND TESTING (Continued) Condition Water comes out of vapour hose or converter drain plugs
Poor fuel economy
Poor starting
All
Probable Cause & Rectification Repair or replace Converter. Note: Converter - related warranty claims require a Ford Prior Approval No. to be issued. Rectify Cooling System fault or blockage. Check Coolant quality and level. Monitor HEGO Sensor and Stepper Motor position during idle, Acceleration, Cruise and Deceleration. Ensure both are operating within normal ranges.
Hints / Cautions Cooling System maintenance is extremely important in all Converter-based LPG systems. Check engine doesn’t overheat or run cool.
Engine Earth Straps and the HEGO Sensor are critical to efficient operation on LPG. Complete intake system sealing and Air Filter Element condition are also important for efficient operation on LPG. Check for deposits / contamination in the Refer above. converter. Verify Prime Valve operation on Note that the Prime Valve operates Cranking. between 300-700 ms on Cranking but there are certain situations where there will be no prime operation. Check sensitive diaphragm (under front) The diaphragm must be free to move cover for sludge or deposits without sticking to the converter or being weighed down.
NOTE: Leak test the LPG system after any
maintenance on LPG high pressure areas. Reset KAM after any maintenance of the LPG system.
Connector Circuit Reference LPG Converter C-913
Pin Number(s) 1 2 3 4 5 6
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Circuit Designation/Description Normal Condition/Measurement Circuit 16H / (R-G) 0 voltage when ignition OFF, Greater than 10 Primary Lockoff power circuit volts when engine cranking and running. Greater than 10,000 ohms between lockoff and ground. Circuit 57Y / (B) 0 voltage, less than 5 Ohms to chassis ground. Secondary Lockoff ground circuit Circuit 16X / (R-G) 0 voltage when ignition OFF, Greater than 10 Secondary Lockoff power circuit volts when engine cranking and running. Greater than 10,000 ohms between lockoff and ground. Circuit 1500 / (B) 0 voltage, less than 5 ohms between solenoid Primary Solenoid ground circuit and EEC-C Pin C21 PRIM. Circuit 57X / (B) 0 voltage, less than 5 Ohms to chassis ground Primary Lockoff ground circuit Circuit 592 / (W) S 12 volt square wave when measured across pin tepper Motor Driver circuit 591 and 592. Greater than 10,000 ohms between stepper motor and ground
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Single Fuel LPG
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DIAGNOSIS AND TESTING (Continued) Pin Number(s) 7 8
9 10
Circuit Designation/Description Normal Condition/Measurement Circuit 594 / (BR-B) 12 volt square wave when measured across pin Stepper Motor driver circuit 593 and 594. Greater than 10,000 ohms between stepper motor and ground Circuit 361D / (R) 0 voltage when ignition OFF, Greater than 10 Primary Solenoid power circuit volts when ignition ON and engine cranking and running. Greater than 10,000 ohms between solenoid and ground Circuit 591 / (BR) 12 volt square wave when measured across pin Stepper Motor driver circuit 591 and 592. Greater than 10,000 ohms between stepper motor and ground Circuit 593 / (BR-Y) 12 volt square wave when measured across pin Stepper Motor driver circuit 593 and 594. Greater than 10,000 ohms between stepper motor and ground
Stepper Motor C-910
Pin Number(s) 1 2 3 4
Circuit Designation/Description Normal Condition/Measurement Circuit 594 (BR-B) 12 volt square wave when measured across 593 and 594. Greater than 10,000 ohms between stepper motor and ground. Circuit 592 (W) 12 volt square wave when measured across 591 and 592. Greater than 10,000 ohms between stepper motor and ground Circuit 591 (BR) 12 volt square wave when measured across 591 and 592. Greater than 10,000 ohms between stepper motor and ground Circuit 593 (BR-Y) 12 volt square wave when measured across 593 and 594. Greater than 10,000 ohms between stepper motor and ground
pin pin pin pin
Primary Solenoid C-905
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Single Fuel LPG
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DIAGNOSIS AND TESTING (Continued) Pin Number(s) 1 2 3
4
Circuit Designation/Description Circuit 1500 / (B) Primary Solenoid ground circuit Not Used Circuit 361D / (R) Primary Solenoid power circuit Circuit 361D / (R) Primary Solenoid power circuit
Normal Condition/Measurement 0 voltage, less than 5 ohms between solenoid and EEC-C Pin C21 PRIM 0 voltage when ignition OFF, Greater than 10 volts when ignition ON and engine cranking and running. Greater than 10,000 ohms between solenoid and ground 0 voltage when ignition OFF, Greater than 10 volts when ignition ON and engine cranking and running. Greater than 10,000 ohms between solenoid and ground
Primary Lockoff C-907
Pin Number(s) 1 2
Circuit Designation/Description Normal Condition/Measurement Circuit 57X / (B) 0 voltage, less than 5 Ohms to chassis ground Primary Lockoff ground circuit Circuit 16H / (R-G) 0 voltage when ignition OFF, Greater than 10 Primary Lockoff power circuit volts when engine cranking and running. Greater than 10,000 ohms between lockoff and ground
Secondary Lockoff C-906
Pin Number(s) 1 2
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Circuit Designation/Description Normal Condition/Measurement Circuit 57Y / (B) 0 voltage, less than 5 Ohms to chassis ground Secondary Lockoff ground circuit Circuit 16X / (R-G) 0 voltage when ignition OFF, Greater than 10 Secondary Lockoff power circuit volts when engine cranking and running. Greater than 10,000 ohms between lockoff and ground
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Single Fuel LPG
303-04c-29
REMOVAL AND INSTALLATION
Primary Service WARNING: Where removal and installation procedures require the handling of LPG which may result in the release of LPG the following precautions must be taken. NOTE: Do not use a memory minder to retain preprogrammed data in computer controlled vehicles systems and the radio security code when the earth lead is removed. Use of memory minder may lead to air bag deployment even though the battery is disconnected.
3. Before any tank is placed into storage the liquid level must be checked to ensure that the contents is not above the maximum permitted fill level (80%). 110 litres for Ute, 92 litres for Sedan, 116 litres for Wagon. 4. The tanks must be stored in the normal attitude i.e. as if installed in the vehicle with the supply line fitting capped with pressure proof fitting. NOTE: If the tank is to be removed for repair, returned to a test station for inspection, or the tank is to be scrapped then the tank is to be emptied and depressurised and the interior purged with inert gas.
Removal and Installation Pressure Decanting 1. Disconnect and safely stow the vehicle’s earth lead. Removal and Installation 2. The working area must be registered and working 1. With the engine running, turn off the manual procedures must comply with Australian service valve and allow the vehicle to stall. One Standards AS 2746. minute after stalling, try to re-start the engine to 3. Normal precautions applicable to LPG Service ensure complete exhaustion of fuel in the fuel stations must be observed ie. No smoking and no lines. ignition sources within the working zone - ignition 2. Disconnect the vehicle battery earth lead. off and parking brake engaged. 3. With the service valve off - disconnect the supply line. Connect the service valve of the vehicle tank LPG Filter via a transfer line to the fill point of a seperate receiving cylinder. Removal 4. Open the ullage valve on the receiving cylinder 1. Disconnect supply connector from filter bowl. and the service valve on the vehicle tank. When 2. Remove bowl retaining screws and lower bowl the liquid LPG has been transferred into the and filter from filter housing. receiving cylinder, shut off ullage valve and the 3. Remove and discard both ‘O’ rings and filter. service valve. Disconnect transfer line and 4. Clean out filter bowl including magnet thoroughly. connect service valve (on the vehicle tank) to a It is recommended that ‘O’ rings and filter be burn off system, to burn off the remaining vapour replaced. They are serviced as a kit. in the vehicle tank. Installation WARNING: Before working on tank valves, 1. Install the ‘O’ rings into grooves - apply Shell R-10 remove any valve apart from the pressure release oil lightly with a brush. valve to be certain there is no residual pressure 2. Position filter with the support gauze facing up left in the vehicle tank. To remove the valve gently (direction of flow is from fine to coarse gauze). loosen all screws to relieve residual pressure. 3. Carefully locate bowl and filter and install screws Rock the valve to be sure there is no pressure. -tighten to 4-6 Nm. Then completely remove the valve.
Tank Assembly
WARNING: To ensure that there is no residual LPG in the tank when the valves are NOTE: If the tank is to be removed to enable body removed, blow out the tank using nitrogen. work or similar to be performed on the vehicle, it is not necessary for the tank to be emptied. However care WARNING: Remove pistons from solenoid must be exercised in handling and storage of the non coils on service valves. Open the hand taps to emptied tank assembly. The following precautions remove some of the residual pressure left in the must be observed: tanks. Removal and Installation CAUTION: Remove pistons from solenoid 1. Store the tanks in a well ventilated area away coils on service valves. Open the hand taps to from sources of ignition and drains or pits. 2. If two unemptied tanks are to be stored, as is the remove some of the residual pressure left in the tanks. case of the ute, the conditions of AS1596 apply. Before working on tank valves, remove any valve apart from the pressure release valve to be certain G86726 en
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Single Fuel LPG
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REMOVAL AND INSTALLATION (Continued) there is no residual pressure left in the vehicle tank. To remove the valve gently loosen all screws to relieve residual pressure. Rock the valve to be sure there is no pressure. Then completely remove the valve. To ensure that there is no residual LPG in the tank when the valves are removed, blow out the tank using nitrogen. NOTE: The receiving cylinder requires an ullage valve.
Tank Decanting
WARNING: LPG is heavier than air and any depression, for example, a vehicle service pit, can be a potential reservoir for the LPG to collect. Removal and Installation 1. Work must be carried out in a well ventilated area, away from any ignition source with the vehicle battery earth disconnected. (In accordance with Australian Standards) NOTE: You can tell that liquid has finished 2. There are three decanting methods as follows: transferring to the cylinder either by the contents gauge in vehicle tank or by feeling the transfer hose. 1. Transfer pump - use in accordance with pump instructions. (Refer note 2 below). NOTE: The dip tube in the vehicle tank will not allow 2. Pressure decanting, refer to instruction below. all liquid to transfer. There may be 2-3 litres remaining in the bottom of the vehicle tank. Hence, the need to 3. Burn off method, refer to instructions below. burn off the remainder.
Tank — Ute
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REMOVAL AND INSTALLATION (Continued) Item 1 2
Description Cyl Assy Fuel Tank Screw M12x30
8. Replace filler neck and tighten 3 retaining bolts to 10 Nm as specified. NOTE: If the tank had been emptied or a new tank was installed, fill the tank with LPG and check the performance of the AFL - i.e. Cuts off at 80% of tank capacity (116 litres).
Removal 1. Start the engine. 9. Conduct a leak test on all connections. 2. Turn the service valve "OFF". 3. Allow the engine to run until it stalls to use up any 10. Open the service valve and conduct a leak test on all down stream connections and components. LPG in the system. 11. Reconnect the battery earth lead. 4. Turn the ignition off. 5. Disconnect the vehicle’s battery earth lead. 6. Raise vehicle on a hoist so it can be worked under. 7. Remove 3 bolts retaining filler assembly - slide upwards to release tabs. 8. Disconnect sender wiring located above right hand tank. Remove wiring from centre upper body mount. 9. Drop driveshaft. 10. Remove exhaust intermediate. 11. Disconnect fuel lines on left hand side under chassis rail. 12. Disconnect left hand side ABS wiring connection and remove clip from chassis rail. 13. Remove 5 x 12mm bolts retaining tank. 14. Carefully lower tanks to the ground using an appropriate lifting stand. NOTE: It is not necessary to remove the stone shield so long as it is protected from scratching. 15. With a helper supporting the cylinder on the frame proceed to slowly lower the cylinder ensuring the wiring loom and LPG hoses do not get caught at the front. 16. Once the cylinder is lower than the vehicle, move it from beneath the vehicle. NOTE: Empty tank mass is 60kg (approx.) so be very careful handling it and move it to a firm base as soon as possible. Installation 1. Raise vehicle on a hoist so it can be worked under. 2. Raise the tanks using an appropriate lifting stand, aligning the 5 bolt mounting holes with the corresponding bolt holes in the chassis. 3. Replace the 5 x 12mm bolts (2 on the chassis rail, 2 on the cross car tube) and tighten to 80 Nm as specified. 4. Replace all wiring connectors. 5. Replace exhaust intermediate. 6. Connect and tighten fuel lines. 7. Replace drive shaft.
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Single Fuel LPG
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REMOVAL AND INSTALLATION (Continued)
Tank — Wagon
Item 1 2 3
Description Cyl Assy Fuel Tank Nut and Washer Asy M12 Screw M10x27
Removal 1. Start the engine. 2. Turn the service valve "OFF". 3. Allow the engine to run until it stalls to use up any LPG in the system. 4. Turn the ignition off. 5. Disconnect the vehicle’s battery earth lead. 6. Raise vehicle on a hoist so it can be worked under. 7. Remove bolt retaining filler assembly. 8. Disconnect sender wiring located above front tank. 9. Remove wiring from centre upper body mount. 10. Remove exhaust rear. 11. Disconnect fuel lines on left hand side under chassis rail.
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12. Remove bolts, nuts and washer assemblies retaining tank. LPG wagons have two bolts that are accessed through holes in the rear floor. 13. Carefully lower tanks to the ground using an appropriate lifting stand. NOTE: It is not necessary to remove the stone shield so long as it is protected from scratching. 14. With a helper supporting the cylinder on the frame proceed to slowly lower the cylinder ensuring the wiring loom and LPG hoses do not get caught at the front. 15. Once the cylinder is lower than the vehicle, move it from beneath the vehicle. NOTE: Empty tank mass is 45kg (approx.) so be very careful handling it and move it to a firm base as soon as possible. Installation 1. Raise vehicle on a hoist so it can be worked under. 2. Raise the tanks using an appropriate lifting stand, aligning the 3 bolt mounting holes with the corresponding studs in the chassis. 3. Replace the nuts and tighten to 80 Nm as specified. Replace the M10x27 screws and tighten to 55Nm. 01/2003 2003.0 BA Falcon
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Single Fuel LPG
303-04c-33
REMOVAL AND INSTALLATION (Continued) 4. 5. 6. 7.
Replace all wiring connectors. Replace exhaust rear. Connect and tighten fuel lines. Replace filler neck and tighten retaining bolt to 10 Nm as specified. NOTE: If the tank had been emptied or a new tank was installed, fill the tank with LPG and check the performance of the AFL - i.e. Cuts off at 80% of tank capacity or 116 litres for Wagon.
8. Conduct a leak test on all connections. 9. Open the service valve and conduct a leak test on all down stream connections and components. 10. Reconnect the battery earth lead.
Tank — Sedan
5. Disconnect the vehicle’s battery earth lead. 6. Raise vehicle on a hoist so it can be worked under. 7. Remove bolt retaining filler assembly. Removal 8. Disconnect sender wiring located above front 1. Start the engine. tank. 2. Turn the service valve "OFF". 9. Remove wiring from centre upper body mount. 3. Allow the engine to run until it stalls to use up any 10. Remove exhaust rear. LPG in the system. 11. Disconnect fuel lines on left hand side under 4. Turn the ignition off. chassis rail. Item 1 2
Description Cyl Assy Fuel Tank Nut and Washer Asy M12
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Single Fuel LPG
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REMOVAL AND INSTALLATION (Continued) 12. Remove 4 nuts and washer assemblies retaining tank. 13. Carefully lower tanks to the ground using an appropriate lifting stand. NOTE: It is not necessary to remove the stone shield so long as it is protected from scratching.
10. Remove the gauge and float retaining screws and lift out the gauge and float assembly. Installation 1. Install a new gasket under the fuel gauge and carefully insert the float into the tank and locate the gauge on the tank. 14. With a helper supporting the cylinder on the frame 2. Install the gauge retaining screws and torque to 5 Nm. proceed to slowly lower the cylinder ensuring the wiring loom and LPG hoses do not get caught at 3. High pressure test the cylinder assemble to 2.3 the front. MPa in accordance with clause 4.2.2 of standard AS/NZS 1425- 1999. 15. Once the cylinder is lower than the vehicle, move it from beneath the vehicle. 4. Refill the tank and check the performance of the NOTE: Empty tank mass is 45kg (approx.) so be AFL, and gauge for correct registration. very careful handling it and move it to a firm base 5. Connect the gauge sender wires. as soon as possible. 6. Refit tank to vehicle as per procedure. Installation 7. Turn the service valve on. 1. Raise vehicle on a hoist so it can be worked 8. Close and clamp the sealed sub compartment under. cover. 2. Raise the tanks using an appropriate lifting stand, 9. Reconnect the battery earth lead. aligning the 4 bolt mounting holes with the corresponding studs in the chassis. Automatic Fill Limiter 3. Replace the nuts and tighten to 80 Nm as Removal specified. 1. Start engine. 4. Replace all wiring connectors. 2. Turn service valves off. 5. Replace exhaust rear. 3. Run the engine until it stalls. 6. Connect and tighten fuel lines. 7. Replace filler neck and tighten retaining bolt to 10 4. Turn ignition OFF and remove battery earth lead. 5. Remove tank from vehicle as per procedure. Nm as specified. NOTE: If the tank had been emptied or a new 6. Remove the LPG in the tank in accordance with tank was installed, fill the tank with LPG and the decanting procedure. check the performance of the AFL - i.e. Cuts off at 7. Slightly loosen all AFL retaining screws to relieve 80% of tank capacity or 93 litres for Sedan. any residual pressure. 8. Conduct a leak test on all connections. 8. Disconnect the filler hose from the AFL elbow. 9. Open the service valve and conduct a leak test on 9. Remove the elbow from the AFL. all down stream connections and components. 10. Remove the AFL from the tank by removing the 10. Reconnect the battery earth lead. AFL retaining screws. Installation Fuel Gauge and Float Assembly 1. Install a new gasket under the AFL and carefully insert the float into the tank and locate the AFL on Removal the tank. 1. Start the engine. 2. Install the AFL retaining screws and torque to 5 2. Turn the service valve off. Nm. 3. Run the engine until it stalls. 3. Apply Permabond A129 sealer, Locktite 577, or 4. Turn off the ignition and remove the battery earth equivalent to the adapter elbow and install into lead. the AFL. 5. Remove tank from vehicle as per procedure. 4. High pressure leak test the cylinder assembly to 6. Remove the LPG in the tank in accordance with 2.3 MPa in accordance with clause 4.2.2 of the decanting procedure. standard AS 1425-1999. 7. Disconnect the gauge sender wires. 5. Connect the filler hose to the AFL adapter elbow. 8. Slightly loosen all gauge and float retaining 6. Refit tank to vehicle as per procedure. screws to relieve any residual pressure in the 7. Refill the tank and check the performance of the tank. AFL against gauge registration. 9. Rock the gauge and float to ensure that no 8. Check for leaks. residual pressure remains. G86744 en
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REMOVAL AND INSTALLATION (Continued) 9. Turn service valve on. 10. Reconnect the battery earth lead.
Service Valve (With Relief Valve on Ute and Wagon)
2. Remove 3 bolts Ute + Wagon, (1 bolt Sedan) fastening fuel filler bracket. 3. Remove valve assembly from body. Installation 1. Installation is the reverse of the removal process, tightening 3 fastening bolts(for Ute + Wagon), 1 bolt for Sedan to 10Nm as specified. NOTE: Ensure that pipe is sealing on the Filler Valve assembly and after installation ensure that LPG filler gun can be applied.
Removal 1. Start the engine. 2. Turn the service valve off. 3. Run the engine until it stalls. 4. Turn the ignition off and remove the battery earth lead. 5. Remove all LPG from the cylinder in accordance with the decanting procedure. 6. Slightly loosen the four retaining screws which secure the service valve to the cylinder. This will relieve any residual pressure in the cylinder. 7. Rock the service valve to ensure that no residual pressure remains. 8. Disconnect the supply hose from the service valve. 9. Remove the solenoid coil from the service valve by removing the M5 bolt and sliding the coil off the service valve. 10. Remove the service valve retaining screws and lift Tray out the service valve and pick-up tube assembly. Note that the pick-up tube has a fuel screen on its lower end. Be careful not to damage this when removing the pick-up tube assembly from the cylinder. Installation 1. Install a new gasket under the service valve and carefully insert the pick-up tube and fuel screen assembly into the cylinder. Locate the service valve on the cylinder. 2. Install the four service valve retaining screws and progressively torque in a cross diagonal pattern to 5 Nm. 3. Reconnect the supply hose to the service valve. 4. Refit the solenoid coil onto the service valve. Cab Chassis 5. High pressure leak test the cylinder assembly to 2.3 MPa as per clause 4.2.2 of standard AS/NZS 1999. 6. Refill the cylinder and check the AFL performance against the dispensing pump. 7. Turn the service valve on. 8. Reconnect battery earth lead.
Fuel Filler Valve Removal 1. Disconnect pipe assembly connector at filler valve. Plug pipe assembly to prevent entry of any foreign matter.
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Single Fuel LPG
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REMOVAL AND INSTALLATION (Continued) Sedan
NOTE: SEDAN & WAGON — There is a connector to hose on the tank assembly. NOTE: The bundy tubing is attached to the floor pan by pop rivets through insulated brackets and is unlikely to ever require replacement. There is a joint, near the base of the A pillar,which has a hydrostatic valve attached ute only. From here, the bundy tubing continues up and across the cowl directly to the connector adaptor in the lower section of the filter lock off in the engine compartment. Fuel Delivery System - Ute
Pressure Relief Valve This is part of the service valve on Ute and Wagon – see service. On the Sedan it is seperate and is on the upper valve pad.
Fuel Filler Hose Removal 1. Disconnect the filler hose connector at AFL. 2. Disconnect the filler hose from the fuel fill valve. Installation 1. Attach filler hose connector to fuel valve. 2. Check that filler hose is not squeezed between the tank and body rail. 3. Connect filler hose to AFL and torque to 28-33 Nm.
Item 1 2
Description Screw Shield
Fuel Delivery System - Ute
LPG Fuel Delivery System Hose WARNING: Before commencing work on the LPG Fuel Delivery System ensure that all gas in the lines is used up. Start engine. Turn off the service valve and run the engine until it stalls. Endeavour to re-start the engine several times. Disconnect the battery negative cable connection. NOTE: UTE — The delivery of LPG from the tank to the Filter/Lock Off is via a preformed bundy tube which is connected to each tank and joined with a ’T’ piece.
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Item 1 2 3
Description Bundy tube Hydrostatic valve Service line connectors
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Single Fuel LPG
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REMOVAL AND INSTALLATION (Continued) SFLPG Fuel Filler - Wagon
Item 1 2 3 4
Description Tank Assy Fuel Fill Reinf RR Floor Pan Side Screw & Washer Screw & Washer
SFLPG Fuel Filler - Wagon
SFLPG Fuel Lines - Sedan
Item 1 2 3
Description Screw Tube Fuel Supply Rivet
Removal Service Valve to Rear Bundy Connection 1. Disconnect the flexible hose at the service valve. 2. From under the vehicle disconnect the flexible hose at the bundy connection. 3. Carefully pull the flexible hose through. Installation 1. Install protective caps to both ends of the flexible hose to prevent entry of foreign matter. 2. Carefully feed the flexible hose and connect to service valve - tighten 28-33 Nm. 3. Connect the other end to the bundy tub connector and tighten to 28-33 Nm. NOTE: Ensure that the flexible hose is not twisted during the tightening process.
Item 1 2
Description Tube Fuel Supply Rivet
Bundy Tube Connection Removal Filter Lock Off to Front Bundy Connection 1. Using two spanners, support the connector adapter attached to the filter lock off lower section.
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Single Fuel LPG
303-04c-38
REMOVAL AND INSTALLATION (Continued) 2. Unscrew the service line connector at converter.
Installation 1. Reverse the above procedure ensuring that the bundy tubing is not twisted during the tightening process. NOTE: When the connections at either the service line to the filter lock off or flexible hose to bundy tube have been completed, conduct an LPG leak test at the connections.
Converter Including Filter Lockoff & Solenoid
Item 1 2 3 4
Description Connector Adapter Service Line Connector Bundy Tube Filter/Lockoff
Item 1 2 3 4 5
Description Stepper Motor Prime Solenoid Prime Hose Mount Bracket Coolant Outlet
G86735 en
WARNING: LPG under pressure is supplied to the converter at the filter/lock off and before removal of the converter or filter lock off is attempted the engine should be run with the service valve turned off until it stalls. A restart should be attempted to ensure that all LPG has been used up. The battery earth lead should be disconnected and safely stowed. Removal and Installation
Item 6 7 8 9 10 11
Description Coolant Inlet Inlet Gas Lock Off Solenoid Liquid Gas Inlet Filter & Magnet Drain Plugs Idle Solenoid 01/2003 2003.0 BA Falcon
303-04c-39
Single Fuel LPG
303-04c-39
REMOVAL AND INSTALLATION (Continued) Item 12 13
Description Balance Hose Fitting Vapour Line Fitting
1. The converter and filter lock off assemblies are bolted to mounting brackets which are in turn bolted to the R.H. front spring tower.
6. Disconnect converter wiring loom. 7. Disconnect solenoid and stepper motor electrical connectors. 8. Remove screws retaining converter assembly mounting bracket to R.H. front spring tower and lift converter from engine bay complete with mounting bracket.
Filter Removal 1. Disconnect supply connector from filter bowl. 2. Remove bowl retaining screws and lower bowl and filter from filter housing. Installation 1. Install new ’O’ rings into housing and bowl grooves. 2. Apply Shell R10 oil to ’O’ rings with a brush. 3. Position filter into bowl with the support gauze facing up (direction of flow is from fine to coarse gauze). 4. Carefully locate bowl and filter and install screws -tighten. 5. Reconnect supply connector - Tighten.
Item 1 2
Description Converter & Bracket Assy Bolt
Item 1 2 3
Description Nut Flanged Mounting Bracket Retainer Clip (Fir Tree)
Main/Idle/Prime Lockoff Solenoids Removal 1. Disconnect electrical connector. 2. Test resistance of induction coil (12.6 Ohms at 20°C. 12.2 Ohms at 12°C. 13.4 Ohms at 36°C ± 4%) replace if necessary. 3. Loosen coil bracket end screw. 4. Unscrew Lockoff solenoid from converter body. Installation NOTE: Lockoff solenoid and lockoff spindle are serviced as an assembly. 1. Locate solenoid and lockoff spindle in position in converter body. 2. Tighten. (Refer to Disassembly and Assembly Section.) 3. Index coil to enable easy connection of electrical connector. 4. Tighten coil bracket end screw to 5 Nm.
Installation 1. Reverse removal instructions. Converter Assembly 2. Refill cooling system of vehicle using drained coolant if coolant is in good condition. Removal 3. Turn on LPG service valve. 1. Turn off service valve (run engine to purge system of LPG). 4. Check for any LPG leaks at service line connection to filter/lock off and connections to 2. Drain vehicle cooling system into a clean converter. container for re-use. 5. After start up reset KAM. 3. Disconnect LPG supply line. 4. Disconnect air balance tube from the converter. 5. Disconnect vapour hose from stepper motor. G86739 en
01/2003 2003.0 BA Falcon
303-04c-40
Single Fuel LPG
303-04c-40
REMOVAL AND INSTALLATION (Continued)
Throttle Body NOTE: LPG vehicles have a Gas/Air mixer built into the throttle body. Removal 1. Disconnect LPG vapour hose. 2. Remove as per petrol throttle body. Installation 1. Reverse removal instructions.
G86739 en
01/2003 2003.0 BA Falcon
303-04c-41
Single Fuel LPG
303-04c-41
DISASSEMBLY AND ASSEMBLY
Converter with integral Filter/Lock Off &Prime Solenoid Disassembly and Assembly NOTE: Ensure that all LPG in the supply system has been used. (Refer instructions for Filter/Lock Off.) 1. After removal of the Converter from the mounting bracket, (Refer Removal and Installation). Dismantle, inspect, adjust and reassemble in accordance with the procedure on the following pages.
Converter NOTE: Before commencing to disassemble the converter ensure that a converter overhaul kit for Vialle Model F5 special converter is available. Follow steps as listed to disassemble and reassemble converter. Reference number identifies the part on the exploded view. Do not remove or adjust second stage nozzle during overhaul. Do not drive a tool in between the sections to separate. NOTE: Tool No. 303-689 is necessary to remove the idle jet from the converter.
G86742 en
01/2003 2003.0 BA Falcon
303-04c-42
Single Fuel LPG
303-04c-42
DISASSEMBLY AND ASSEMBLY (Continued)
G86742 en
01/2003 2003.0 BA Falcon
303-04c-43
Single Fuel LPG
303-04c-43
DISASSEMBLY AND ASSEMBLY (Continued) Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47
Description Nut x 8 Front cover Cardboard gasket (thick) Sensitive diaphragm Bolt Sensitive diaphragm support plate Support plate seal Idle Jet Venturi Brass seat Idle Jet O-Ring Idle Jet Spring Solenoid O-Ring Idle Seat and O-Ring Solenoid Plunger Stepper Motor Bolt x 2 Solenoid Stem Solenoid Assembly Balance plug Aluminium Washer Slotted Prime Solenoid (where fitted) Idle transfer tube O-Ring Idle transfer tube Bolt x 2 Primary Valve Shaft Plastic Washer (where fitted) Brass Union Brass Tee Bracket Nut Bolt Secondary stage valve shield Bolt x 2 First stage body section Plastic Washer Secondary stage valve shaft Secondary valve E-Clip Secondary Pin Guide Bush Secondary Slice Label Secondary Diaphragm Cardboard gasket (Thin) Rear Cover Main Bolt x 8 Secondary stage pin Bolt x 2 Coolant Chamber gasket
G86742 en
Item 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 68 69 70 71 72 73 74 75 76 77 78
Description Secondary Lever Shield Second stage lever Second stage valve Spring cap Spring support cap Spring second stage Coolant Gasket Support plate plastic Brass Washer Primary seat Primary Valve lever Primary Valve Plastic Washer O-Ring x 2 Clevis Primary Diaphragm support plate Filter Filter Bowl Bolt x 4 Support Plate Bolt Primary Stage diaphrgm Primary Valve Retaining Clip Primary Spring Support plate Belville spring washer x 2 Nut Primary stage spring Bolt x2 Idle slice Copper Washer Drain Plug x 2
Disassembly 1. Prime hose from stepper motor to prime valve. 2. Stepper motor retaining bolts and stepper motor. 3. Prime valve retaining bracket. 4. Solenoid coil and plunger from prime valve discard ’O’ ring and plunger. 5. Idle and main solenoid coils. 6. Idle and main lock off and idle seat assembly. NOTE: Beware idle seat spring pressure. NOTE: Discard idle and main lock off plunger and 0-rings and the idle seat assembly. 7. Spring and idle jet. Use tool 303-689. NOTE: Screw tool onto idle jet and pull unit out. 8. Use a wire (paper clip) with small hook on the end to remove jet O-Ring. Discard O-Ring. 9. All nuts and studs. NOTE: Remove all nuts from studs. Take notice of position of longer mounting studs in converter. 01/2003 2003.0 BA Falcon
303-04c-44
Single Fuel LPG
303-04c-44
DISASSEMBLY AND ASSEMBLY (Continued) 10. Back cover, back cover gasket and second stage diaphragm. Discard diaphragm and gasket. NOTE: Re-Assembly will be easier if the converter studs remain on the main bracket and the converter body (minus the rear cover) is gently pulled from the studs. 11. Second stage pin. Discard pin. 12. Front cover, front cover gasket and sensitive diaphragm. Discard gasket and sensitive diaphragm. 13. Sensitive diaphragm support plate and gasket. Discard gasket. 14. Two idle body section bolts. NOTE: Beware of primary spring pressure. 15. Separate idle body section from first stage body section. 16. First stage diaphragm assembly primary lever assembly at the same time by lifting diaphragm and removing screws. Separate assembly and discard first stage diaphragm, washers and first stage lever assembly. Remove and discard O-Ring and idle transfer tube. 17. First stage cover and screw. NOTE: Do not remove the first stage nozzle from the housing. 18. Second stage body section bolts. 19. Separate second stage body section from first stage body section. Retain water chamber gasket support. Discard water chamber gasket. 20. Cap, spring button and second stage spring. 21. Second stage lever assembly and screws. Discard second stage lever seat. 22. Bolt and water pipe bracket (not shown on exploded view). 23. Inlet and outlet coolant connectors (not shown on explored view). Discard coolant connecters O-Rings. NOTE: Clean coolant connector openings in first stage body section with 22mm or 7/8" round wire brush. Clean coolant connectors and especially the grooves for the O-Rings.
1. Second stage lever pin. Lubricate pin with molybdenum grease only . 2. Reinstall second stage shield. 3. Second stage lever spring, button and cap. Ensure spring is correctly is seated. 4. Coolant chamber gasket. Install second stage pin guide bush to second stage body section. 5. Coolant chamber gasket support and second stage body section onto first stage body section. Use eight studs to hold diaphragm in place while assembling. NOTE: Position longer mounting studs in original location, ensure gasket is not binding. 6. Second stage body section bolts. 7. Second stage lever pin. Lubricate pin with molybdenum grease only . 8. Second stage diaphragm gasket cover and gasket paper. NOTE: Install large disc of second stage diaphragm towards body section. 9. Idle jet, O-Ring, and seat in body section use tool 303-689. NOTE: Use same type of idle jet as removed. Bevelled edge of seat should be towards ejector. Push in until firmly seated. NOTE: 0.8mm idle jet has a machined groove in it. 10. Spring idle seat with O-Ring and idle lock off assembly. 11. First stage lever assembly and screws. 12. O-Ring and idle transfer tube. Take care when assembling body’s that transfer tube does not dislodge. 13. First stage cover with screw. 14. First stage diaphragm assembly and spring. Install spring with small end towards diaphragm. NOTE: Slide retainer over end of first stage lever. LUBRICATE RETAINER WITH MOLYBDENUM GREASE ONLY.
15. Idle body section to first stage body section and two idle body section bolts. 24. Remove and discard filter and O-Rings. 16. Sensitive diaphragm support plate gasket into 25. Remove and discard second stage pin guide sensitive diaphragm support plate. bush. 17. Sensitive diaphragm support plate and screw. NOTE: Use a punch that is smaller than the guide 18. Sensitive diaphragm, gasket, front cover, and bush. nuts. NOTE: Clean all parts with solvent or mineral NOTE: Prime valve retaining bracket. spirits. Do not use carburator cleaner or lacquer thinner. 19. Main solenoid. 20. 0-rings on coolant fittings (not shown). Assembly 21. Lower and upper coolant fitting into first stage NOTE: It is advised to use oil (Shell R-10) or acid free body section. The coolant in connector has two vaseline on all O-Rings prior to assembly. alignment K.
G86742 en
01/2003 2003.0 BA Falcon
303-04c-45
Single Fuel LPG
303-04c-45
DISASSEMBLY AND ASSEMBLY (Continued) 22. Bracket and screw to retain water pipes in place (not shown). 1. Prime hose from stepper motor to prime valve. 2. Stepper motor retaining bolts and stepper motor with new O-Ring. 3. Solenoid coil and plunger from prime valve with new O-Ring and plunger. 4. Prime valve retaining bracket.
Idle Jet Disassembly 1. Remove idle solenoid (8mm headed bolt). 2. Remove idle solenoid stem (17mm). Take care that the idle seat does not eject due to spring pressure. 3. Remove idle seat carefully as seat can be easily damaged. 4. Remove idle jet using removing tool (No. 303-689). 5. Clean idle jet with high pressure air in both directions. Usual precautions should be taken when using high pressure air. NOTE: Never blow the idle jet while it is still installed in the converter. Assembly 1. Reassemble in the reverse order.
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01/2003 2003.0 BA Falcon
303-05-1
Accessory Drive
303-05-1
SECTION : 303-05 Accessory Drive VEHICLE APPLICATION : 2003.0 BA Falcon CONTENTS
PAGE
SPECIFICATIONS Specifications ........................................................................................................................303-05-2 DESCRIPTION AND OPERATION Accessory Drive ....................................................................................................................303-05-3 Belt Tensioner - I6 & V8 .........................................................................................................303-05-3 Water Pump ..........................................................................................................................303-05-4 DIAGNOSIS AND TESTING Accessory Drive ....................................................................................................................303-05-5 Inspection and Verification ...................................................................................................303-05-5 Symptom Chart ....................................................................................................................303-05-5 Belt Tensioner ......................................................................................................................303-05-5 REMOVAL AND INSTALLATION Accessory Drive Belt .............................................................................................................303-05-6 Accessory Drive Belt Tensioner ............................................................................................303-05-6 Accessory Drive Belt Idler Pulley ..........................................................................................303-05-6
01/2003 2003.0 BA Falcon
303-05-2
Accessory Drive
303-05-2
SPECIFICATIONS General Specifications Description Sealer
Specification ESZ - M4G281 - A
Torque Specifications Description Accessory drive belt tensioner bolt 4.0L I6 Accessory drive belt idler pulley bolt - 4.0L I6 Water pump bolts - 4.0L I6
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Nm 25 25 20
01/2003 2003.0 BA Falcon
303-05-3
Accessory Drive
303-05-3
DESCRIPTION AND OPERATION
Accessory Drive
8 Cylinder
6 cylinder with air conditioning
Item 1 2 3 4 5 6 7
Description Power steering pump pulley Belt idler pulley Belt tensioner A/C compressor pulley Crankshaft damper Alternator pulley Water pump pulley
Item 1 2 3 4 5 6 7
Description Alternator pulley Pulley Power steering pump pulley Crankshaft damper A/C Compressor pulley Belt tensioner Belt idler pulley
Belt Tensioner - I6 & V8
6 cylinder without air conditioning
Item 1 2 3 4 5 6 7
Description Power steering pump pulley Belt idler pulley Belt tensioner A/C idler pulley Crankshaft Alternator pulley Water pump pulley
G97112 en
Item 1 2
Description Worn belt mark 3/8" Square drive. Use to rotate Auto Tensioner Body 3 New belt mark 4 Belt wear reference mark Automatic belt tensioners are spring loaded devices which set and maintain the drive belt tension. The drive belt does not require tension adjustment for the life of the belt. Automatic tensioners have belt wear indicator marks. If the indicator mark is not between the indicator lines, the belt is worn or an incorrect belt has been installed. Replace belt as outlined.
01/2003 2003.0 BA Falcon
303-05-4
Accessory Drive
303-05-4
DESCRIPTION AND OPERATION (Continued)
Water Pump A centrifugal-type water pump is mounted on the front of the cylinder block. A vane-type impeller supplies coolant through centrifugal action to the water pump outlet port. If the pump is found to be faulty remove and discard as it is of a sealed unit type which cannot be repaired. Refer to Engine Cooling in Section 303-03.
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01/2003 2003.0 BA Falcon
303-05-5
Accessory Drive
303-05-5
DIAGNOSIS AND TESTING
Accessory Drive Inspection and Verification 1. Verify the customer’s concern by operating the engine to duplicate the condition. 2. Inspect to determine if any of the following mechanical concerns apply: Visual Inspection Chart Mechanical Drive belt cracking/chunking Drive belt contamination Drive belt length incorrect Drive belt noise or squeal Pulley misalignment or excessive pulley run-out
3. Install a new drive belt if any of the following conditions exist: rib chunk-out, sever glazing, frayed cords, belt back delamination or other concerns. NOTE: Minor cracks in the V-grooved portion of the drive belt are considered normal and acceptable. If the drive belt has chunks missing from the ribs, a new drive belt should be installed. 4. If the concern is not visually evident, verify the symptom and refer to the Symptom Chart.
Symptom Chart Condition
Source
Action
Drive belt cracking
Drive belt
System OK
Drive belt chunking
Drive belt
INSTALL a new drive belt. REFER to ’Accessory Drive Belt’ in this section
Drive belt noise or squeal
Pulleys
DETERMINE where the noise is coming from. CHECK pulley alignment, freedom of rotation or damage. REPAIR or INSTALL as necessary.
Lubrication or other contamination
CHECK belt for contamination. If belt is damaged, INSTALL a new belt.
Drive belt
CHECK correct belt is fitted
Drive belt cracked or damaged
INSPECT belt for parallel cracking through to backing. INSTALL new drive belt as necessary.
Tensioner worn or damaged
CHECK belt tensioner for damage and correct operation. INSTALL a new belt tensioner if required.
Drive belt does not hold tension
Belt Tensioner NOTE: The only mechanical check that needs to be made is a check for tensioner stick, grab or bind. 1. Remove the belt in the area of the tensioner. 2. Rotate the tensioner from its relaxed position through its full stroke and back to the relaxed position to make sure there is no stick, grab or bind and to make sure there is tension on the belt tensioner spring. 3. If the tensioner does not meet the above criteria, install a new tensioner. See ’Accessory Drive Belt Tensioner’ in this section.
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01/2003 2003.0 BA Falcon
303-05-6
Accessory Drive
303-05-6
REMOVAL AND INSTALLATION
Accessory Drive Belt Removal and Installation 1. Rotate the tensioner arm clockwise using a 3/8" square drive and remove the drive belt. 2. To install, reverse the removal procedure.
Accessory Drive Belt Tensioner Removal and Installation 1. Remove the accessory drive belt. Refer above. 2. Remove tensioner bolt and the drive belt tensioner.
3. To install, reverse the removal procedure, ensuring the pin locates correctly.
Accessory Drive Belt Idler Pulley Removal and Installation 1. Remove the accessory drive belt. Refer above. 2. Remove idler bolt and the idler pulley assembly. 3. To install, reverse the removal procedure.
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01/2003 2003.0 BA Falcon
303-06-1
Starting System
303-06-1
SECTION : 303-06 Starting System VEHICLE APPLICATION : 2003.0 BA Falcon CONTENTS
PAGE
SPECIFICATIONS Specifications ........................................................................................................................303-06-2 DESCRIPTION AND OPERATION Starting System — 6 Cylinder (Bosch) .................................................................................303-06-3 General Service ....................................................................................................................303-06-3 Description ...........................................................................................................................303-06-3 Operation .............................................................................................................................303-06-3 Roadside Service ..................................................................................................................303-06-3 Jump Starting .......................................................................................................................303-06-3 Connecting and Starting Procedure .....................................................................................303-06-4 Engine Starting .....................................................................................................................303-06-4 DIAGNOSIS AND TESTING Starting System .....................................................................................................................303-06-5 Symptom Chart ...................................................................................................................303-06-5 Pinpoint Tests ......................................................................................................................303-06-5 Component Tests .................................................................................................................303-06-9 GENERAL PROCEDURES Starting System ...................................................................................................................303-06-12 REMOVAL AND INSTALLATION Starter Motor .......................................................................................................................303-06-14 DISASSEMBLY AND ASSEMBLY Starter Motor .......................................................................................................................303-06-15 Starter Drive Assembly .......................................................................................................303-06-16 Solenoid Switch ..................................................................................................................303-06-16 Drive End Housing ..............................................................................................................303-06-16 Armature .............................................................................................................................303-06-16
01/2003 2003.0 BA Falcon
303-06-2
Starting System
303-06-2
SPECIFICATIONS General Specifications Description Solenoid Burn off reserve Solenoid Pre-stressed tension of reset spring for moving contact Solenoid Pre-stressed tension of contact pressure spring Solenoid Pre-stressed tension of plunger spring with 9mm plunger clearance Solenoid Total spring force Commutator Runout Commutator minimum size Commutator laminations runout Starter current draw Load No Load Torque Specifications Description Starter Retaining bolts
G86721 en
Specification 0.8 - 1.4mm 12 ± 3N 19N 45 ± 7N 113N 0.1mm 31.2mm 0.5mm =<300A =<8-A Nm 21 - 27
01/2003 2003.0 BA Falcon
303-06-3
Starting System
303-06-3
DESCRIPTION AND OPERATION
Starting System — 6 Cylinder (Bosch) The starting system includes the permanent magnet gear-reduction starter with a solenoid-actuated drive, the battery, a remote control starter switch (part of the ignition switch), the neutral start switch (automatic transmission), the starter relay, the heavy circuit wiring, the body electronics module (BEM) and the power train control module (PCM). Turning the ignition switch to the START position actuates the starter relay, through the starter control circuit. The starter relay then connects the battery to the starter solenoid, causing it to energize. When the starter solenoid is energized, a magnetic field is created in the solenoid windings. The iron plunger core is drawn into the solenoid coil and a lever connected to the drive assembly engages the drive pinion gear into the flywheel ring gear. When the plunger is pulled all the way in, its contact disk closes the circuit between the battery and motor feed terminals. This sends current to the motor and the drive pinion gear cranks the flywheel to start the engine. When current flows to the motor, the solenoid pull-in coil is bypassed and the hold-in coil keeps the drive pinion gear engaged with the flywheel until the ignition switch is released from the START position. An overrunning clutch in the drive assembly protects the starter from excessive speeds during the brief period before the driver releases the ignition switch from the START position (as the engine starts).
General Service Description The function of the starting system is to crank the engine at a high enough speed to permit it to start. The system contains the following components: starter motor and solenoid
Item 1 2 3
Description Terminal 30 Terminal 50 Magnets
battery inhibitor switch (auto trans) electrical circuitry incorporating the ignition switch, BEM and EEC V (’smartshield’), starter diode and resistor. (Refer schematics section of this manual).
Operation Turning the ignition to the IGN or ACC position activates the BEMs ’smartshield’ system (Refer to Section 419-10.) and disarms the engine immobilisation. If the inhibitor switch is closed, the circuit is completed and current flows through the starter relay. This, in turn, completes the circuit from the battery to the starter solenoid. This connects the battery to the starter motor. The starter utilizes an integral positive engagement drive. The electrical circuit also incorporates a starter diode and starter resistor connected to ground. This completes the starter solenoid circuit through ground after the solenoid is switched off to prevent any voltage surges at the solenoid caused by back EMF.
Roadside Service Jump Starting To avoid damage to the vehicle and battery or the possibility of personal injury, follow these instructions and precautions: CAUTION: Hydrogen and oxygen gases are produced during normal battery operation. The gas mixture can explode if flames, sparks, or cigarettes are brought near the battery in an enclosed space, always provide ventilation and shield your eyes. Keep out of reach of children. Batteries contain sulphuric acid. Avoid contact with skin, eyes or clothing. Also, shield your eyes when working near the battery to protect against possible splashing of the acid solution. In case of acid contact with skin, eyes or clothing, flush immediately with water for a minimum of fifteen minutes. If acid is swallowed, drink large quantities of milk or water, followed by milk of magnesia, a beaten egg, or vegetable oil. Call a physician immediately. NOTE: If instructions are not observed, damage to electronic components may result. Ensure the battery to be used for boosting is 12-volt and that the negative terminal is grounded. Remove the filler vent caps from both batteries and place damp cloth over batteries. If the booster battery is installed in another vehicle, do not allow the two vehicles to touch. Turn off all unnecessary electrical loads. Select neutral gear on manual transmission, or ’P’ (Park) position in automatic transmission, and engage the parking brake on both vehicles.
starter relay G86729 en
01/2003 2003.0 BA Falcon
303-06-4
Starting System
303-06-4
DESCRIPTION AND OPERATION (Continued) Connecting and Starting Procedure Connect the jumper leads in the exact sequence as illustrated.
Connect end of jumper lead to the positive (+) terminal of the discharged battery. (Red lead if coloured). Connect the other end of the same jumper lead to the positive (+) terminal of the booster battery. Connect end of second jumper lead (Black if coloured) to the negative (-) terminal of the booster battery. Connect the other end of the second jumper lead to the engine of the vehicle with the discharged battery - NOT TO THE NEGATIVE TERMINAL OF THE DISCHARGED BATTERY. Take care that the jumper clamps do not touch each other or any metal on either vehicle, and are clear of cooling fans and drive belt. Do not lean over the battery when making connections.
Engine Starting First start the engine in the vehicle with the booster battery and let it run for a few minutes. Then start the engine in the vehicle with the discharged battery. Leave the jumper leads connected until the engine reaches idle speed (at least 1 minute) – otherwise damage to the electrical system may occur. Switch heater fan to boost position to ‘load’ the vehicle’s electrical system prior to disconnecting the jumper cables. Disconnect the cables in reverse order. Do not disconnect or change over the discharged battery while the engine is running – damage to the electrical system may occur. WARNING: Jump starting could be dangerous if done incorrectly. Do not attempt a jump-start if the discharged battery is frozen or if the battery fluid level is low, as the battery may rupture or explode.
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01/2003 2003.0 BA Falcon
303-06-5
Starting System
303-06-5
DIAGNOSIS AND TESTING
Starting System Symptom Chart
Symptom Chart - Starting System Condition
Source
Action
Starter Motor Cranks Slowly
Loose connections in starter solenoid battery feed or ground circuit. Undercharged battery. (Battery acid in all cells should have a specific gravity reading greater than 1.20, with all cells within 10 points variation). Malfunctioning starter motor. Voltage drop on power cable.
GO to Pinpoint Test A.
Starter Motor Does Not Crank But Starter Solenoid Operates
Loose or corroded connections at starter solenoid. Undercharged battery Malfunctioning starter motor. Main power cable open circuit.
GO to Pinpoint Test B.
Starter Motor Does Not Crank and Starter Solenoid Does Not Click
Loose or corroded battery cable connections. Undercharged battery. Faulty TR/NDS (neutral drive switch). Faulty ignition circuit grounds. Malfunctioning starter motor. Poor earth circuit.
GO to Pinpoint Test C.
Starter Motor Spins But Does Not Crank Engine
Malfunctioning starter drive. Damaged flywheel.
GO to Pinpoint Test D.
Unusual Starter Motor Noise During Starter Motor Overrun
Starter motor improperly mounted. Malfunctioning starter motor. Improper starter drive engagement to flywheel.
GO to Pinpoint Test E.
Starter Motor Remains Engaged and Runs with Engine
Battery cable touching solenoid S-terminal (defective or mispositioned battery cable). Shorted turns in starter solenoid.
GO to Pinpoint Test F.
Starter Motor Noisy in Operation
Worn or damaged ring gear. Drive end bush or commutator end bush dry/not lubricated. Excessive clutch dust (Manual Transmission)
Inspect ring gear repair or replace as required. Clean and lubricate bushes as required.
Pinpoint Tests PINPOINT TEST A : THE STARTER MOTOR CRANKS SLOWLY Test Step A1
Result / Action to Take
CHECK BATTERY CONNECTIONS Inspect the battery terminals for loose or corroded connections. Test voltage drop between battery negative terminal to case of starter motor, should be < 300mV. Are the battery terminals clean and tight?
G86730 en
Yes
Go to A2
No
CLEAN and TIGHTEN battery cable connections.
01/2003 2003.0 BA Falcon
303-06-6
Starting System
303-06-6
DIAGNOSIS AND TESTING (Continued) Test Step A2
Result / Action to Take
CHECK BATTERY Check the battery state of charge. Battery acid in all cells should have a specific gravity reading greater than 1.20, with all cells within 10 points variation. Load test the battery.
Yes
Go to A3
No
CHARGE or REPLACE the battery.
Is the battery OK?
A3
CHECK STARTER MOTOR CONNECTIONS Inspect the starter motor terminals for loose or corroded connections. Test voltage drop between battery postive terminal to solenoid main terminal, should be <350mV. Are starter motor terminal connections clean and tight?
A4
Yes
Go to A4
No
CLEAN and TIGHTEN starter motor connections.
CHECK STARTER MOTOR Yes
Check the starter cranking current draw, using a suitable digital multimeter and current clamp or by following starter load test procedure detailed in Components Tests of this section.
REMOVE starter and test. REPAIR or REPLACE.
Is the current draw lower than Specification?
No
Go to A5
A5
CHECK CURRENT DRAW Yes
Remove the stater motor and check the starter current draw with no load, using a suitable digital multimeter and current clamp or by following starter no load test procedure detailed in this section.
Engine has excessive friction. Refer to Section 303-01.
Is the current draw to Specification?
No
Test starter REPAIR or REPLACE.
PINPOINT TEST B : STARTER MOTOR DOES NOT CRANK BUT STARTER SOLENOID OPERATES Test Step B1
Result / Action to Take
CHECK STARTER MOTOR CONNECTIONS Inspect the starter motor terminals for loose or corroded connections. Are starter motor terminal connections clean and tight?
Yes
Go to B2
No
CLEAN and TIGHTEN starter motor connections.
B2
CHECK BATTERY Check the battery state of charge. Battery acid in all cells should have a specific gravity reading greater than 1.20, with all cells within 10 points variation. Load test the battery.
Yes
Go to B3
No
CHARGE or REPLACE the battery.
Is the battery OK?
B3
CHECK SOLENOID By-pass the solenoid with a heavy jumper cable. Does the engine crank now?
Yes
REPLACE solenoid.
No
Go to B4
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01/2003 2003.0 BA Falcon
303-06-7
Starting System
303-06-7
DIAGNOSIS AND TESTING (Continued) Test Step B4
Result / Action to Take
CHECK STARTER ENGAGEMENT Yes
Is the starter engagement firm?
Engine locked up. Refer to Section 303-01.
No
Remove starter and test. REPAIR or REPLACE.
PINPOINT TEST C : THE STARTER MOTOR DOES NOT CRANK/THE SOLENOID DOES NOT CLICK Test Step C1
Result / Action to Take
CHECK BEM SMARTLOCK STATE Use WDS to monitor the theft status (THEFT _ S) PID. With the ignition switched on is the BEM status “moblised”?
Yes
Go to C2
No
Refer Section 419-10 (BEM).
C2
CHECK FUSES Ensure vehicle is in Park or Neutral (Auto. Trans.). Check all fuses in the vehicle. Check all fuses in the vehicle.
C3
Yes
REPLACE and RETEST.
No
Go to C3
CHECK ENGINE ENABLE INPUT Use WDS to monitor the engine enable input signal No (ATS) EEC PID. With the ignition switched on is the ATS signal being received by the EEC?
Yes
Problem exists in ‘Smartshield’ system or communication between EEC and BEM.
No
Go to C4
C4
CHECK BATTERY CONNECTIONS Inspect the battery terminals for loose or corroded connections. Are the battery terminals clean and tight?
Yes
Go to C5
No
CLEAN and TIGHTEN battery cable connections.
C5
CHECK BATTERY Check the battery state of charge. Battery acid in all cells should have a specific gravity reading greater than 1.20, with all cells within 10 points variation. Load test the battery.
Yes
Go to C6
No
CHARGE or REPLACE the battery.
Is the battery OK?
C6
CHECK POWER SUPPLY TO STARTER MOTOR Key in OFF position. Disconnect the starter motor solenoid terminal 50 (connector C-11). Key in START position. Measure the voltage at Connector C-11
Yes
Go to C9
No
Go to C7
Is the voltage greater than 10 volts?
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Starting System
303-06-8
DIAGNOSIS AND TESTING (Continued) Test Step C7
Result / Action to Take
CHECK POWER SUPPLY TO STARTER MOTOR With the vehicle in park and the handbrake on, bridge the starter relay Yes across its switching circuit (relay pins 30 AND 87) with a heavy Go to C10 jumper cable. Does the starter crank now?
C8
No
Go to C8
CHECK THE STARTER CIRCUIT Yes
Check continuity of circuit from fuse block to starter relay and from starter relay to starter motor solenoid.
Go to C9
Is the circuit OK?
No
Rectify and Retest.
C9
CHECK THE SOLENOID Yes
With the vehicle in park and the handbrake on, bridge the starter motor battery connection to the solenoid terminal.
REPLACE solenoid. Retest.
Does the engine crank?
No
No Test starter motor. REPAIR or REPLACE.
C10
CHECK POWER BETWEEN IGN & STARTER RELAY Yes
With ignition switched to the start position, check the voltage at the starter motor relay (winding input).
Go to C11
Is there greater than 8 volts?
No
Check continuity of circuit from fuse through ignition switch to relay. Rectify and Retest.
C11
CHECK EEC STARTER RELAY SWITCHING Use the WDS to monitor the starter relay enable starter signal (ENABLE_ S) EEC PID. With the ignition switched to the start postion is the signal “ ON”?
C12
Yes
Go to C12
No
Perform further EEC diagnostic tests. Refer to Section 303-14.
CHECK STARTER CIRCUIT Ensure vehicle is in Park or Neutral (Auto. Trans.). Check continuity of circuit from, EEC; Starter relay Inhibitor switch
Yes
Replace starter motor.
No
Rectify and Retest.
Ground Is the circuit OK?
PINPOINT TEST D : THE STARTER SPINS BUT THE ENGINE DOES NOT CRANK Test Step D1
Result / Action to Take
CHECK BATTERY Check the battery state of charge. Is the battery OK?
Yes
Go to D2
No
CHARGE or REPLACE the battery.
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Starting System
303-06-9
DIAGNOSIS AND TESTING (Continued) Test Step D2
Result / Action to Take
CHECK FLYWHEEL Remove the starter motor. Refer to procedure in this section.
Yes
REPLACE as necessary.
Inspect the starter drive and flywheel for damage.
No
Is the starter drive or flywheel damaged?
Perform Bench Test procedures this section.
PINPOINT TEST E : UNUSUAL STARTER NOISE DURING STARTER OVERRUN Test Step E1
Result / Action to Take
CHECK STARTER MOTOR MOUNTING Yes
Inspect the starter motor mounting.
Go to E2
Check the starter motor mounting bolts for looseness.
No
Is the starter motor mounted properly?
E2
REMOUNT or REPLACE the starter motor.
CHECK STARTER DRIVE ENGAGEMENT Yes
Remove the starter motor. Inspect the starter drive and flywheel for damage. Refer to inspection procedure in this section.
PERFORM the Bench Test procedures in this section.
No
Are the starter drive and flywheel OK?
REPLACE as necessary.
PINPOINT TEST F : STARTER MOTOR REMAINS ENGAGED AND RUNS WITH ENGINE Test Step F1
Result / Action to Take
CHECK STARTER MOTOR TERMINALS Inspect the starter motor connectors for corrosion and incorrect installation. Are the starter motor connectors clean and installed properly?
Yes
PERFORM the Bench Test procedures in this section.
No
CLEAN or ADJUST starter motor connectors.
Component Tests Starter Motor Load Test Conduct this test if the starter cranks slowly and it is desired to compare current draw to specifications. This test is performed with the starter motor fitted to the vehicle. 1. Connect the starter motor tester equipment to the vehicle’s battery. Ensure that current is not flowing through the ammeter and heavy duty carbon pile rheostat portion of starter tester circuit, (rheostat at maximum counter clockwise position). 2. Disconnect the push on connector at the starter solenoid (terminal 50) and connect a remote control starter switch from the positive battery terminal to solenoid terminal 50. 3. Place transmission in neutral or park. With the ignition off crank the engine using the remote G86730 en
starter switch, and determine exact reading on voltmeter. NOTE: Ensure ignition switch is in the off position and the solenoid terminal 50 connector has been removed so that the engine does not start. 4. Disconnect battery to vehicle cables and reduce resistance of carbon pile until voltmeter indicates the same reading as that obtained while the starter cranked the engine. The ammeter will indicate starter current draw under load. Check this value with value listed in specifications.
Starter Motor No Load Test The starter motor no load test will uncover such conditions as open or shorted windings, rubbing armature, and bent output shaft. The starter can be tested, at no load, on the test bench only. 1. Clamp the starter motor securely in a starter test bench. 01/2003 2003.0 BA Falcon
303-06-10
Starting System
303-06-10
DIAGNOSIS AND TESTING (Continued) 2. Connect Starter Tester to a fully charged battery starter motor should operate smoothly. Determine (Specific Gravity > 1260) and connect the battery the exact reading on the voltmeter. positive to the battery supply (terminal 30) of the NOTE: The duration of this test should be as starter motor and battery negative to the starter short as possible. motor case. Starter motor connection cables 5. Disconnect starter from battery then reduce should be large enough to carry high currents, resistance of rheostat until voltmeter indicates the (equivalent to those used on the vehicle). same reading as that obtained while the starter 3. Connect a remote starter switch between the was running. The ammeter will indicate starter no solenoid terminal 50 and the power supply on load current draw. Refer to specifications for a terminal 30. comparative value. 4. Ensure that no current can flow through the 6. If the current exceeds Specification, check for ammeter (rheostat at maximum counter clockwise rubbing armature, bent output shaft, binding position). Engage the remote starter switch, the bearings, or shorts in armature or brush pinion should shift to the crank position and the assembly.
Starter Solenoid
Armature
Inspect the solenoid for damage and test the winding dc resistance.
The commutator should be examined for any sign of burned or darkened segments as this is usually an indication of open circuited windings. Check for short circuits using an armature growler or similar tester. Test the insulation resistance to earth using a megger or similar tester. A reading 1 MegaOhm or greater should be expected.
Hold-in Winding 1.16 - 1.3 Ohms. Pull-in Winding 0.248 - 0.281 Ohms. Test temperature +20°C During hold in and pull in tests the solenoid is held vertically, ie plunger uppermost. It is recommended that a rubber band be installed to prevent the plunger from flinging out during testing.
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303-06-11
Starting System
303-06-11
DIAGNOSIS AND TESTING (Continued)
Inhibitor Switch Test On vehicles equipped with an automatic transmission, apply the brakes and attempt to start the engine while moving the selector lever through all ranges. This may determine if the problem is caused by a maladjusted or defective neutral-start switch. Refer to Section 307-01 for the adjustment of this switch.
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01/2003 2003.0 BA Falcon
303-06-12
Starting System
303-06-12
GENERAL PROCEDURES
Starting System Cleaning Components CAUTION: The Armature, solenoid switch and drive assembly components must not be cleaned with spirit based agents, only clean rags and compressed air must be used. NOTE: All other mechanical components may be cleaned using non volatile or low inflammable agents in a well ventilated area, it is important that the parts are thoroughly dried before assembly, take care not to breath in the vapours. Please observe the safety regulations and precautions issued by the manufacturer of the cleaning agent in use.
2. Press the plunger fully home, it will be held by the hold-in winding. 3. Now decrease the voltage until the winding will no longer hold the plunger. Brushes and brush holder Inspection 1. Check the brush holder for shorts to ground using an insulation tester with a minimum AC voltage of 40 volts. 2. Ensure that the brushes move freely in their holders and that the brushes are free from chips and burn marks. 3. Check brush length if shorter than the minimum length (7mm) replace the brush set. Armature Inspection
1. Clean and inspect the armature for broken or burned insulation and unwelded or open Pull-In Voltage Testing connections. 1. Using a power supply capable of supplying 30 2. Inspect armature shaft and bearing surfaces for amperes, set the voltage to 3.0 volts. A battery scoring and excessive wear. and variable resistor may also be used. 3. Check commutator for runout using a dial 2. Connect the solenoid. Connect a 12 volt test lamp indicator. If commutator is rough, or out of round, between terminal 30 (main battery supply input) turn it down to Specification or replace. and +12 volt supply and a voltmeter between terminal 50 and ground.
Item Description 3. Fully press in solenoid plunger until lamp lights. 1 Rotate armature chafts on bearing Allow the plunger to spring out by approximately surfaces 8-10mm and hold in this position. 2 Dial indicator 4. Slowly increase the voltage on terminal 50 until 3 “V” blocks the plunger pulls in; note voltmeter reading. At the same time the lamp must light fully (main contact Machining and undercutting the commutator continuity). 1. If worn segments are evident on the commutator it NOTE: The voltage should be between 3.0 - 6.5 must be machined until the working surface is volts. Test duration should NOT exceed 2 clean, note that the minimum size for the seconds. commutator is 31.2mm. When machining the armature it must not be held by the laminations. Hold-In Voltage Testing The Armature must be held at the drive end and NOTE: The voltmeter reading, this is the release supported at the commutator end bearing surface. voltage which should be between 0.2 - 2.0 volts. 1. Set the power supply to 12 volts, connect the positive lead to terminal 50 of the solenoid and connect the negative lead to the case of the solenoid. G86731 en
01/2003 2003.0 BA Falcon
303-06-13
Starting System
303-06-13
GENERAL PROCEDURES (Continued) 2. It is recommended that the commutator be turned 2. Examine drive end housing mounting surfaces in two stages, that is pre turning and finish and threaded holes for damage. turning. In the pre turning stage the commutator is Drive shaft and planetary assembly inspection undercut to a maximum depth of 0.8mm. NOTE: It is most important to use dust extraction 1. Carefully examine the assembly for signs of wear or cracking. when undercutting commutators. 2. If worn replace the whole planetary drive. The 3. After undercutting the commutator place the planetary gear hub and bush may be replaced armature in the lathe and finish cut using a fine separately if required. tool. The cut should be no more than 0.03mm. 3. To replace the hub remove the circlip and thrust After turning, brush out the commutator slots washer and withdraw the planetary shaft. To using a stiff brush and polish surface if necessary. reassemble reverse the procedure. NOTE: Runout should be less than 0.1mm for the NOTE: The planetary gears are pre lubricated, a commutator and 0.5mm for the laminations. small amount of light oil may be used to lubricate Drive end and commutator end bushes the armature spigot bushing prior to reassembly. The helix for the drive assembly must be NOTE: Replace bushes whenever excessive lubricated with lithium based grease only. armature shaft side play is evident. If bushes are excessively worn the starter motor is likely to operate inefficiently or the armature may foul the pole pieces.
1. Remove both the commutator end housing and drive end bush by carefully tapping out with a mandrel. Be sure that the commutator end cover/drive end housing is well supported. This can be achieved by soaking the bushes over night in mineral oil. If time does not permit over night soaking oil can be forced into the bush by placing a thumb over one end of the bush and filling it with oil. Using the other thumb press firmly until the oil is visible on the outer surfaces of the bush. NOTE: Note that the bushings used in starter motors are made from porous sintered metal and as such they will hold oil to provide lubrication. It is important that the bushes are pre lubricated prior to fitting. 2. New bushes may be pressed or tapped into position using a suitably sized shouldered mandrel. Do not ream bushes after installation as the self lubricating qualities will be impaired.
Drive assembly inspection 1. Inspect the pinion for signs of wear or chipped teeth. 2. Rotate the pinion by hand and check for any signs of roughness or slipping, examine the pinion bush for wear or scoring, if in doubt replace the drive assembly. Contact burn off reserve testing 1. Press the plunger until the contacts close, this will be indicated when the test lamp comes on. 2. It must be possible to push the plunger another 1mm or more towards the magnetic core. If less than 1 mm the solenoid must be replaced. Interwinding short circuit testing 1. A 24 volt supply is required for this test. Apply positive supply to terminal 30 (main battery supply input) and negative to the casing. 2. Press the plunger fully home. 3. Release the plunger, it should return to it’s rest position by the action of the return spring. If it does not the windings have inter winding short circuits. NOTE: When the solenoid is connected in this way the windings are differentially compounded, that is, their fields are in opposition to each other.
Drive end housing & Commutator end cover inspection 1. Inspect the housing and cover for damage, wear or cracking. G86731 en
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Starting System
303-06-14
REMOVAL AND INSTALLATION
Starter Motor Removal 1. Disconnect Battery Negative Ground Cable. 2. Raise vehicle on hoist. 3. Disconnect starter cable and solenoid connector. 4. Remove starter retaining bolts and withdraw starter. Installation 1. Position starter and install retaining bolts. Torque to Specification. 2. Install starter cable and solenoid connection. 3. Lower Hoist. 4. Reconnect Battery Negative Ground Cable.
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Starting System
303-06-15
DISASSEMBLY AND ASSEMBLY
Starter Motor
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Starting System
303-06-16
DISASSEMBLY AND ASSEMBLY (Continued) Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
Description Drive end shield Solenoid Parts set, solenoid Overrunning clutch drive Fork bearing Epicycloidal gear train Gear hub Closure cap Hexagon screw Sintered - Metal bushing Commutator end shield Brush holder Armature Pole housing Needle bushing
Starter Drive Assembly Special Tool(s) Bosch fixture KDAL 5047
5. Using a pair of circlip pliers expand the stop ring and remove it from the planetary drive shaft taking care not to damage the shaft. 6. Carefully remove any burrs from the planetary drive shaft before removing the drive assembly, failure to do so will damage the drive assembly internal bush.
Solenoid Switch 1. Disconnect the main braided cable from the short threaded terminal (13mm spanner). 2. Remove the 3 mounting screws withdraw the solenoid, disengage the plunger from the fork lever and remove complete with the plunger and spring. NOTE: Solenoid position relative to drive end housing.
Drive End Housing 1. Loosen and remove through bolts (7mm socket). 2. Withdraw the drive end housing complete with the planetary gear assembly, drive assembly and fork lever from the armature gear taking care not to disengage the cover plate.
Armature Special Tool(s) Bosch fixture KDAW 9999
Bosch fixture KDAL 5028
Bosch tool KDAL 5048 1. Clamp the mounting lug of the drive end housing in the vice using soft jaws. 2. Remove the rubber sealing block. Remove the planetary drive assembly, fork lever and planetary drive from the drive end housing. 3. Ease fork lever from the drive assembly. In order to avoid damage to the planetary gears when removing the stop ring use Bosch fixture KDAL 5047 this supports the output shaft and prevents the shock being absorbed by the planetary gear hub. 4. Using Bosch striking sleeve KDAL 5028 and a non metallic hammer, with a sharp tap drive back the stop ring retainer. Alternatively clamp the protruding end of the planetary drive shaft in a vice (using soft jaws) and prise the stop ring retainer towards the drive assembly.
G86733 en
1. Clamp the pole housing in a vice using soft jaws or Bosch clamping fixture KDAW 9999. 2. Remove the screws and the dust cover cap from the commutator end cover. 3. Remove the rubber ring, circlip and adjustment washers. 4. Slide commutator end cover from armature shaft. 5. Using special Bosch tool KDAL 5048, slide tool onto the armature shaft until it contacts the face of the commutator.
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Starting System
303-06-17
DISASSEMBLY AND ASSEMBLY (Continued) 6. Gently push the tool until the annular flange contacts the brushplate, the armature may now be withdrawn. The tool will support the brushes in their holders until the armature needs to be reinserted. 7. Remove the armature thrust washer.
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01/2003 2003.0 BA Falcon
303-12-1
Intake Air Distribution and Filtering
303-12-1
SECTION : 303-12 Intake Air Distribution and Filtering VEHICLE APPLICATION : 2003.0 BA Falcon CONTENTS
PAGE
SPECIFICATIONS Specifications ........................................................................................................................303-12-2 DESCRIPTION AND OPERATION Intake Air Distribution and Filtering .......................................................................................303-12-3 Intake Air Distribution and Filtering ......................................................................................303-12-3 The Intake Air System ..........................................................................................................303-12-3 DIAGNOSIS AND TESTING Intake Air Distribution and Filtering .......................................................................................303-12-4 GENERAL PROCEDURES Cleaning and Inspection .......................................................................................................303-12-5 REMOVAL AND INSTALLATION Air Cleaner Body — I6 Engine ..............................................................................................303-12-6 Air Cleaner Element — I6 and V8 Engines ..........................................................................303-12-6 Engine Air Ducting — I6 and V8 Engines .............................................................................303-12-6
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303-12-2
Intake Air Distribution and Filtering
303-12-2
SPECIFICATIONS Torque Specifications Description Air cleaner bolt Air cleaner intake pipe screw Air cleaner assembly screw Air cleaner intake manifold duct screw Air cleaner to intake manifold duct clamp
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Intake Air Distribution and Filtering
303-12-3
DESCRIPTION AND OPERATION
Intake Air Distribution and Filtering All engines are equipped with dry type air cleaners that have serviceable PET(plastic fibre) filtering elements. Air enters the air cleaner from the front grille, through a duct above the radiator shroud, and then passes through the filter element. Dust particles are trapped in the filter element as the air passes through it. After leaving the filter element, the air passes through an intake duct into the throttle body.
The air cleaner assembly is secured to the LH fender inner panel with three insulator mountings. The top cover is attached to the air cleaner tray by four spring clips. I6
Intake Air Distribution and Filtering The air intake system consists of the following components: air cleaner air cleaner element mass air flow (MAF) sensor air cleaner outlet tube inlet tube resonator
V8
The Intake Air System filters intake air with a replaceable air cleaner element. measures intake Air Temperature and manifold absolute pressure. I6
V8
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Intake Air Distribution and Filtering
303-12-4
DIAGNOSIS AND TESTING
Intake Air Distribution and Filtering For diagnosis and testing of the intake Air temperature and Manifold absolute pressure sensor, refer to Section 303-14.
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Intake Air Distribution and Filtering
303-12-5
GENERAL PROCEDURES
Cleaning and Inspection Air Cleaner Element The PET plastic fibre filter element must not be cleaned with a solvent or cleaning solution. Also, oil must not be added to the surfaces of the filter element or air cleaner body. The element should be cleaned by tapping it lightly on a horizontal surface or using compressed air. Direct a stream of compressed air through the element in the opposite direction to intake air flow, that is, from the inside outward. Extreme care must be exercised to prevent rupture of the element material. Inspection Hold the filter in front of a light and carefully inspect it for any splits or cracks. If the filter is split or cracked, replace it. Body and Cover Clean the air cleaner body and the cover with a solvent or compressed air. Wipe the air cleaner dry if a solvent is used. Inspect the air cleaner body and cover for distortion or damage at the gasket mating surfaces. Replace the cover or body if they are damaged beyond repair.
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Intake Air Distribution and Filtering
303-12-6
REMOVAL AND INSTALLATION
Air Cleaner Body — I6 Engine Removal 1. Remove the retaining screws from the front sheet metal crossmember. Detach the air intake tube from the front crossmember and air cleaner body. 2. Back off the air cleaner lid to flexible air duct tube worm drive clamp until loose on its collar. 3. Remove the three air cleaner mounting screws and remove the air cleaner assembly. Installation 1. Position the air cleaner assembly to the fender inner panel and install the three mounting screws. 2. Slide the flexible air duct forward into the air cleaner lid and tighten the air cleaner lid worm drive clamp. 3. Attach the air intake tube to the lower air cleaner body, position on front sheet metal and install retaining screws.
Air Cleaner Element — I6 and V8 Engines Removal 1. Release the spring clips and lift the air cleaner cover away. 2. Remove the air filter element. Installation 1. Install the air cleaner element into the air cleaner body. 2. Install the cover and air duct assembly. Secure the cover retaining clips (ensuring tights seal of mating surfaces).
Engine Air Ducting — I6 and V8 Engines Removal 1. Back off the air cleaner lid worm drive clamp until loose on its collar. 2. Remove screws from plastic air duct above engine intake manifold. 3. Slide air duct rearwards out of air cleaner. 4. Slide air duct off throttle body and remove from engine bay. Installation 1. Position duct assembly in engine bay. 2. Position duct and rubber collar onto throttle body. 3. Slide the duct forward into the air cleaner lid. 4. Install duct to inlet manifold screws. 5. Tighten the air cleaner lid worm drive clamp.
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01/2003 2003.0 BA Falcon
303-14-1
Powertrain Control Management
303-14-1
SECTION : 303-14 Powertrain Control Management VEHICLE APPLICATION : 2003.0 BA Falcon CONTENTS
PAGE
DESCRIPTION AND OPERATION General Information ...............................................................................................................303-14-4 Precautions ..........................................................................................................................303-14-4 Special Notes .......................................................................................................................303-14-4 PCM Systems ........................................................................................................................303-14-8 System Overview .................................................................................................................303-14-8 Control Systems .....................................................................................................................303-14-8 Fuel System .........................................................................................................................303-14-8 Fuel tank ..............................................................................................................................303-14-8 Fuel pump ............................................................................................................................303-14-8 Fuel Supply and Return Lines .............................................................................................303-14-9 Fuel Filters ...........................................................................................................................303-14-9 Fuel Rail ...............................................................................................................................303-14-9 Fuel Injector .........................................................................................................................303-14-9 Fuel Pressure Regulator ....................................................................................................303-14-10 Intake Air System ...............................................................................................................303-14-10 Air Mass Measurement System .........................................................................................303-14-10 Variable Camshaft Timing ..................................................................................................303-14-11 5.4L, 3 Valve V8 Engine ....................................................................................................303-14-11 Intake Manifold Charge Control (IMCC) (I6 only) ..............................................................303-14-12 Ignition System ...................................................................................................................303-14-12 Spark Advance Map ...........................................................................................................303-14-13 Engine Cooling System ......................................................................................................303-14-13 Evaporative Emission System ...........................................................................................303-14-13 Positive Crankcase Ventilation ..........................................................................................303-14-13 Catalyst and Exhaust System ............................................................................................303-14-13 Air Conditioning System .....................................................................................................303-13-14 Traction Control ..................................................................................................................303-14-14 Automatic Transmission Control ........................................................................................303-14-14 Control Software ..................................................................................................................303-14-15 Powertrain Control Module Memory ..................................................................................303-14-15 Operating Strategies ..........................................................................................................303-14-15 Operating Modes ................................................................................................................303-14-16 Normal Mode ......................................................................................................................303-14-16 Crank Mode ........................................................................................................................303-14-17 Under-Speed Mode ............................................................................................................303-14-17 Open Loop .........................................................................................................................303-14-17 Closed Loop .......................................................................................................................303-14-17 Powertrain Control Hardware ...............................................................................................303-14-18 Powertrain Control Module ................................................................................................303-14-18 Module Programming .........................................................................................................303-14-18 General Procedures .............................................................................................................303-14-19 General Procedures ..........................................................................................................303-14-19 Power and Ground Signals ................................................................................................303-14-19 Inputs ...................................................................................................................................303-14-20 Crankshaft Position Sensor (CKP) .....................................................................................303-14-20 Temperature and Manifold Absolute Pressure Sensor ......................................................303-14-21 Trimming Sensors ................................................................................................................303-14-23 Camshaft Position Sensor .................................................................................................303-14-23 01/2003 2003.0 BA Falcon
303-14-2
Powertrain Control Management
303-14-2
(Continued) Cylinder Head Temperature Sensor ..................................................................................303-14-24 Engine Oil Temperature Sensor ........................................................................................303-14-25 Engine Oil Pressure Sensor ...............................................................................................303-14-26 Boost Pressure Sensor, I6 Turbo Engine ..........................................................................303-14-26 TAS ......................................................................................................................................303-14-27 Failure Mode ......................................................................................................................303-14-27 Feedback Inputs ..................................................................................................................303-14-27 Heated Exhaust Gas Oxygen Sensor ................................................................................303-14-27 Knock Sensor .....................................................................................................................303-14-30 Feed Forward Inputs ............................................................................................................303-14-30 Transmission Range Sensor (TRS-A1) .............................................................................303-14-30 Transmission Range Sensor (TRS-A2) .............................................................................303-14-31 Power Steering Pressure Switch .......................................................................................303-14-32 Vehicle Speed ....................................................................................................................303-14-33 Electronic Throttle Control Inputs .........................................................................................303-14-34 Pedal Position Sensor ........................................................................................................303-14-34 Throttle Position Sensor .....................................................................................................303-14-35 Clutch Engagement Switch, Manual Transmission ............................................................303-14-36 Brake Switches ..................................................................................................................303-14-36 Reverse Gear Switch .........................................................................................................303-14-37 Speed Control Range Switch Assembly ............................................................................303-14-37 Air Conditioner Inputs ..........................................................................................................303-14-38 Air Conditioner Demand .....................................................................................................303-14-38 Air Conditioner Relay .........................................................................................................303-14-38 Air Conditioner Pressure Transducer .................................................................................303-14-39 Transmission Inputs .............................................................................................................303-14-39 Transmission Fluid Temperature Sensor ...........................................................................303-14-39 Output Actuators ..................................................................................................................303-14-40 Fuel Pump ..........................................................................................................................303-14-40 Fuel Injectors 1-8 ...............................................................................................................303-14-41 Ignition Coils .......................................................................................................................303-14-43 Actuators ..............................................................................................................................303-14-44 Intake Manifold Charge Control .........................................................................................303-14-44 Electro Drive Fans .............................................................................................................303-14-45 Variable Camshaft Timing ..................................................................................................303-14-46 Electronic Throttle Body .....................................................................................................303-14-54 Evap Canister Purge Solenoid ...........................................................................................303-14-55 Turbocharger Westgate Control .........................................................................................303-14-55 Transmission Outputs ..........................................................................................................303-14-56 Shift Solenoid 1 ..................................................................................................................303-14-56 Shift Solenoid 2 ..................................................................................................................303-14-57 Shift Solenoid 3 ..................................................................................................................303-14-57 Shift Solenoid 4 ..................................................................................................................303-14-57 Variable Pressure Solenoid 5 ............................................................................................303-14-58 Power Control Solenoid 6 ..................................................................................................303-14-58 Lock up Solenoid 7 ............................................................................................................303-14-59 LPG Fuel System Outputs ...................................................................................................303-14-59 LPG Prime Solenoid PRIME ..............................................................................................303-14-59 Gas Cut-out Solenoid GCO ...............................................................................................303-14-60 LPG Stepper Motor A-D .....................................................................................................303-14-60 Control Area Network (CAN) ..............................................................................................303-14-61 Smartshield Security ..........................................................................................................303-14-63 Diagnosis .............................................................................................................................303-14-65 Diagnosis ..........................................................................................................................303-14-65
01/2003 2003.0 BA Falcon
303-14-3
Powertrain Control Management
303-14-3
(Continued) DIAGNOSIS AND TESTING Powertrain Control Management .........................................................................................303-14-71 Powertrain Control Management .......................................................................................303-14-71 GENERAL PROCEDURES Powertrain Control Module ................................................................................................303-14-101 Intake Manifold Charge Control .........................................................................................303-14-101 VCT Solenoid Valve ..........................................................................................................303-14-101 REMOVAL AND INSTALLATION Crankshaft Position (CKP) Sensor (I6 Engine) ..................................................................303-14-103 Crankshaft Position (CKP) Sensor (V8 Engine) ................................................................303-14-103 Camshaft Position Sensor (I6 Engine) ...............................................................................303-14-103 Camshaft Position Sensor (V8 Engine) .............................................................................303-14-103 Knock Sensor (I6 Engine) ..................................................................................................303-14-103 Cylinder Head Temperature (CHT) Sensor (I6 Engine) .....................................................303-14-104 Cylinder Head Temperature (CHT) Sensor (V8 Engine) ...................................................303-14-104 Throttle Position (TP) Sensor (I6, LPG & Turbo Engines) .................................................303-14-104 Throttle Position (TP) Sensor (V8 Engine) ........................................................................303-14-105 Powertrain Control Module (PCM) (I6 Engine) ..................................................................303-14-105 HEGO Sensor (I6 & V8 Engines) .......................................................................................303-14-106 HEGO Sensor (Turbo) .......................................................................................................303-14-107 Boost Pressure Sensor (Turbo Engine) .............................................................................303-14-107 Turbocharger Wastegate Control Solenoid ........................................................................303-14-107 Reverse Gear Switch .........................................................................................................303-14-107 Temperature and Manifold Absolute Pressure (T-MAP) Sensor .......................................303-14-108 Fuel Rail (I6 Engine) ..........................................................................................................303-14-108 Fuel Rail (V8 Engine) .........................................................................................................303-14-108 Brake Switches .................................................................................................................303-14-109 Clutch Engagement Switch, (Manual Transmission) ........................................................303-14-109 Pedal Position Sensor ........................................................................................................303-14-109 Air Conditioning Relay .......................................................................................................303-14-110 Air Conditioner Pressure Transducer .................................................................................303-14-110 Transmission Fluid Temperature Sensor ..........................................................................303-14-110 Fuel Pump .........................................................................................................................303-14-110 Transmission Range Sensor (TRSA1) .............................................................................303-14-110 Transmission Range Sensor (TRSA2) .............................................................................303-14-110 Intake Manifold Charge Control .........................................................................................303-14-110 Phaser removal .................................................................................................................303-14-110 OCV removal ....................................................................................................................303-14-110 CID sensor removal ..........................................................................................................303-14-110 VCT oil filter removal ..........................................................................................................303-14-110 EVAP Canister Purge Solenoid .........................................................................................303-14-110 Power Steering Pressure Switch .......................................................................................303-14-110
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DESCRIPTION AND OPERATION
General Information This section describes the operation and components of the Powertrain Control Module (PCM). The system is designed to provide optimal performance and emission control. Modifying the system or substituting non-Ford components may have an adverse effect on drivability and emissions. Diagnosis of the system requires special tools and training. Maintenance of the PCM system should be performed by Ford trained technicians.
Precautions The fuel supply lines retain pressure that must be relieved before servicing the fuel system. Leaking fuel poses a potential fire hazard. The spark ignition system produces high voltages. Use care to avoid personal injury. When the ignition is ON, the electric engine cooling fans can start at any time. Keep clear of the fans to avoid entanglement and personal injury. With the engine running, there are rotating components within the engine compartment. Use extreme care to avoid entanglement and personal injury. Some components in the engine compartment are HOT. The cooling system contains hot liquid under pressure. Allow the engine to cool to ambient temperature before removing the cooling system cap. Do not reconnect a PCM to the vehicles wiring harness with the ignition turned ON.
Special Notes With this issue of the Falcon Workshop Manual, some terminologies in this section for PCM components now reflect Ford’s Global Naming Conventions. The full title of the component is spelt out in full the first time it is mentioned in a section. The acronym for the component is shown in brackets and, where applicable, the previous acronym is shown in Chevrons. Elsewhere in the section, only the acronym is used. Information in this section regarding the Traction Control System is only applicable where fitted. Information in this section regarding LPG applies only to Ford Factory fitted LPG systems. Installation of after-market LPG systems may operate differently from that described here. Information in this section regarding Air Conditioning and Automatic Climate Control Air Conditioning is only applicable where fitted.
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DESCRIPTION AND OPERATION (Continued) PCM Control Components, I6 Engine
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DESCRIPTION AND OPERATION (Continued) Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21
Description Transmission Range Sensor (TR) Vehicle Speed Sensor (VSS) (where fitted) Cylinder Head Temperature (CHT) Camshaft Position Sensors (CMP) Reverse Gear Switch (RGS) Throttle Body Throttle Position Sensor (TP) Powertrain Control Module (PCM) Evaporator Canister Purge Solenoid (EVAP) Temperature and Manifold Absolute Pressure (T-MAP) Sensor Air Conditioner Refrigerant Pressure Intake Manifold Runner Control (IMCC) Fuel Injector (INJ1-6) Knock Sensor (KS) Crankshaft Position Sensor (CKP) Oil Pressure Switch and Engine Oil Temperature Variable Cam Timing (VCT) Solenoid Power Steering Pressure Switch (PSP) Heated Exhaust Gas Oxygen Sensor (HEGO) Power Distribution Box, PCM Relay, Fuel Coil On Plug (1-6)
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DESCRIPTION AND OPERATION (Continued) PCM Control Components, V8 Engine
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DESCRIPTION AND OPERATION (Continued) Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
Description Transmission Range Sensor (TR)
Vehicle Speed Sensor (VSS) (where fitted) Cylinder Head Temperature (CHT) Reverse Gear Switch (RGS) Throttle Position Throttle Body Sensor (TP) Temperature and Manifold Absolute Pressure T-MAP Powertrain Control Module (PCM) Evaporator Canister Purge Solenoid (EVAP) Heated Exhaust Gas Oxygen Sensors (HEGO1-2) Oil Pressure Switch Fuel Injector (INJ1-8) Camshaft Position Sensor (CMP) Crankshaft Position Sensor (CKP) Engine Oil Temperature Sensor Air Conditioner Refrigerant Pressure Power Distribution Box, PCM Relay, Start Enable Relay, Fuel Pump Relay Coil On Plug (1-8)
PCM Systems System Overview The Powertrain Control Module (PCM) manages the powertrain, providing optimal performance, maximum fuel economy and minimal exhaust emissions. The PCM system manages the following: Fuel Injection Ignition Throttle Variable Camshaft Timing Automatic Transmission Gear Shift Fuel Pump Air-Conditioning Evaporative Emissions Vehicle Immobilisation Engine Cooling Powertrain Electric’s Diagnostics Turbocharger (where fitted) LPG (where fitted) At each engine revolution the PCM monitors driving conditions through signals and switches situated on the powertrain. Optimal air, fuel, ignition and camshaft settings for the current driving conditions are then calculated by the PCM using algorithms and look up tables stored in memory. G98119 en
A sophisticated diagnostics system monitors the PCM and the interfacing components, compensating for faults and wear during operation. The diagnostics are accessed using the WDS tester.
Control Systems Fuel System The fuel system supplies the fuel injectors with filtered fuel at a controlled pressure. The Powertrain Control Module (PCM) controls the fuel pump and the on/off duration (pulse width) and timing of the fuel injectors.
Fuel Injection The PCM electronic fuel injection system supplies the correct amount of fuel to the engine as required for the operating conditions. Each cylinder has an individual fuel injector controlled sequentially to inject the fuel at the optimum point in the engine cycle. The Powertrain Control Module (PCM) adjusts the fuel injection pulse width, delivering a precise quantity of fuel into the intake ports. Fuel is injected into the cylinders in the same sequence as the ignition firing order. As the fuel is injected into a close port, the period that each charge remains in the port is even for all cylinders, ensuring optimum mixture throughout the engine.
Fuel System Components The fuel system consists of the following components. Fuel Tank Fuel Pump Fuel Supply and Return Lines Fuel Filter Fuel Rail Fuel Injector Fuel Pressure Regulator
Fuel tank The fuel tank is located at the rear of the vehicle and contains a store of fuel to operate the engine. The fuel tank is described in more detail in Section 310-00, Fuel System - General Information.
Fuel pump The fuel pump assembly is mounted inside the fuel tank within a reservoir. The reservoir maintains a pool of fuel at the pick-up point and prevents fuel starvation during hard acceleration, braking and cornering. To enhance engine start-up, the fuel pump has a discharge check valve that maintains pressure in the fuel lines after the ignition has been turned OFF. When the ignition switch is in the ON position, the PCM power relay is energised. The PCM ignition power relay provides power to the PCM and the fuel pump relay. The fuel pump relay is then energised by the PCM under certain conditions. 01/2003 2003.0 BA Falcon
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DESCRIPTION AND OPERATION (Continued) The PCM monitors the Crankshaft Position Sensor (CKP) signal to determine engine speed. Once the engine is running the PCM will keep the fuel pump relay energized until the engine stops. If the engine does not start after two seconds, the PCM disengages the fuel pump relay.
within a special fitting on the fuel rail pipe. An o-ring on the fuel injector prevents leakage around the joint. On I6 engines the injectors are secured and oriented with a clip.
Fuel Supply and Return Lines Fuel is routed to the fuel rail from the fuel tank along the supply pipe. Excess fuel from the fuel pressure regulator is returned to the fuel tank through the return line. The fuel lines are described in more detail in Section 310-00, Fuel System - General Information.
Fuel Filters To prevent the fuel injectors becoming clogged or contaminated with foreign material, the fuel system contains four levels of filtering: Fuel Pump: A filter screen is mounted on the intake side of the fuel pump. The filter is part of the assembly and cannot be replaced separately. Fuel Filter Assembly: The fuel filter assembly is located in the fuel supply line between the fuel pump and the fuel rail. The fuel filter assembly must be periodically replaced according to the maintenance schedule. Fuel Pressure Regulator: A filter is located on the inlet side of the fuel pressure regulator. The filter is part of the assembly and cannot be replaced separately. Fuel Injectors: A mesh screen on the inlet side of the fuel injector prevents foreign debris and materials from entering the fuel injector mechanism. The filter is part of the assembly and cannot be replaced separately.
Fuel Rail Fuel from the supply line is conveyed to the fuel injectors through the fuel rail and excess fuel is returned to the fuel tank via the fuel pressure regulator and return line. Each fuel injector seats
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Item 1 2 3
Description Fuel Injector Injector Seat Clip
Fuel Injector CAUTION: The fuel injectors pulse open momentarily using a signal from the PCM. Applying battery voltage directly to the fuel injector’s electrical connector terminals will damage the internal solenoid. The fuel injector is a solenoid-operated valve that meters fuel flow to the engine. The injector is opened and closed a constant number of times per crankshaft revolution by the Powertrain Control Module (PCM). The length of time the injector is held open and the fuel rail pressure controls the amount of fuel admitted to the engine. The fuel injectors are described in more detail under Components in this section.
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DESCRIPTION AND OPERATION (Continued) Fuel Injector
Fuel Pressure Regulator The fuel pressure regulator is attached to the outlet side of the fuel rail and controls the pressure within the fuel rail. Fuel is delivered to each injector at the same pressure to ensure the volume of fuel injected is equal for each cylinder. The regulator is a diaphragm-operated relief valve. One side of the diaphragm senses fuel pressure, and the other side is connected to the intake manifold vacuum. Fuel pressure is established by a spring pre-loading applied to the diaphragm. Balancing one side of the diaphragm with manifold vacuum maintains a constant pressure across the fuel injectors. Excess fuel is bypassed through the regulator and returned to the fuel tank. Fuel pressure is high when engine vacuum is low.
Intake Air System The intake air system provides clean air to the engine, optimises airflow and is designed to minimise induction noise. The intake air system consists of: Air Cleaner Assembly Inlet Ducting Electronic Throttle Body Inlet Manifold
Air Cleaner Assembly
Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
Description O-ring Filter Adjusting Sleeve Weld Shells (2 of) Weld Weld Support Ring O-ring Seat & Spray Plate Assy. Tube Assy. Needle, Ball & Armature Assy. Spring Coil & Bobbin Assy. Plastic Body
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The air cleaner assembly is an essential component of the intake air system. The air cleaner assembly houses a disposable air filter element that removes dust from the intake air. The air cleaner element must be periodically replaced according to the maintenance schedule.
Air Mass Measurement System The I6 and V8 engines use the “speed density” fuel injection system. In this system, the PCM has stored in its memory the theoretical mass of intake air that will be drawn into the engine at any given speed of operation. Using the engine speed sensor (Crankshaft Position CKP) signal, the Intake Air Temperature and Manifold Absolute Pressure sensor (T-MAP), the PCM can compute the intake air mass, and from it the fuel required to be injected into the engine for combustion. This amount of fuel injected is further corrected by feedback information obtained from the Heated Oxygen Sensor (HEGO) sensor, providing close loop control of fuel injection. A further feature of this system is the ability to ‘re-calibrate’ itself for changes in fuel requirements as the engine wears and the sensors age. This is known as adaptive strategy or learning and is an additional function derived from HEGO sensor information.
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DESCRIPTION AND OPERATION (Continued)
Intake Air Ducting The intake air ducting connects the air filter assembly to the throttle body. The ducts prevent entry of foreign material to the air intake system after the air filter. The design minimises restriction and is tuned to reduce intake noise.
Electronic Throttle Control The Electronic Throttle Body (ETB) controls the amount of air admitted to the engine by restricting the air intake with a throttle plate. The accelerator pedal position sensor (APPS) senses the driver’s acceleration request to the PCM. The PCM processes this information into an output signal for the ETB. The electric motor in the ETB moves the throttle plate through a gear set. The throttle plate is adjusted and monitored by the PCM in a closed control loop. The TP sensor provides the PCM with feedback on the actual position of the throttle plate. The electronic throttle body and the Positive Crankcase Ventilation (PCV) provides airflow during idle. The PCM trims the throttle continuously to maintain the proper idle speed under all conditions from cold start to normal operating temperatures. It also compensates for additional loads such as air-conditioning and power steering. The idle speed is not manually adjustable.
Inlet Manifold The inlet manifold is an aluminium casting, which directs the intake air to the inlet ports on the cylinder head.
Variable Camshaft Timing I6 Engine The I6 Engine is fitted with variable inlet and exhaust camshaft timing. Both camshafts are variable over a 60-degree crank angle. This is achieved by two separate hydraulic mechanisms called ‘Phasers’, which are integral with the intake and exhaust camshaft drive sprockets. The camshaft timing is controlled by directing oil under pressure (from the engine oil pump) into one of G98122 en
two ports in the Phaser, one port will retard the cam timing (‘Retard port’) and the other will advance the timing (‘Advance port’). An Oil Control Valve (OCV), one for each camshaft, is used to control the flow of oil into the retard and advance ports of both cams. The OCV is controlled by the PCM. The PCM uses a pulse width modulated (PWM) voltage or ‘Duty Cycle’ (DC) to control each OCV to attain the desired camshaft angle. VCT1 output controls the inlet camshaft OCV. VCT2 controls the exhaust camshaft OCV. A 3 + 1 tooth wheel on the front of each camshaft with an associated sensor mounted on the intake and exhaust sides of the cylinder head are used to calculate the ‘Actual cam angle’ for both camshafts. The two sensors are called, intake cam position or ‘CID1’ and exhaust cam position or ‘CID2’. Intake and exhaust cam positions are calculated separately. The PCM uses engine rpm, throttle position and engine load to determine the optimum camshaft timing setting or ‘Desired Cam Angle’ for both camshafts. Once the PCM has determined the Desired Cam Angle, it will control the Duty Cycle output VCT1 and VCT2, to the intake and exhaust OCVs based on the difference between the Desired Cam Angle and the Actual Cam Angle. This difference is called the Cam Angle Error. The Cam Angle Error for each cam is calculated individually and used to control both camshafts independently to a single Desired Cam Angle. An engine oil temperature sensor, which measures oil temperature in the oil gallery, is used to compensate for Phaser response with changing oil viscosity at different temperatures.
5.4L, 3 Valve V8 Engine The 5.4, 3V, V8 Engine is fitted with variable inlet and exhaust camshaft timing on each cylinder head bank. The camshaft on each bank is variable over a 60-degree crank angle using two separate hydraulic ‘Phasers’, which are integral with the Bank1 and Bank2 camshaft drive sprockets. The camshaft timing is controlled by directing oil under pressure (from the engine oil pump) into one of two ports in the Phaser, one port will retard the cam timing (‘Retard port’) and the other will advance the timing (‘Advance port’). An Oil Control Valve (OCV), one for each camshaft, is used to control the flow of oil into the retard and advance ports of both cams. The OCV is controlled by the PCM. The PCM uses a pulse width modulated (PWM) voltage or ‘Duty Cycle’ (DC) to control each OCV to attain the desired camshaft angle. VCT1 output controls the inlet RH Bank OCV. VCT2 controls the LH Bank camshaft OCV. A 4 + 1 tooth wheel on the front of each camshaft with an associated sensor mounted on the intake and exhaust sides of the cylinder head are used to 01/2003 2003.0 BA Falcon
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DESCRIPTION AND OPERATION (Continued) calculate the ‘Actual cam angle’ for both camshafts. The two sensors, CID1 and CID2 measure the camshaft angle on Bank 1 and Bank 2 respectively. The PCM uses engine rpm, throttle position and engine load to determine the optimum camshaft timing setting or ‘Desired Cam Angle’ for both camshafts. Once the PCM has determined the Desired Cam Angle, it will control the Duty Cycle output VCT1 and VCT2, to the intake and exhaust OCVs based on the difference between the Desired Cam Angle and the Actual Cam Angle. This difference is called the Cam Angle Error. The Cam Angle Error for each cam is calculated individually and used to control both camshafts independently to a single Desired Cam Angle. An engine oil temperature sensor in the engine sump is used to compensate for Phaser response with changing oil viscosity at different temperatures.
Intake Manifold Charge Control (IMCC) (I6 only) To improve engine torque over the entire engine operating range, the I6 engine has an Intake Manifold Charge Control (IMCC) system, which contains two air runners for each cylinder. A butterfly valve situated in the intake runner for each cylinder controls the effective length of the intake path. The Powertrain Control Module (PCM) controls operation of the IMCC system. At low engine speeds a long intake path improves volumetric efficiency, while at higher engine speeds a short intake path provides better efficiency. Changing the effective length of the intake air path improves drivability and engine power throughout the engines operating range. The lengths of the runners are designed to suit the Ram Air Effect of the I6 engine.
In normal operation, below approximately 3,800 RPM, the butterfly valves are closed, causing the intake air to follow the longer path into the engine. At higher engine speeds, above approximately 3,800 RPM, the butterfly valves open allowing the intake air to follow a shorter path into the engine. A vacuum actuator operates the butterfly valves. The Powertrain Control Module (PCM) controls vacuum to the actuator via a solenoid valve. NOTE: On I6 Turbo engines, there are no butterfly valves.
Ignition System The ignition Coil-On-Plug (COP) assembly consists of a coil mounted on top of a spark plug. For each of the engine’s cylinders, there is a corresponding COP assembly. Individual low side coil drives in the PCM control the COP’s that ignites the air-fuel mixture within the cylinders. The COP’s provide a controlled high voltage spark to each spark plug at the correct time under all engine operating conditions. The ignition system comprises: Individual coil drives: one per cylinder Spark Plugs Crankshaft Position Sensor (CKP) input
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DESCRIPTION AND OPERATION (Continued) Camshaft Position Sensors (Cylinder Identification) (CID1 & 2)
The powertrain control module (PCM) controls the Evaporative (EVAP) Canister Purge solenoid. The solenoid controls the flow of vapours from the carbon Spark Advance Map canister to the intake manifold for combustion during various engine operating modes. The EVAP canister The Powertrain Control Module (PCM) memory purge solenoid is a normally closed valve. contains a complex spark advance map to ensure optimum ignition timing under all conditions. The ideal Canister purge occurs at all engine operating advance is applied ensuring the best possible conditions including idle and after engine warm-up. performance, economy and minimal emissions. The solenoid valve purges continuously until the EGO sensor detects no more fuel vapours. The solenoid Spark Plugs valve then shuts down for a two minute period before starting the purge cycle again. Spark plugs are described in Section 303-07.
Engine Cooling System
Positive Crankcase Ventilation
The engine cooling system is described in Section 303-03A. The Powertrain Control Module (PCM) controls operation of the Electro Drive Fans 1-2 (EDF1-2). The PCM operates both fans at low or high speeds through relays depending on engine temperature load and A/C System pressure. The PCM uses the Cylinder Head Temperature Sensor (CHT) and Air Conditioner Refrigerant Pressure Transducer (ACPT), Vehicle Speed and Air Conditioner Control Relay, B2 (ACR) signals to calculate the cooling requirements, then switches the fan relays accordingly. The PCM transmits CHT information to the instrument cluster temperature gauge and the Climate Control air conditioning on the CAN line.
The Positive Crankcase Ventilation (PCV) system cycles crankcase gases back through the engine where they are burned during the combustion process. The PCV valve regulates the amount of ventilating air entering the intake air system and prevents any backfire from reaching the crankcase.
Engine Cooling Strategy (excludes LPG) The I6 and V8 engine cooling strategy ensures the continued operation of the engine in the event of coolant loss or extremely high temperatures. If the engine temperature exceeds approximately 120 degrees, to maintain a safe engine operating temperature, the fuel injectors are sequentially shut off to allow each cylinder to be cooled by the intake air. The engine may run rough when operating in overheat management strategy mode. The jewel in the cluster will light when the PCM senses that the engine has exceeded a safe operating temperature. The jewel will flash when fail-safe cooling strategy no longer can keep the engine running. Shortly afterwards, the engine will shutdown.
Catalyst and Exhaust System The exhaust system carries engine emissions from the engine through the exhaust manifold, engine pipe, and catalytic converter to the atmosphere. The exhaust system is described in Section 309-00. A Heated Exhaust Gas Oxygen Sensor (HEGO) is mounted before the catalytic converter. The catalytic converter reduces the concentration of carbon monoxide, unburned hydrocarbons and oxides of nitrogen in the exhaust emissions to an minimum level.
Heated Oxygen Sensors The Heated Exhaust Gas Oxygen Sensor (HEGO) provides the Powertrain Control Module (PCM) with a voltage level that relates to the oxygen content of the exhaust gas.
Evaporative Emission System The Evaporative Emission System prevents fuel vapours from the fuel tank being vented to the atmosphere. Fuel vapours from the fuel tank are collected in a carbon canister while the engine is not running. The vapours remain trapped within the canister until it is purged to the inlet manifold, where the vapours are burnt as part of the normal combustion process. The Powertrain Control Module (PCM) monitors several system inputs to determine when purging the vapours will have minimum impact on engine operation. G98122 en
Item 1 2
Description Fuel Injector HEGO Sensor
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DESCRIPTION AND OPERATION (Continued) Catalytic Converter A catalyst is a material that initiates and increases a chemical reaction without itself being consumed. The catalytic converter minimises the concentration of toxic gases released to the atmosphere from the exhaust system. It contains a catalyst in the form of a specially treated honeycomb structure saturated with catalytically active precious metals. As the exhaust gases come in contact with the catalyst, they are changed into mostly harmless products. The catalyst initiates and speeds up heat producing chemical reactions of the exhaust gas components so they are used up as much as possible. The catalytic reaction only occurs when the air fuel/ratio is near the stoichiometry point.
Air Conditioning System The PCM controls the air conditioning compressor clutch relay on and off in response to the AC Clutch request sent on the CAN by the Climate Control HIM Module. The Climate Control HIM Module determines the operational state of the AC compressor needed to maintain a desired evaporator air temperature based on the comfort temperature selected by the driver and passenger. When the compressor is commanded to turn on, the PCM utilizes and Air Conditioner Refrigerant Pressure Transducer (ACPT) input (B15), and the Air conditioning Evaporator Air Temperature (AEAT) data on the CAN to monitor the Air Conditioner system performance. In the event of overheating or a low refrigerant charge condition, the Powertrain Control Module (PCM) shuts down the air conditioning compressor to prevent damage. A malfunction of the air conditioning system is detected by the failure of an individual sensor or by a combination of factors calculated from the combined outputs of ACPT and AEAT being out of range over a period of time. The failure mode can be accessed through the diagnostic connector using the WDS tester.
Traction Control On vehicles fitted with the Traction Control System, the Traction Control (ASR) module works with the Powertrain Control Module (PCM) to minimise wheel slippage. The ASR monitors the speed of each wheel using wheel sensors on each wheel. Wheel spin is detected when one of the rear wheels is spinning or accelerating faster than the front or opposite side wheel. When spin occurs, the ASR module works to stop wheel spin by, if necessary, momentarily applying the brake of the spinning wheel and signaling the Powertrain Control Module (PCM) to reduce engine torque to a specific level. When the PCM receives a torque reduction message
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from the ASR on the CAN line, it reduces engine torque by retarding ignition timing, inhibiting injector operation, closing the throttle plate and leaning the air-fuel ratio. The system continues to monitor for wheel slip. When traction is restored, engine torque can be returned to normal levels.
Automatic Transmission Control The Powertrain Control Module (PCM) controls the automatic transmission gear shift. The PCM calculates the shift points and controls the transmission according to driving conditions, engine load and throttle demand. The PCM controls or monitors the following automatic transmission functions: Transmission Range Sensor (TR) Transmission Fluid Temperature Sensor (TFT) Shift Solenoid 1 (SS1) Shift Solenoid 2 (SS2) Shift Solenoid 3 (SS3) Shift Solenoid 4 (SS4) Variable Pressure Solenoid 5 (VPS) Power Control Solenoid 6 (PCS) Lock Up Solenoid 7 (LUS) Operation, maintenance and the control strategy for the transmission are described in Section 307-01, Automatic Transmission.
Electronic Sport Shift The electronic sports shift feature allows driver control of the automatic transmission. The TRS-A1 sensor on the side of the transmission housing senses the sport-shift selection of “P”, “R”, “N” and “D” position. The resistance of the sensor changes for each position and is measured by the PCM as a voltage on the TRS-A1 input. The sport shift manual, tip-up and tip-down position is sensed by the TRS-A2 sensor, a printed circuit board with 3 Hall-effect switches in the T-bar console. The sport shift lever contains a magnet in its base that activates the appropriate Hall-effect switch in different shift position. The switches are resistively multiplexed together and are read as a voltage by the PCM on the TRS-A2 input.
Column Shift Auto Vehicles fitted with column shift automatics use the same TRS-A1 sensor on the side of the transmission as the electronic sport shift. The column shift mechanism moves the sensor through an arc to allow selection of “P”, “R”, “N” and “D” as well as the “3”, “2” and “1” gear positions.
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DESCRIPTION AND OPERATION (Continued) a 14.64:1 air-fuel ratio during closed-loop operation. The range of LONGFT is from -35%to +35%. The ideal value is near 0% but variations of +20%are Powertrain Control Module Memory acceptable. Information gathered at different engine The Powertrain Control Module (PCM) uses flash speeds and loads is stored in the adaptive fuel tables Electrically Erasable and Programmable Read Only for later use in fuel calculations. Memory (EEPROM) to store the software code SHRTFT and LONGFT work together. If the HEGO required to control the powertrain. EEPROM can be indicates the engine is running rich the PCM will electrically erased and reprogrammed without correct the rich condition by moving SHRTFT in the removing the PCM from the vehicle. negative range (less fuel to correct for a rich combustion). If after a certain amount of time Operating Strategies SHRTFT is still compensating for a rich condition, the Adaptive Idle Air Control Strategy PCM adapts, moving LONGFT into the negative range to compensate and allows SHRTFT to return to The adaptive idle air control strategy is designed to a value near 0%. adjust the idle calibration to correct for wear and ageing of components. When engine conditions meet As the fuel control and air metering components age and vary from nominal values, the adaptive fuel the adaptive strategy-learning requirement, the strategy learns corrections while in closed-loop fuel strategy monitors the engine and determines the values required for ideal idle calibration. The adaptive control. The corrections are stored in a table that is a strategy stores these values within a table in memory function of engine speed and load. The tables reside for later reference. This table is used by the PCM for in Keep Alive Memory (KAM) and are used to correct fuel delivery during open and closed-loop operation. correction factors when controlling idle speed. The As changing conditions continue the individual cells adaptive idle table is stored in Keep Alive Memory are allowed to update for that speed load point. If, (KAM) and retains the learned values even after the during the adaptive process, both SHRTFT and engine is turned OFF. A Diagnostic Trouble Code LONGFT reach their high or low limit and can no (DTC) is output when the adaptive strategy has longer compensate, a Diagnostic Trouble Code (DTC) reached its limits. is reported. Whenever an idle air control system component is Whenever an injector or the fuel pressure regulator is renewed or cleaned, or a repair affecting idle is performed, the KAM should be reset to ensure the idle renewed, the Keep Alive Memory (KAM) should be reset to delete the existing adaptive values. The strategy does not use the previous adaptive values. system will generate new values for the replaced Re-training the PCM is described in the ‘Resetting component. Refer to the ‘Resetting The Powertrain The Powertrain Control Module’ section. Control Module’ section.
Control Software
Adaptive Fuel Control Strategy
The fuel control system uses the adaptive fuel table to compensate for normal variability of the fuel system components caused by wear or ageing. During closed-loop operation, if the fuel system is biased lean or rich, the adaptive fuel table will shift the fuel delivery calculations to remove the bias. The fuel system monitor has two means of adapting; Short Term Fuel Trim (SHRTFT) and Long Term Fuel Trim (LONGFT). In both cases the range is displayed as a percentage on the WDS tester. Short Term Fuel Trim (SHRTFT) is a parameter that indicates short-term fuel adjustments. The Powertrain Control Module (PCM) calculates the SHRTFT from Heated Exhaust Gas Oxygen Sensor (HEGO) inputs to maintain a 14.64:1 air-fuel ratio during closed-loop operation. A negative percentage means that the HEGO is indicating a rich mixture and the PCM is attempting to lean the mixture. Ideally, SHRTFT should remain near 0% but has the ability to adjust from between -25%to +35%. Long Term Fuel Trim (LONGFT) indicates long-term fuel adjustments. LONGFT is also referred to as adaptive fuel control. LONGFT is calculated by the PCM using information from the SHRTFT to maintain G98122 en
Failure Mode Effects Management Failure Mode Effects Management (FMEM) is a Powertrain Control Module (PCM) strategy that maintains vehicle operation if one or more of the major input sensors fail. When an input sensor is out of limits, an alternative strategy is initiated by the PCM. A fixed value is substituted for the faulty one. The PCM then continues to monitor the incorrect sensor input. If the sensor later operates within limits, the PCM returns to the normal engine operation. This mode allows the PCM to compensate for any of the four major sensor or sensor circuit failures by either inferring sensor values from remaining operational sensors or by using calibrated default values. T-MAP sensor failure TP sensor failure ECT sensor failure IAT sensor failure
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DESCRIPTION AND OPERATION (Continued) Speed Limiting Strategy
The road speed limit varies according to model. The engine speed is limited to approximately 6,000 RPM NOTE: In some cases, excessive engine or road (I6) and 5,300RPM (V8). On automatic transmission speed may be caused by loss of traction due to wheel vehicles, selecting the T-bar in NEUTRAL, “N” slippage on loose surfaces such as; sand, gravel, wet position limits the engine speed to approximately roads, mud, snow or ice. 3,000 RPM. Engine and vehicle speed limiting is Over-revving of the engine in park, neutral or while nominally controlled by reducing throttle opening to an driving may also cause the PCM to initiate its speed appropriate level. Speed overshoots beyond these limiting strategy. limits are controlled by momentarily disabling the fuel injectors. To prevent damage to the powertrain components, the Powertrain Control Module (PCM) reduces the Operating Modes throttle and disables the fuel injectors whenever the The mode used by the Powertrain Control Module engine or road speed reaches specific limits. Once (PCM) to control the fuel injection and ignition the speed is reduced to below the set limit, normal operation will resume. Diagnostic Trouble Code (DTC) systems depends on the operating conditions. P1270 is reported if the engine or road speed exceed Operating modes are shown in the diagram below, and are described in the following section. the limit. No repair is required. However, the DTC should be cleared and the driver informed of the engine and road speed limits applicable to the vehicle.
Normal Mode In normal operating mode the PCM controls the powertrain in all operating conditions. Normal mode commences when the engine is started, either cold or hot, then continues throughout the entire range of engine operation. Normal mode is made-up of two parts: Start-Up Mode and Run Mode. Each mode has further sub-modes that control the powertrain under specific conditions. If engine or vehicle speed exceeds the specified limit, the PCM will initiate the G98122 en
Engine Speed Limiting Strategy to prevent damage to the powertrain.
Start-Up Mode In Start-Up Mode the PCM starts the engine and manages the engine until it reaches Run Mode. The Start-Up strategy manages the transition between cranking, start-up, cold running and normal engine operation. The PCM uses several phases to reach Run mode. 01/2003 2003.0 BA Falcon
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DESCRIPTION AND OPERATION (Continued) Crank Mode Crank Mode provides the engine with the correct parameters for rapid, “no touch” start-up. Crank mode occurs when the ignition switch is moved to the START position and the engine speed is below 200 RPM. In Crank Mode the ignition timing is set to 10 …BTDC, and the injector pulse width is determined by the signal from the Cylinder Head Temperature Sensor (CHT). Whilst cranking, all the injectors fire simultaneously on the rising edge of every internal PIP signal. With each opening, each injector supplies 1/6th (I6) or 1/8th (V8) of the fuel required for one cycle. Once engine speed reaches approximately 240 RPM, the PCM will enter under-speed mode. To assist in clearing a flooded condition, the PCM disables the fuel injectors if the throttle is held wide open during Crank mode.
During rapid throttle opening, the PCM will provide acceleration enrichment by applying additional pulses to the injectors (increasing injection frequency).
Open Loop There are two basic modes of fuel injection control: Open Loop and Closed Loop. The PCM will operate in Open Loop depending on the driver’s throttle demand, measured by the Throttle Position Sensor (TP) or when the Heated Exhaust Gas Oxygen Sensor (HEGO) sensor has not reached operating temperature. The PCM will operate the engine in Open Loop mode during warm engine start-up, engine warm-up, part throttle mode and wide open throttle conditions. In Open Loop Mode, the PCM updates the adaptive fuel strategy tables stored in memory. The adaptive fuel strategy is described in the ‘Adaptive Fuel Strategy’ section.
Under-Speed Mode
Start-Up and Idle
Under-speed Mode assists the transition from Crank mode to Run mode and prevents stall. Under-speed mode occurs once the engine fires, indicated by an engine speed of more than 200 RPM. Once the engine fires, the PCM switches to sequential fuel injection, using Crankshaft Position Sensor (CKP) and the Camshaft Position Sensors (Cylinder Identification) (CMP) to synchronise the fuel injection and ignition timing. The injector pulse width is switched to use the values stored in the adaptive fuel strategy tables and trimmed by input from various sensors. Ignition timing is held at 10…BTDC and the Electronic Throttle Control (ETC) controlling the air intake to maintain idle speed. When operating in sequential injection mode, the PCM delivers the correct amount of fuel to the port above each intake valve, once every 720… of engine revolution. The PCM will maintain Under-speed mode until the engine speed reaches or exceeds 400 RPM, and until the engine reaches normal operating temperature, at which time the PCM will switch to Run mode.
During Crank Mode and under-speed mode the engine operates in Open Loop mode. The PCM varies the air-fuel ratio (fuel mixture) to maintain the engine speed or assist in warm-up. During cold start and warm-up the fuel mixture is enriched to promote easy starting and smooth idle. As the engine warms to normal operating temperature, the fuel injector pulse width is gradually reduced, bringing the mixture with the normal operating range. Once the engine is running at normal operating temperature the PCM will switch to Closed Loop Mode once the engine has been idling for approximately 60 seconds. The engine normally operates in Closed Loop Mode when the throttle is closed.
Run Mode The Powertrain Control Module (PCM) switches from Under-speed to Run mode when engine speed is greater than 400 RPM. Once the engine and Heated Exhaust Gas Oxygen Sensor HEGO) have reached normal operating temperature, the PCM operates in Run Mode and selects either Open or Closed Loop operation according to the throttle position and driving conditions. In addition to the control sequences for Under-speed mode, in Run mode the ignition timing is varied by the PCM to suit engine load and demand. The engine will operate in Open or Closed Loop mode according to the signal from the Throttle Position Sensor (TP) . G98122 en
Wide Open Throttle Wide Open Throttle (WOT) mode is used to enrich the mixture according to the driver’s throttle demand. Wide Open Throttle is indicated when the Throttle Position Sensor (TP) signal exceeds approximately 4 volts. Under these conditions, the Powertrain Control Module (PCM) enters Wide Open Throttle mode, enriching the mixture to obtain maximum performance. The EVAP Canister Purge Solenoid (EVAP) is turned OFF during WOT mode.
Closed Loop There are two basic modes of fuel injection control: Open Loop and Closed Loop. The PCM will operate in Closed Loop depending on the driver’s throttle demand, measured by the Throttle Position Sensor (TP) and when the engine and the Heated Exhaust Gas Oxygen Sensor (HEGO) sensor has reached operating temperature. Closed Loop Mode controls exhaust emissions of hydrocarbon (HC), carbon monoxide (CO) and 01/2003 2003.0 BA Falcon
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DESCRIPTION AND OPERATION (Continued) nitrogen oxide (NOX) gasses, while providing excellent fuel economy, optimal power and performance. The system regulates emissions and fuel economy by controlling the air-fuel ratio at the optimum level during different driving conditions. Within the closed loop system, deviations from the optimal air-fuel ratio are measured. The PCM monitors the signal from the HEGO sensor, then adjusts fuel-air mixture to maintain the correct ratio. The principle is based on measuring the residual oxygen content in the exhaust with a HEGO sensor. The oxygen content of the exhaust is a measure of the air-fuel ratio being provided to the engine. Where the air-fuel ratio deviates from the stoichiometric point of 14.64:1, the sensor voltage output changes sharply. The PCM evaluates the change and adjusts the injector pulse width to maintain the air fuel ratio within the stoichiometric point. In Closed Loop Mode, the air-fuel ratio is kept at the optimum for all driving conditions. This precise control of the fuel-air ratio allows a catalytic converter to be used in the exhaust system to burn-up the harmful particles and maintain the lowest exhaust emissions. After the HEGO has reached operating temperature, the PCM selects Closed Loop Mode during closed throttle or part throttle operation.
Module Programming Special Tool(s) Worldwide Diagnostic System (WDS) —
Principles of Operation
PCM modules must be programmed as part of the repair procedure. If this procedure is not followed the module will not function correctly and may set a number of DTCs, including P1639, which indicate that some necessary data has not been programmed into the module. PCMs should not be exchanged between vehicles. In most cases the parameter values or settings are unique to that vehicle, and if not set correctly will cause malfunctions or faults. WDS will automatically attempt to retrieve the module configuration information from all modules, and from a backup location in the PCM when the vehicle ID is carried out. If the module and the PCM do not contain correct information the diagnostic tool will display a list Closed Throttle Mode of items that you will need to manually configure. The diagnostic tool will program the module based on the Closed Throttle Mode occurs whenever there is no data you enter. demand on the throttle. This occurs during idle, coasting and deceleration. The PCM is able to detect There are three different methods that are used for module programming: a closed throttle condition by monitoring the signal from the Throttle Position Sensor (TP) . programmable module installation (PMI) The PCM controls idle speed, injector pulse width and module reprogramming ignition timing in Closed Throttle Mode to maintain the programmable parameters correct air-fuel ratio. Some modules do not support all three methods. Under periods of prolonged idle, the PCM will exit closed loop mode and hold the mixture slightly richer Programmable Module Installation (PMI) than the stoichiometric point to enhance idle quality. The programmable module installation (PMI) method During deceleration at engine speeds above is used when a new PCM module is installed on the approximately 2,000 RPM, the injectors are shut off. vehicle. The diagnostic tool automatically obtains any At engine speeds below 2,000 RPM, the fuel injectors available module option content information for the old are re-enabled. PCM during the vehicle ID routine that runs when the diagnostic tool is initially connected to the vehicle. It is Powertrain Control Hardware important that you connect WDS to the vehicle and allow it to identify the vehicle and obtain configuration Powertrain Control Module data prior to removing the old PCM. The centre of the PCM system is a microprocessor Module Programming controlled Powertrain Control Module (PCM). Depending on model, the PCM has 92 or 122 Calibration update is used to install a new calibration electrical connector pins through which it receives and strategy into a module. The updates are usually input from sensors and other electronic components. issued to fix a concern in the module software and Based on information received and programmed into would normally be addressed by another technical its memory, the PCM generates output signals to service bulletin (TSB). control the engine and transmission through various relays, solenoids and actuators.
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DESCRIPTION AND OPERATION (Continued) Vehicle Identification (VID) Block The PCMs contain a memory area called a vehicle identification (VID) block. The VID block is used to store powertrain configuration information. The PCM VID block contains the factory settings for the configurable modules unless the PCM is flashed with a new calibration in which case some PCM parameters may be modified.
General Procedures General Procedures Tire Size and Axle Ratio Using the WDS, select Module Configuration and Programming, then follow the screen prompts. Tire Size, Axle Ratio and Option Index Feature Falcon Tire Size 215/60R16 225/50R17 245/40R18 235/45R17 255/60R16 215/55R16 Axle Ratio 3.23 3.45 Speed Control Not Present Present Speed Source ABS Only Other Traction Control
Power and Ground Signals Vehicle Power TURN-ON
Keep Alive Power (KAPWR) when the ignition key is in the OFF position so that this information is not lost. KAPWR is routed through a fuse, situated in the instrument panel. If the PCM power supply is interrupted then the PCM may lose the "Keep Alive Memory" data. The KAM data retention time for the PCM depends on the module temperature during the period without power (e.g. battery disconnected). Vehicle Reference Voltage Vehicle Reference Voltage (VREF) is a positive 5.0 Volt output from the PCM used by 3-wire sensors. Signal Return The Signal Return (SIGRTN) is a dedicated ground circuit used by engine sensors. Power Ground Power Ground (PWRGND) is an electric ground return for the Powertrain Control Module (PCM).
Power Supply The PCM’s power relay voltage supply (VPWR) is controlled by the PCM’s power sustain (PWRSTN) output circuit. The PWRSTN output turns on immediately when the ignition is “ON” and maintains power to the PCM power relay for a further 1 second after key-off. This key-off delay enables the PCM to position the ETC throttle plate close during engine shut down.
Connections PCM Pin B9….……………………………… IGNSNS PCM Pin B37….…………………………… PWRSTN PCM Pin B34, B36…………………………… VPWR
Failure Mode
If the PCM does not appear to turn on (no engine crank and no PRNDL display when T-bar is moved), When the ignition switch is turned to the START or ascertain that the PCM is being correctly powered up. RUN positions, positive battery voltage (B+) is applied Failure in the IGNSNS and PWRSTN circuit or wiring to the PCM’s IGNSNS input. The PCM’s PWRSTN circuit will result in no power to the PCM. output grounds the VPWR relay. Since the other end Testing of the VPWR relay coil is wired to B+, this energises the coil and closes the contacts of the PCM power Refer to wiring diagrams 303-14-00/01 (I6) and relay. This supplies VPWR to the PCM, turning it on. 303-14-00/02 (V8). TURN-OFF 1. Ensure that the vehicle ignition system and the When the ignition switch is turned to the OFF or ACC instrument cluster is working correctly by positions, the PCM’s IGNSNS input reads 0V. The observing the warning lamps on the instrument PCM turns off the injectors and commands the cluster at the ignition “RUN” position. electronic throttle to the closed position. 2. Remove the PCM power relay. Approximately 1 second later, the PWRSTN output 3. While the ignition is in the RUN position, measure turns off and de-energises the PCM power relay. This the voltage of the 4 relay pin and ground. Ensure turns off VPWR to the PCM. that the contact pin 361A and the relay coil pin 513 measure 12V. Rectify wiring if required. Keep Alive Memory The PCM stores some information in Keep Alive Memory (KAM). The KAM remains powered through G98125 en
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DESCRIPTION AND OPERATION (Continued) 4. Measure the voltage of the relay coil pin 175E to CKP Sensor, I6 Engine the battery 12V. If this measures 12V, replace the relay with a known good unit and ensure that the relay clicks as it is inserted into the relay socket. If 12V is not measured, remove the PCM and probe the IGNSNS pin for 12V (ensure key is in the “RUN” position) and check the wiring continuity between PWRSTN and the relay coil pin 175E. Rectify wiring if required. 5. Reinstall the PCM power relay. 6. To confirm that the relay circuitry is operational, ground the PWRSTN pin and ensure that 12 V is present at the VPWR pins at the PCM. 7. Turn the key to the “OFF” position. 8. Plug the wiring harness to the PCM. The CKP signal is produced by an Inductive Pulse 9. Start the vehicle. Generator. Its main components are a reluctor If the PCM is still non-functional, replace the PCM. (toothed wheel on the harmonic balancer) and a pick-up coil. When the engine rotates, the toothed Inputs wheel passes the coil pick-up. The strength of the magnetic field changes from strong to weak, and Crankshaft Position Sensor (CKP) vice-versa, as the teeth rotate past the pick-up coil. The amplitude and frequency of the CKP signal is The Crankshaft Position (CKP) sensor is a magnetic proportional to engine speed. As engine speed transducer mounted on the front timing cover. A increases, so does the voltage amplitude. reluctor (tooth wheel) is mounted on the front of the crankshaft internal to the engine. The CKP is the primary sensor for ignition timing information used by CKP Sensor, V8 Engine the powertrain control module (PCM). The reluctor, or trigger wheel, has a total of 35 teeth, spaced 10 degrees apart with one empty space for a missing tooth. By monitoring the trigger wheel, the CKP indicates crankshaft position and speed information to the PCM. The PCM uses the CKP signal and the Camshaft Position Sensor (Cylinder Identification) (CMP) signal to determine the position of piston 1 within the cycle. From this, the PCM calculates spark and fuel injection timing. The CKP signal converts the crankshaft position to an electrical signal as shown below. The analogue AC voltage CKP signal is converted to a digital PIP signal; this signal is used internally by the Powertrain Control The reluctor has a missing tooth positioned before cylinder No. 1 reaches TDC. The PCM keeps count of Module (PCM), every rising edge signals that the crankshaft is 10° before TDC for a particular cylinder the teeth as they pass the pick-up, using the missing tooth as a reference point. The PCM can then s compression stroke. calculate the exact crankshaft position at any time. As the crankshaft rotates twice between each combustion stroke, he CKP uses a signal from the CMP sensor to determine the position within the cycle. On I6 engines the missing tooth is 60° BTDC, while on V8 engines it is 90° BTDC.
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DESCRIPTION AND OPERATION (Continued) Crankshaft Position Sensor
Failure Mode The PCM will not be able to determine the current engine speed or crankshaft position without the correct signal from the CKP sensor. If the CKP sensor fails, or an improper signal is received at the PCM, fuel pump operation, spark and fuel injection are suspended.
Testing Sensor Test
Item Description 1 Sensor Housing 2 Timing Cover 3 Soft Iron Core 4 Coil Winding 5 Toothed Wheel 6 Permanent Magnet The Coil On Plug (COP) Ignition System uses the CKP and CMP signals to generate a digital Profile Ignition Pick-Up (PIP) signal. The PIP signal produces a rising edge when the crankshaft is at 10º BTDC of any cylinder s compression stroke. The PCM uses the PIP signal to calculate spark timing.
Connections PCM Pin A30.................................... CKP Positive PCM Pin A41.................................... CKP Negative
Circuit
1. Disconnect the harness from the CKP connector. 2. Measure the resistance across the connector terminals using a suitable multimeter. Replace the solenoid if not within specification. CKP Resistance Specification 280 - 380 Ω 3. Check the harness for open circuits and short circuits.
Temperature and Manifold Absolute Pressure Sensor The I6 Temperature And Manifold Absolute Pressure (T-MAP) sensor is located on the inlet manifold, below the throttle body. The 5.4, 3V V8 T-MAP sensor is located on the inlet manifold, adjacent to cylinder 8. The 5.4L, 4V, V8 T-MAP sensor is located on the inlet manifold, adjacent to throttle body. The T-MAP sensor is a combined pressure and temperature sensor that measures both intake air temperature and manifold absolute pressure. The Powertrain Control Module (PCM) uses these signals for air mass calculations. The T-MAP sensor uses a Piezo resistive sensor and outputs a voltage proportional to the manifold absolute pressure. The voltage increases as manifold vacuum falls. A temperature-sensing element is incorporated into the T-MAP senor to measure the temperature of the intake air within the manifold. The temperature element employs a thermistor that is sensitive to temperature variations. The resistance of the thermistor decreases as the temperature rises. The sensor also measures barometric pressure when the ignition is moving from the ON to the START positions or whenever the throttle is wide open.
Connections PCM Pin A38……................…...............MAP Signal PCM Pin A25……................…...............IAT Signal PCM Pin A36.....Vehicle Reference Voltage (VREF) Diagnosis Diagnostic Trouble Codes (DTC) are retrieved through PCM Pin A32......................Signal Return (SIGRTN) the diagnostic connector using the WDS tester.
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DESCRIPTION AND OPERATION (Continued) Circuit
the operating range, or not present at all, the PCM will substitute a value proportional to the Throttle Position Sensor (TP) signal and adaptive values stored within its memory. The appropriate trouble code will be logged in memory for retrieval during Self-test mode.
Testing The T-MAP sensor is tested continuously during vehicle operation (cont.) and whenever Key On Engine Off (KOEO) or Key On Engine Running (KOER) tests are performed. Testing Manifold Absolute Pressure 1. Connect a WDS tester to the diagnostic connector. 2. Check the Manifold Absolute Pressure Sensor Diagnosis readout on the screen when the engine is at If the T-MAP sensor is damaged or faulty, but still normal operating temperatures. If the value is operating within the operating range, no fault code will within specification, then check for other be logged in memory and value substitution will not Diagnostic Trouble Codes (DTC) or component take place. Under these conditions the PCM will faults. increase the injector timing in an attempt to T-MAP Specification (Normally aspirated engines) compensate; causing difficult starting, rough running and poor fuel economy. Manifold Pressure Signal Voltage 15 kPa 0.3 Incorrect or modified valve timing, worn piston rings or an alteration in manifold vacuum (particularly at idle) 30 kPa 1.0 can cause a lower than normal vacuum. 50 kPa 2.0 Diagnostic Trouble Codes (DTC) are retrieved through 70 kPa 3.0 the diagnostic connector using the WDS tester. 90 kPa 4.0 DTCs applicable to the T-MAP are shown in the 105 kPa 4.8 following table. DTC P0106
Test Mode KOEO, Throttle
P0107
KOEO, KOER, Cont. KOEO, KOER, Cont. KOEO, KOER
P0108 P0112
P0112 P0113
KOEO, KOER, Cont. KOEO, KOER, Cont.
Condition MAP circuit range / performance problem MAP circuit low input MAP circuit high input Temperature circuit range / performance problem Temperature circuit low input. Temperature circuit high input.
Failure Mode The Failure Mode Effects Management (FMEM) strategy will, in most cases, ensure almost normal operation of the vehicle in the event of a T-MAP sensor fault or failure. If the T-MAP signal is not within G98127 en
T-MAP Specification (Turbo) Manifold Pressure Signal Voltage 10 kPa 0.3 50 kPa 1.0 100 kPa 1.9 150 kPa 2.8 200 kPa 3.7 3. Check the harness for the conditions described in ‘Fault Finding’ in this section if the displayed pressure is not within the expected range. Testing Temperature 1. Connect a WDS tester to the diagnostic connector. 2. Check the Intake Air Temperature readout on the screen when the engine is at room temperatures and at normal operating temperatures. If the value is within specification, then check for other Diagnostic Trouble Codes (DTC) or component faults.
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DESCRIPTION AND OPERATION (Continued) Sensor Test
CMP Sensor Location, V8 Engine
1. Disconnect the harness from the T-MAP connector. 2. Measure the resistance across the connector terminals using a suitable multimeter. Replace the sensor if not within specification. 3. Check the harness for open circuits and short circuits. T-MAP Resistance Specification Temperature Resistance, Voltage Nominal (±3º C.) Nominal 0º 5960 Ω 4.3 10º 3820 Ω 4.0 20º 2500 Ω 3.6 25º 2050 Ω 3.4 30º 1690 Ω 3.1 40º 1160 Ω 2.7 60º 580 Ω 1.8
Trimming Sensors
Connections PCM Pin 31.......................... CMP1 Sensor Positive PCM Pin 32......... CMP1 Sensor Negative/ SIGRTN PCM Pin 33.......................... CMP2 Sensor Positive PCM Pin 32.......... CM2 Sensor Negative/ SIGRTN
Circuit
Camshaft Position Sensor The 2 engine Camshaft Position Sensor (Cylinder Identification) (CMP) are Variable Reluctance Sensors. On the I6, the 2 sensors are located on both sides of the cylinder head rear. On the V8 the sensors are located on the two engine front covers. The sensors are used in conjunction with the CKP to synchronize the ignition system and the fuel injectors to the firing of each cylinder and to feedback the camshaft position for VCT control. The I6 engine uses a 3+1 tooth reluctor wheel on the inlet camshaft and another on the exhaust camshaft. The V8 engine uses a 4+1 tooth reluctor wheel for the camshaft on bank 1 and another on the camshaft on the bank 2. CMP Sensor Location, I6 Engine
Diagnosis Diagnostic Trouble Codes (DTC) are retrieved through the diagnostic connector using the WDS tester. DTCs applicable to the CMP sensor are shown in the following table.
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DTC P0320
Test Mode Cont.
P0340
Cont.
P1340
Cont.
Condition Ignition engine speed input circuit Malfunction CID1 Circuit malfunction CID2 Circuit malfunction
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DESCRIPTION AND OPERATION (Continued) Failure Mode
CHT Sensor Location, V8 Engine
Should a CMP signal be missing then the PCM will be unable to identify the camshaft position and VCT operation will be disabled. Should both CMP sensors or signal fail, the PCM will not operate the fuel injectors sequentially, and the engine may run rough.
Testing The CMP sensor is tested continuously during vehicle operation (cont.). 1. Connect a WDS tester to the diagnostic connector. 2. Check the Parameter Identification (PID) value of the CMP. If the PID value is within specification, then check for other Diagnostic Trouble Codes The CHT sensor measures the cylinder head (DTC) or component faults. temperature for the fail-safe cooling strategy. The PID Specification PCM also uses this sensor signal in conjunction with the Intake Air Temperature signal to determine fuel PID Description requirements and to inhibit activation of some features that only work properly when the engine is at normal CMPFM CMP Failure mode flag operating temperature. These feature include closed SYNC CMP and CKP signals are loop fuel control and canister purge control. synchronised The sensor employs a thermistor that is sensitive to temperature variations. The resistance of the Sensor Test thermistor decreases as the temperature rises. 1. Disconnect the harness from the CMP Sensor Connections connector. 2. Measure the resistance across the connector PCM Pin A45.................... CHT Temperature Signal terminals using a suitable multimeter. Replace the PCM Pin A32.....................Signal Return (SIGRTN) sesnor if not within specification. Circuit CMP Resistance Specification Ω 280 - 380 3. Check the harness for open circuits and short circuits.
Cylinder Head Temperature Sensor The Cylinder Head Temperature (CHT) sensor is mounted at the rear of the cylinder head on the I6 and between cylinder 3 & 4 on the cylinder head of the V8 engines. CHT Sensor Location, I6 Engine
Diagnosis The CHT sensor element is encased is brass for protection against corrosion. Diagnostic Trouble Codes (DTC) are retrieved through the diagnostic connector using the WDS tester. DTCs applicable to the CHT sensor are shown in the following table.
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DESCRIPTION AND OPERATION (Continued) DTC P0116
Test Mode KOEO, KOER
P0117
KOEO, KOER, Cont. KOEO, KOER, Cont.
P0118
Condition circuit range / performance problem circuit low input
Connections PCM Pin A13……..……………… …… EOT Signal PCM Pin A32…..…………. Signal Return (SIGRTN)
Circuit
circuit high input
Failure Mode (Petrol Engines only) The PCM has a Failure Mode Effects Management (FMEM) strategy mode that, in most cases, will ensure almost normal operation of the vehicle in the event of a CHT sensor fault or failure. If the CH sensor fails or produces an invalid signal, the PCM will not be able to sense the engine temperature. Under these conditions, the PCM will substitute the value from the Intake Air Temperature Sensor (IAT). During crank mode, the PCM will substitute the IAT signal for the missing CHT, since both sensors will have “soaked” to approximately the same temperature. When the engine is switched OFF, the whole engine will soak up heat from the cooling system and reach a similar temperature. When the engine starts, the PCM will infer a value for the CHT of approximately 80º C.
Testing
Diagnosis If the sensor is damaged or faulty, but still operating within the operating range, no fault code will be logged DTCs applicable to this sensor are shown on the following table. DTC 0196
Test Mode KOEO
Condition Engine Oil Temperature Sensor temperature is inconsistent with engine temperature
The CHT sensor is tested continuously during vehicle operation (cont.) and whenever Key On Engine Off (KOEO) or Key On Engine Running (KOER) tests are performed. 1. Connect a WDS tester to the diagnostic connector. 2. Check the Cylinder Head Temperature readout on the screen when the engine is at normal operating Failure Mode temperatures. The Failure Mode Effects Management (FMEM) strategy will, in most cases, ensure normal operation PID Description of the vehicle in the event of an EOT sensor failure. If Cylinder Head 85° to 100° the EOT signal is not within the normal operating Temperature range, or not present at all, the PCM will substitute a temperature value calculated from CHT. The Engine Oil Temperature Sensor appropriate trouble code will be logged in memory for The Engine Oil Temperature (EOT) sensor is located retrieval during Self-test mode. on the engine block directly above the engine oil filter Testing (I6) and on the engine sump on the V8 engine. The EOT sensor is tested continuously during vehicle The EOT sensor measures the temperature of the operation (cont.) and whenever Key On Engine Off engine oil for the variable cam timing strategy. (KOEO) or Key On Engine Running (KOER) test are A temperature-sensing element is incorporated into performed. the EOT sensor to measure the temperature of the engine oil within the engine. The temperature element Testing Engine Oil Temperature Sensor employs a thermistor that is sensitive to temperature 1. Disconnect the EOT sensor wire connector. variations. The resistance of the thermistor decreases 2. Measure the resistance across the connector as the temperature rises. terminals using a suitable multimeter. Replace the sensor if not within specification.
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DESCRIPTION AND OPERATION (Continued) EOT Resistance Specification Temperature Resistance, kΩ Voltage Nominal (±3º C.) 0º 96 4.5 20º 37 3.9 25º 30 3.8 30º 24 3.5 40º 16 3.1 60º 7.6 2.2 80º 3.9 1.4 90º 2.8 1.1 100º 2.1 0.9 3. Check the harness for open circuits and short circuits.
Engine Oil Pressure Sensor The I6 Engine Oil Pressure (EOP) switch is located on the engine block above and right of the engine oil filter. The V8 engine oil pressure switch is located on the adaptor between the oil filter and the engine block. The EOP sensor switches to ground at normal oil pressures and opens at low engine oil pressure. Engine oil pressure is not used for powertrain control but is transmitted on the CAN for display on the instrument cluster to warn the driver the oil pressure is low.
Connections
Testing 1. Connect a WDS tester to the diagnostic connector. 2. Check the Parameter Identification (PID) value of the EOP. PID Specification PID OIL_PRESS
Description Engine Oil Pressure
EOP sensor specification Oil Pressure Normal Low
PID Count Less than 50 Greater than 230
Resistance Less than 20 Ω Greater than 100kΩ
Boost Pressure Sensor, I6 Turbo Engine The Boost Pressure Sensor (BPS) is located on the aluminium duct between the intercooler and the throttle body inlet duct. The BPS measures the absolute pressure of the pre-throttle intake system for speed control and wastegate control strategy. The pressure-sensing element in the BPS employs a Piezo resistive sensor that outputs a voltage proportional to absolute pressure.
Connections
Circuit
PCM Pin C2…………………..Boost Pressure Signal PCM Pin C30… Vehicle Reference Voltage (VREF) PCM Pin B33..……………. Signal Return (SIGRTN)
EOP Sensor Circuit
Circuit
PCM Pin A26…………………… Pressure Signal
Failure Mode In the event the EOP sensor fail, the instrument cluster warning lamp will not indicate correctly. NOTE: The instrument cluster warning lamp glows regardless of EOP switch status when the engine is not running. G98128 en
Diagnosis DTCs applicable to this sensor are shown on the following table.
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DESCRIPTION AND OPERATION (Continued) DTC P0236
Test Mode Cont
P0237
KOERKOEO Cont
P0238
KOERKOEO Cont
Condition Boost Pressure Sensor Circuit /Range Performance Boost Pressure Sensor Circuit Low Boost Pressure Sensor Circuit High
Failure Mode The Failure Mode Effects Management (FMEM) strategy will, in most cases, ensure reasonable operation of the vehicle in the event of a BPS failure. If the BPS signal is not within the normal operating range, or not present at all, the PCM will substitute a default value for pre-throttle absolute pressure and use MAP for boost control. The appropriate trouble code will be logged in memory for retrieval during Self-test mode.
Testing
PID Specification PID
Description Turbo Boost Pressure
BPS Specification Absolute Pressure (kPa) Signal 10 50 100 150 200
Voltage (V) 0.3 1.0 1.9 2.8 3.7
TAS The TAS signal consists of two distinct frequencies, one for normal conditions and a higher frequency for impact event notification. The PCM recieves a continuous 12 Volt sqare wave signal on pin B6 while G98129 en
Failure Mode If the TAS signal is not within the normal operating frequency range or not present at all, the PCM sets a DTC in memory for retrieval during self test mode. The TAS is tested continuously during vehicle operation. DTC Test Mode Condition P1534 Cont TAS signal outside of allowable frequency range or not present
Feedback Inputs Heated Exhaust Gas Oxygen Sensor
The BPS is tested continuously during vehicle operation (cont.) and whenever Key On Engine Off (KOEO) or Key On Engine Running (KOER) tests are performed. Testing Boost Pressure Sensor 1. Connect a WDS tester to the diagnostic connector. 2. Check the Parameter Identification (PID) value of the BPS. If the PID value is within specification, (at key-on engine off it should be at atmospheric pressure or 1.8 to 2.2 volts) then check for other Diagnostic Trouble Code (DTC) or component faults
TURBO
the ignition is on, from the Restraint Control Module, RCM. During a non impact phase, the frequency read by the PM is 0.8Hz. In the event of an impact that is registered by the RCM, the RCM changes the frequency of the TAS signal to 5Hz for 5 cycles only. The PCM detects the change in frequency of the TAS signal and places on the CAN bus in message 427, bit 6, where circumstances allow it, a message to the BEM and the RCM has registered an impact and that the vehicles doors should be unlocked.
On I6 engines, there is one Heated Exhaust Gas Oxygen (HEGO) sensor mounted in the exhaust manifold above the engine pipe connection flange. On V8 engines, there are two HEGO sensors, one for each bank, mounted in the engine pipe just below the exhaust manifold. The sensor has a built in heating element to bring the sensor to its operating temperature quickly and to prevent it from dropping below its operating temperature during periods of extended engine idle. The PCM uses the HEGO sensor signal to adjust the fuel injector pulse width to maintain the air-fuel ratio at stoichiometry. The PCM compares the amount of fuel that is being used in closed loop operation to the amount of fuel it predicts would be required if there was no HEGO signal. If there is a difference, the PCM adjusts its ‘Open Loop’ (ie. no feedback) predicted values to reflect the actual requirements of the engine as signaled by the HEGO sensor. These corrections are stored in the KAM for use when the system next operates in the open loop mode, ie. in cold drive conditions, or wide open throttle operation. This adaptive learning enables the PCM to precisely control the air-fuel ratio and compensate for component wear and injector fouling. It does this by having one of its electrodes exposed to the exhaust gas and the other electrode exposed to normal air. The difference in the level of oxygen produces a voltage across the electrodes. The platinum electrodes of the Zirconia element typically operate only above 350ºC so the HEGO sensor has heaters permanently switched.
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DESCRIPTION AND OPERATION (Continued) HEGO Sensor, Typical.
Closed Loop Process
The HEGO detects the amount of unburnt oxygen in the exhaust gasses as a measure of the air-fuel ratio. Since a single sensor is used for a bank of cylinders the signal represents the average air-fuel ratio. In Closed Loop Mode the HEGO sensor provides the PCM with a signal indicating whether the engine is running ‘rich’ or ‘lean’.
Item 1 2 3 4 5 6
HEGO Sensor Operation
Description Ideal ratio Oxygen Sensor Signal Lean Increase Pulse Time Ideal Ratio Oxygen Sensor Signal Rich Reduce Pulse Time
Connections PCM Pin B8………..................... HEGO11(I6, V8) PCM Pin B26……………............ HEGO11(V8) PCM Pin B33.................…..Signal Return (SIGRTN)
Circuit
The PCM uses the HEGO signals to maintain the correct air-fuel ratio during closed loop mode by varying the fuel injector pulse width. In open loop mode the HEGO signal is disregarded by the PCM. The PCM also stores values from the sensor in a look-up table as part of its adaptive strategy. See the ‘Operating Modes’ section.
Diagnosis Diagnostic Trouble Codes (DTC) are retrieved through the diagnostic connector using the WDS tester. DTCs applicable to the HEGO sensors are shown in the following table.
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DESCRIPTION AND OPERATION (Continued) DTC P0171
Test Mode KOER
P0172
KOER
P0174
KOER
P0175
KOER
P1128
Cont
Condition HEGO Sensor, I6 Turbo I6, bank 1-V8Fuel System too lean I6, bank 1-V8Fuel System too rich V8 bank 2 - Fuel System too lean V8 bank 2- Fuel System too rich Connection for Bank1 and Bank2 HEGO sensors Failure Mode swapped.
HEGO Sensor, I6 Engines
In the event the HEGO fails, the PCM is not able to operate in Closed Loop Mode. In Open Loop Mode the PCM will use values stored in its look-up tables. These values are stored from the adaptive strategy. As the strategy constantly updates the table, the PCM should be able to maintain a suitable air-fuel ratio with a faulty HEGO. A trouble code for HEGO failure is only logged when an Key On Engine Running (KOER) self-test is performed.
Testing
HEGO Sensor, V8 Engines
The HEGO sensors are tested continuously during vehicle operation (cont.) and whenever Key On Engine Off (KOEO) or Key On Engine Running (KOER) tests are performed. 1. Connect a WDS tester to the diagnostic connector. 2. Check the Parameter Identification (PID) value of the HEGO sensor. If the PID value is within specification, then check for other Diagnostic Trouble Codes (DTC) or component faults. PID Specification PID O2S1 O2S21 O2S11FM O2S21FM
Item 1 2
Description HEGO Sensor (LHS only) HEGO Sensor (LHS & RHS)
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Bank Bank Bank Bank
Description 1 HEGO Voltage 2 HEGO Voltage (V8) 1 HEGO Failure 2 HEGO Failure
Sensor Test 1. Disconnect the harness from the HEGO sensor connector. 2. Measure the Heater element resistance across the heater wire terminals using a suitable multimeter. HEGO Sensor Heater Resistance Specification 01/2003 2003.0 BA Falcon
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DESCRIPTION AND OPERATION (Continued) 4-8 Ω @20º C. 3. Reconnect the HEGO harness and start the engine. With the throttle held open to maintain approximately 2,000 RPM, The HEGO voltage should be switching between High and Low at least once per second; and the rich/lean periods should be reasonably even. If this does not occur and the voltage remains constant, either High or Low, open and close the throttle rapidly and look for a change in voltage. If the voltage changes with throttle movement, it indicates that the sensor is operating correctly but the PCM, is not able to control the air-fuel ratio. 4. Check the harness for open circuits and short circuits.
Connections PCM Pin A29.......................Knock Sensor Positive PCM Pin A40.......................Knock Sensor Negative
Circuit
HEGO Sensor Signal Voltage Specification
Diagnosis Diagnostic Trouble Codes (DTC) are retrieved through the diagnostic connector using the WDS tester. DTC applicable to the KS sensor is shown in the following table. DTC P0325
Knock Sensor Sensor Description Vehicles fitted with the I6 engine have a linear Knock Sensor (KS) located on the left hand side of the cylinder block, adjacent to cylinder No. 5 to detect pre-ignition detonation (engine knock) within the cylinders. The system detects engine knock by comparing engine noise at crank angles when cylinder pressure of the combustion fuel is highest with engine noise at quieter portions of the engine cycle. If the noise is louder, indicating knock, the Powertrain Control Module (PCM) retards ignition timing until knocking ceases. The KS is used as a feed-back signal to control ignition timing. The KS is a piezo-electric accelerometer comprised of a piezo crystal mounted in a ceramic case. Whenever the KS detects knock the PCM retards the ignition timing until the knock ceases. The PCM then advances the ignition timing in small increments until knock is again detected. The cycle of retarding and advancing the ignition is continuous in Closed Loop Mode, and maintains the ignition at the optimum spark advance for the fuel quality. The PCM uses the KS to automatically adjust the engine tune for low octane unleaded fuel or higher performance Premium unleaded fuel. G98129 en
Test Mode Cont.
Condition Sensor or circuit malfunction
Failure Mode Should the KS fail, or produce the incorrect signal, the PCM will log a fault code, then revert to minimum ignition advance. The vehicle will otherwise operate as normal, possibly with marginally less performance, and some engine knock may occur under certain conditions.
Testing Testing Knock Sensor 1. Disconnect the knock sensor wire connector. 2. Measure the resistance across the knock sensor connector terminals using a suitable multimeter. Replace the sensor if not within specification. KS Resistance Specification 4 - 6 mΩ 3. Check the harness for open circuits and short circuits.
Feed Forward Inputs Transmission Range Sensor (TRS-A1) The automatic Transmission Range Sensor A1 (TRS-A1) , is incorporated in the inhibitor switch mounted on the side of the transmission case. The TRS-A1 sensor reports the current gear lever 01/2003 2003.0 BA Falcon
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DESCRIPTION AND OPERATION (Continued) selector position to the Powertrain Control Module (PCM). The TRS-A1 signal is used by the PCM for automatic transmission control operations and by the engine management system to predict an impending increase in engine load. The TRS-A1 is a rheostat that, with the reference voltage, produces a voltage proportional to the gear lever selector position. The TRS-A1 is a Feed Forward sensor that produces a signal change at the PCM before the actual event takes place. For example, when moving the gear lever selector from shifting from Park to reverse, the PCM receives the changed signal prior to the engine load actually increasing. This allows the PCM sufficient time to open the Idle Air Control Valve (IAC) valve and increase the fuel injector pulse width to compensate for the additional load. The Key On Engine Running (KOER) self-test is disabled whenever the gear selector is in any gear. KOER self-test is only operational in either the Park or Neutral positions. Electrical Description The TRS-A1 is series of stepped resistors that will drop Vehicle Reference Voltage (VREF) in seven distinct steps from Park down to Manual.
Connections PCM Pin B41.................................. TRS-A1 Sensor PCM Pin 45.....................................................VREF PCM Pin B33.....................Signal Return (SIGRTN)
Circuit
DTCs applicable to the TRS-A1 sensor are shown in the following table. DTC P1705
Test Mode KOEO
P0707
KOEO, Cont.
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Condition Not in Park or Neutral during self-test (Auto) Circuit low input
DTC P0708
Test Mode KOEO, Cont.
Condition Circuit high input
Failure Mode In the event the TRS-A1 fails, or the signal is outside the expected range, the PCM will log a fault code, then assume the gear lever selector is in Drive for the purpose of setting the idle speed.
Testing The TRS-A1 sensor is tested continuously during vehicle operation (cont.) and whenever a Key On Engine Off (KOEO) test is performed. 1. Connect a WDS tester to the diagnostic connector. 2. Check the Parameter Identification (PID) value of the TR sensor. If the PID value is within specification, then check for other Diagnostic Trouble Codes (DTC) or component faults. PID Specification PID TR / PRNDL
Description Units Park/Neutral Position Position (PRNDL) sensor
Sensor Test 1. Disconnect the harness from the TRS-A1 sensor connector. 2. Measure the resistance across the TRS-A1 sensor connector terminals using a suitable multimeter. Replace the TRS-A1 sensor if not within specification. 3. Check the harness for open circuits and short circuits. TRS-A1 Resistance Specification Shift Lever Position Resistance Nominal Park (P) 17,300 -20,300 Ω Reverse (R) 10,900 -11,850 Ω Neutral (N) 6,500 -7,600 Ω Drive (D) 4,300 - 5,000 Ω 3rd Gear (3) 2,900 -3,400 Ω 2nd Gear (2) 1,850 -2,200 Ω 1st Gear (1) 1,050 -1,270 Ω
Transmission Range Sensor (TRS-A2) The electronic sport shift manual, tip-up and tip-down position is sensed by 3 Hall-effect switches mounted on a printed circuit board in the T-bar console. The sport shift lever contains a magnet in its base that activates the appropriate Hall-effect switch in different shift position. The switches are resistively multiplexed
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DESCRIPTION AND OPERATION (Continued) together and are read as a voltage by the PCM on the TRS-A2 input.
Connections PCM Pin B43................................... TRS-A2 Sensor PCM Pin B45................... ...............................VREF PCM Pin B33......................Signal Return (SIGRTN)
Circuit
Pin-out 2 and 3
Sport Shift Voltage ESS Lever in 2.6V - 3.3V “Manual” Position 2 and 3 ESS Lever in 1.5V - 2.0V “Tip +” Position 2 and 3 ESS Lever in 0.5V - 1.3V “Tip -” Position Pin-out numbers are marked on the back of the white ESS connector
Power Steering Pressure Switch NOTE: This circuit must not remain by-passed or bridged, since steering load applied when cornering may stall the engine and cause loss of steering control. The Power Steering Pressure Switch (PSP) which is a pressure sensitive switch that detects when pressure within the power steering system reaches a specified level. To prevent engine stall and maintain idle quality during parking manoeuvres the PCM boosts the engine idle speed by approximately 100 RPM. The PSP switch is a normally closed pressure switch. Failure Mode Under no load conditions the switch connects the PSP In the event the TRS-A2 fails, or the signal is outside pin B31 to Signal Return (SIGRTN). When the power the expected range, the PCM will log a fault code, and steering load is high, the PSP opens causing 5 volts then assume the gear lever selector is in the to be detected at PCM Pin. automatic plane.
Connections
Testing
PCM Pin B31..........................................PSP Signal The TRS-A2 sensor is tested continuously during PCM Pin B33......................Signal Return (SIGRTN) vehicle operation and whenever Key On Engine Off (KOEO) or Key On Engine Running (KOER) tests are Circuit performed. Testing TRSA-2 Sensor 1. Connect a WDS tested to the diagnostic connector. 2. Check the Parameter Identification (PID) value of the sensor. If the PID value is within specification, then check for other Diagnostic Trouble Code (DTC) or component faults PID Specification PID GLP_D Manual TP+ TPPin-out 1 and 2 2 and 3
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Description ESS Lever in Auto Position ESS Lever in “Manual” Position ESS Lever in “Tip +” Position ESS Lever in “Tip -” Position Sport Shift All positions ESS Lever in Auto Position
Voltage 4.8V - 5.2V 3.7V - 4.2V
Diagnosis Diagnostic Trouble Codes (DTC) are retrieved through the diagnostic connector using the WDS tester. DTCs applicable to the PSP switch are shown in the following table.
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DESCRIPTION AND OPERATION (Continued) DTC P1650 P1651
Test Mode KOEO KOER
Condition Failure did not switch
Testing The PSP switch is tested whenever Key On Engine Off (KOEO) or Key On Engine Running (KOER) tests are performed. When a P1650 and a P1651 DTC is reported after a KOEO and KOER test, check the PSP for correct operation.
Speed control operation Vehicle speed limiting. Engine fan control NOTE: A 19-tooth gear is used on the OSS for all axle and tyre size variants. Alternative OSS gears will result in vehicle speed calculation errors and must not be used. Vehicle speed data is transmitted on the CAN line for the speedometer, odometer, trip computer and air-conditioner functions.
Switch Test
Connections
1. Disconnect the PSP connector harness. 2. Using a multimeter with suitable connectors, measure the resistance if the PSP Switch. 3. Start and run the engine. 4. Actuate the PSP switch by turning the steering wheel and releasing. Ensure that the switch resistance conforms to specifications. If the switch is within specifications, check the wiring for open and short circuits.
PCM Pin B7…………….Vehicle Speed Signal VSS PCM Pin B45…. Vehicle Reference Voltage (VREF) PCM Pin B33..……………. Signal Return (SIGRTN)
Steering Steering turned Steering released
VSS Installation
PSP Resistance PSP voltage Greater than 4.5 - 5.2V 10kΩ Less than 10Ω 0.0 - 1.0V
Vehicle Speed The PCM determines the vehicle speed from 3 sources depending on vehicle option. Vehicle speed source, tyre rotations per mile, axle ratio is Diagnosis programmed into the PCM using the WDS tester (see If the sensor is damaged or faulty, but still operating ‘Module Configuration’ in this section). within the operating range, no fault code will be Option VSS input Signal Type logged ABS Connected to Square wave DTCs applicable to this sensor are shown on the ABS speed frequency signal following table. output pin (0V to 5 V) DTC Test Mode Condition Traction Control Not used CAN signal P0500 KOEO Cont Missing/erratic None Connected to Square wave speed signal output shaft frequency signal from ABS, ASR speed sensor in (0V to 5V) or OSS the transmission housing
Failure Mode
Output Shaft Speed (OSS) Sensor The output shaft speed sensor is used in vehicles without the ABS or traction controlled option. It is a gear driven Hall effect sensor mounted in the transmission extension. The output signal frequency is proportional the output shaft speed. The PCM calculates vehicle speed using this signal and the programmed axle ratio and tyre rotation per mile. The PCM uses vehicle speed signal to control: Automatic transmission gear shifts G98130 en
Failure of the vehicle speed sensor signal source will result in normal engine running but no speedometer readout, no speed control operation. Automatic transmission will default to 3rd gear when DRIVE is selected.
Testing 1. Check that the instrument cluster is working correctly by observing warning lamps, tachometer, fuel and temperature gauges. Rectify before continuing. 01/2003 2003.0 BA Falcon
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DESCRIPTION AND OPERATION (Continued) 2. Where ABS and traction control is fitted, ensure Circuit that the warning lights are not illuminated. Rectify before continuing. 3. Connect a WDS tester to the diagnostic connector. 4. Check the check the Output Shaft Speed and the Vehicle Speed on the WDS screen. If these reads 0, check the electrical connections between the PCM and the vehicle speed source. 5. If vehicle speed is inaccurate, reconfigure the PCM VID block as detailed in the Module Configuration section. PID Specification PID AXLE TIRE SIZE
Description Axle Ratio used by the PCM Tire size used by the PCM - revs per mile
Vehicle Speed Output (VSOUT) The PCM transmits a 12V square wave vehicle speed output signal on the VSOUT pin for the satellite navigation system. This pin may be used to drive other devices such as taximeters. The recommended load for this pin is 4.7 to 15 k Ω to ground.
Connections PCM Pin B7…………………………………. VSOUT
Electronic Throttle Control Inputs Pedal Position Sensor A triple output Throttle Position Sensor (TPS) is used to provide pedal position signal to the PCM. It has an 8-way electrical connector providing 3 independent potentiometer signals.
Connections PCM PCM PCM PCM PCM PCM PCM
Pin B17………….……………… PPS1 Signal Pin B18………….……………… PPS2 Signal Pin B19………….……………… PPS3 Signal Pin B20………….…………..…… PPSVREF1 Pin B28………….…………….…. PPSVREF2 Pin B21…………………………….PPSRTN1 Pin B29……………………………. PPSRTN2
Diagnosis DTCs applicable to this sensor are shown on the following table. DTC P2122
Test Mode KOEO Cont
P2123
KOEO Cont
P2124
KOEO Cont
P2138 P2139 P2127
KOEO Cont KOEO Cont
P2128
KOEO Cont
P2129
KOEO Cont
P2138 P2140 P2132
KOEO Cont KOEO Cont
P2133
KOEO Cont
P2134
KOEO Cont
P2139 P2140 P2110
KOEO Cont KOEO Cont
Condition PPS1 fails - Out-of-range low PPS1 fails - Out-of-range high PPS1 fails - intermittent, Out-of-range PPS1 fails - In-range (one sensor disagrees) PPS2 fails - Out-of-range low PPS2 fails - Out-of-range high PPS2 fails - intermittent, Out-of-range PPS2 fails - In-range (one sensor disagrees) PPS3 fails - Out-of-range low PPS3 fails - Out-of-range high PPS3 fails - intermittent, Out-of-range PPS3 fails - In-range (one sensor disagrees) Two or three PPS fail (pedal position > or = no pedal)
Failure Mode The Failure Mode Effects Management (FMEM) strategy will, in most cases, ensure normal operation of the vehicle if one of the PPS potentiometers fail. The ETC warning light will flash. If two or more sensors fail, the ETC will default to limp home part G98130 en
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DESCRIPTION AND OPERATION (Continued) throttle mode. The appropriate trouble code will be logged in memory for retrieval during Self-test mode.
Circuit
Testing The PPS sensor is tested continuously during vehicle operation (cont.) and whenever Key On Engine Off (KOEO) or Key On Engine Running (KOER) test are performed. Testing Pedal Position Sensor 1. Connect a WDS tester to the diagnostic connector. 2. Check the Parameter Identification (PID) value of the PPS. If the PID value is within specification, then check for other Diagnostic Trouble Code (DTC) or component faults PID Specification PID APP_F APP_MODE APP1
APP2
APP3
Description Accelerator Pedal Position Status Pedal position mode: -1=pedal not depressed, 0=pedal partially depressed, 1=pedal fully depressed Voltage of the Pedal Position Sensor number 1 (PPS1) at the PCM connector pin, relative to signal return (SIGRTN) Voltage of the Pedal Position Sensor number 2 (PPS2) at the PCM connector pin, relative to signal return (SIGRTN) Voltage of the Pedal Position Sensor number 3 (PPS3) at the PCM connector pin, relative to signal return (SIGRTN)
Throttle Position Sensor A dual (opposing slope) output Throttle Position Sensor (TPS) is used to provide feedback to the Powertrain Control Module (PCM). It has a four way electrical connector providing 5v supply, a return and two output signals. The TPS is replaceable in service and simply bolts onto the ETB in one orientation only by way of a locating pin on the TPS.
Diagnosis DTCs applicable to this sensor are shown on the following table DTC P0122
Test Mode KOEO Cont.
P0123
KOEO Cont.
P0124
KOEO Cont.
P0221
KOEO Cont.
P0222
KOEO Cont.
P0223
KOEO Cont.
P0224
KOEO Cont.
P1124
KOEO,KOER
P2111
Cont.
P2112
Cont.
P2135
KOEO Cont.
P0124 P0224 P0124 P0224
KOEO Cont.
Connections PCM PCM PCM PCM
Pin A44…………………………… TP1 Signal Pin A16…………………………… TP2 Signal Pin A21………………………..…. TPS_VREF Pin A22……………………………. TPS_RTN
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KOEO Cont.
Condition TP1-NS fails Out-of-range low TP1-NS fails Out-of-range high TP1-NS fails intermittent, Out-of-range TP2-PS fails Out-of-range at commanded settings TP2-PS fails Out-of-range low TP2-PS fails Out-of-range high TP2-PS fails intermittent, Out-of-range Throttle Out Of Self-test Range Throttle Actuator Control System - Higher throttle opening than driver demand Throttle Actuator Control System - Lower throttle opening than driver demand Sensor disagreement, in range Intermittent sensor disagreement, in range Both TPS fail Out-of-range intermittent
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DESCRIPTION AND OPERATION (Continued) Failure Mode
Connections
The Failure Mode Effects Management (FMEM) strategy will, in most cases, ensure normal operation of the vehicle if one of the TPS potentiometers fails. The ETC warning light will flash. If both sensors fail, the ETC will default to limp home part throttle mode. The appropriate trouble code will be logged in memory for retrieval during Self-test mode.
PCM Pin B5……………………………………. CES
Circuit
Testing The TPS sensor is tested continuously during vehicle operation (cont.) and whenever Key On Engine Off (KOEO) or Key On Engine Running (KOER) test are performed. Testing Throttle Position Sensor 1. Connect a WDS tester to the diagnostic connector. 2. Check the Parameter Identification (PID) value of the TPS. If the PID value is within specification, then check for other Diagnostic Trouble Code (DTC) or component faults. PID Specification PID ETC_ACT TP1
TP2
Description The actual throttle angle in degrees as determined from the throttle sensor inputs. Voltage of the Electronic Throttle Control (ETC) Throttle Position Sensor number 1 (TPS1) at the PCM connector pin, relative to signal return (TPS_RTN) Voltage of the Electronic Throttle Control (ETC) Throttle Position Sensor number 2 (TPS2) at the PCM connector pin, relative to signal return (TPS_RTN)
Clutch Engagement Switch, Manual Transmission The PCM monitors clutch engagement using the Clutch Engagement Switch (CES). The CES is mounted on the pedal assembly and is actuated by the clutch pedal in the released position. When the clutch is applied, the PCM cancels speed control operation.
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Failure Mode Failure of clutch switch in the open circuit position will inhibit speed control operation. A shorted CES will result in engine flaring to a high engine rpm when the clutch pedal is depressed with the speed control engaged.
Testing Testing Clutch Engagement Switch 1. Connect a WDS tester to the diagnostic connector. 2. Check the Parameter Identification (PID) value of the CES while depressing and releasing the clutch pedal. PID CPP
Description Clutch Pedal Depressed
Brake Switches The PCM monitors the brake pedal position using two switches - the Brake On-Off (BOO) switch and the Redundant Brake Switch (RBS). Both switches are mounted on the pedal assembly and are directly actuated by the brake pedal. When the brakes are applied, the PCM cancels speed control operation. BOO is a normally-open switch that switches 12V to the PCM’s BOO input when the brakes are applied. RBS is a normally-closed switch that switches 12V to the PCM’s RBS input when the brakes are released. BOO is designed to switch to 12V before RBS breaks the circuit to 12V. If the RBS 12V circuit breaks without the BOO switching to 12V, the speed control cannot be engaged or re-engaged until the next key-on.
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DESCRIPTION AND OPERATION (Continued) Connections PCM Pin B25……………………………………. BOO PCM Pin B32……………………………………. RBS
gear selection. When 12V is sensed on RGS, engine torque is limited to a suitable value for reverse gear operation. The switch status is transmitted on the CAN for the optional reverse parking sensor.
Circuit
Connections PCM Pin B30…………………………………. RGS
Diagnosis Ensure that the reverse lamps operate correctly. Rectify before continuing. DTCs applicable to this sensor are shown on the following table. DTC P0812
Test Mode KOEO Cont
Condition Reverse switch or circuit faulty
Failure Mode Diagnosis Ensure that the brake lamps operate correctly before continuing. DTCs applicable to this sensor are shown on the following table.
The ETC will implement reverse gear torque limiting under the following conditions: RGS switch short circuit fault; RGS wire open circuit; Both reverse lamps are faulty.
Testing
Failure of either brake switch will inhibit speed control operation.
Testing Reverse Gear Switch 1. Ensure that the reverse lamps operate correctly. Rectify before continuing. 2. Connect a WDS tester to the diagnostic connector. 3. Check the Parameter Identification (PID) value of TRANS_GEAR while selecting reverse gear.
Testing
PID Specification
DTC P1572
Test Mode KOEO Cont.
Condition Brake switch circuit faulty
Failure Mode
The BOO and RBS switches are tested continuously during vehicle operation (cont.) and whenever Key On Engine Off (KOEO) or Key On Engine Running (KOER) test are performed. Testing Brake Pedal Switches 1. Connect a WDS tester to the diagnostic connector. 2. Check the Brake ON/OFF status on the WDS screen and the Parameter Identification (PID) value of the BPA. If these are correct, check for other Diagnostic Trouble Code (DTC) or component faults. PID Specification PID BPA
PID TRANS_GEAR
Description Transmission Gear state
Speed Control Range Switch Assembly The Speed Control Range Switch Assembly (SCRSA) is located right side of the steering wheel airbag. The switches are resistively multiplexed and connect to the steering wheel clock spring wiring to the PCM. Each switch connects a specific resistor value to ground and produces a distinctive voltage level signal at the SCRSA input. The PCM uses the SCRSA signal to determine driver command of the speed control system.
Description Redundant Brake Pedal Switch Status
Reverse Gear Switch The PCM monitors the reverse gear switch (RGS) on manual transmission vehicles to check for reverse G98131 en
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DESCRIPTION AND OPERATION (Continued) Connections
Switch Specification
PCM Pin B16…………………………………SCRSA PCM Pin B33…………………………………SIGRTN
Switch
Circuit
Default (none) RES COAST SET + SET CRUISE
Voltage Range (V) 4.5 - 4.8 4.0 - 4.3 3.2 - 3.8 2.1 - 3.0 0 - 0.4
Resistance (± 5% Ω) 4,330 1,630 810 420 0
Air Conditioner Inputs Refer to Section 412-03.
Air Conditioner Demand The Powertrain Control Module (PCM) controls operation of the air conditioning compressor clutch. When an Air Conditioner Demand (ACD) signal is received by the PCM on the CAN, it energises the ACR to engage the air conditioning compressor.
Failure Mode In the event the SCRSA fails, or the signal is outside the expected range, the PCM will log a fault code. Some or all of the speed control functions will not be available.
Testing
Air Conditioner Relay The Powertrain Control Module (PCM) energises the Air Conditioning Relay (ACR) whenever air conditioning is required. The air conditioning relay then energises the air conditioning compressor clutch.
Connections
The SCRSA is tested continuously during vehicle operation (CONT) and whenever a Key On Engine Off PCM Pin B2.......................................... ACR Signal (KOEO) test is performed. Circuit 1. Connect a WDS tester to the diagnostic connector. 2. Monitor the speed control switch status on the WDS screen 3. Operate the speed control switches in sequence. 4. Check the Parameter Identification (PID) value for each of the status as the button is pressed. If the PID value is within specification, then check for other Diagnostic Trouble Code (DTC) or component faults PID Specification PID SCCS_NULL
Description Speed Control Range Switch in “NULL” state SCCS_CANCEL Speed Control Range Switch “RESUME / CANCEL” SC_ON Speed Control Range Switch “ON / OFF” SCCS_TAP_UP Speed Control Range Switch “SET +” SCCS_TAP_DN Speed Control Range Switch “SET -”
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Diagnosis Diagnostic Trouble Codes (DTC) are retrieved through the diagnostic connector using the WDS tester. Fault Finding Tables for DTCs are in the ‘Diagnosis’ section. DTCs applicable to the ACR relay are shown in the following table.
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DESCRIPTION AND OPERATION (Continued) DTC P1465 P1463
Test Mode KOEO, Cont. Cont.
Condition Circuit malfunction Insufficient pressure change when AC compressor commanded on.
DTC P0532
Test Mode KOEO, Cont.
P0533
KOEO, Cont.
P0534
Cont.
The AC relay is tested continuously during vehicle operation (cont.) and whenever a Key On Engine Off (KOEO) test is performed.
P1463
Cont.
Testing
Relay Test 1. Remove the AC relay from its socket in the relay/fuse box adjacent to the battery. 2. Check the condition of the relay 3. Check the harness for open circuits and short circuits.
Air Conditioner Pressure Transducer The Air Conditioner Pressure Transducer (ACPT) sensor is located on the compressor discharge pipe. The Powertrain Control Module (PCM) uses this signal to monitor the air conditioner discharge pressure and actuate the air conditioning and cooling strategies accordingly.
Connections PCM Pin B15...................................... ACPT Signal PCM Pin A36.....Vehicle Reference Voltage (VREF) PCM Pin A32......................Signal Return (SIGRTN)
Circuit
Condition ACPT sensor circuit low input ACPT sensor circuit high input Air conditioning refrigerant charge loss or A/C system blockage Insufficient pressure change when AC compressor commanded on.
Testing The ACPT sensor is tested continuously during vehicle operation (cont.) and whenever a Key On Engine Off (KOEO) test is performed. 1. Connect a WDS tester to the diagnostic connector. 2. Start and run the engine. Engage the air-conditioning. 3. Check the Parameter Identification (PID) value of the ACPT. If the PID value is within specification, then check for other Diagnostic Trouble Codes (DTC) or component faults. PID Specification PID ACP
Description A/C pressure
4. Check the harness for open circuits and short circuits.
Transmission Inputs Transmission Fluid Temperature Sensor
Diagnosis Diagnostic Trouble Codes (DTC) are retrieved through the diagnostic connector using the WDS tester. Fault Finding Tables for DTCs are in the ‘Diagnosis’ section.
The Transmission Fluid Temperature (TFT) sensor is located in a harness within the Automatic Transmission oil pan. The TFT measures the temperature of the oil in the automatic transmission sump. The Powertrain Control Module (PCM) uses the TFT signal to vary shift pressures in response to the transmission oil temperature for consistent and smooth shifts. It is also used to indicate transmission overheat conditions. The TFT sensor uses a thermistor that is sensitive to temperature variations. The resistance of the thermistor decreases as the temperature of the transmission oil increases.
DTCs applicable to the ACPT sensor are shown in the following table.
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DESCRIPTION AND OPERATION (Continued) Connections
Output Actuators
PCM Pin A37......................................... TFT Signal PCM Pin A32......................Signal Return (SIGRTN)
Fuel Pump
Circuit
Diagnosis DTCs applicable to the TFT sensor are shown in the following table. DTC P0712 P0713
Test Mode KOEO, Cont. KOEO, Cont.
Condition TFT circuit low input TFT circuit high input
Testing The TFT sensor is tested continuously during vehicle operation (cont.) and whenever a Key On Engine Off (KOEO) test is performed. Testing Engine Oil Temperature Sensor 1. Disconnect the Automatic transmission harness connector. 2. Locate the TFT sensor pins on the harness. 3. Using a suitable measure the resistance of the TFT sensor. Replace the sensor if not within specification.
The Fuel Pump (FP) is powered by the fuel pump relay situated in the power distribution box on the right hand side of the engine compartment. The PCM and the PCM Power Relay control operation of the Fuel Pump. The fuel pump is a two-stage turbine pump. The first stage is a low-pressure impeller pump. As it rotates, the impeller draws fuel from the tank. Fuel is then forced into the second high pressure stage. The second stage is a gear type pump. As the inner gear rotates, it carries fuel around with the rotor, pressurising it and directing fuel into the outlet. This two stage system eliminates vapour bubbles and ensures the fuel is supplied at the correct pressure. The large number of low volume chambers within the gear pump produces smooth pressure characteristics with minimal pressure pulsation resulting in quiet operation. The fuel pump relay winding is supplied with power when the ignition is switched to the ON position. The FP relay switches battery voltage to the Fuel Pump when the coil is energised by the PCM Power Relay and grounded by the PCM. When the ignition is first switched ON, the PCM will operate the fuel pump for one second. If no CKP signal is received at the PCM, the PCM will open the ground circuit, switching OFF the fuel pump relay. This ensures that if the engine stalls, for any reason, fuel pump operation will cease immediately.
Connections PCM Pin B27.................... Fuel Pump Relay (FP)
Circuit
TFT Specification Temperature Resistance Voltage Nominal (±3º C.) Nominal 10º 3800 Ω 4.0 20º 2500 Ω 3.5 30º 1700 Ω 3.1 40º 1200 Ω 2.7 60º 600 Ω 1.9 80º 320 Ω 1.2 Diagnosis 100º 190 Ω 0.8 120º 110 Ω 0.5 Diagnostic Trouble Codes (DTC) are retrieved through the diagnostic connector using the WDS tester. Fault 4. Check the harness for open circuits and short Finding Tables for DTCs are in the ‘Diagnosis’ circuits. section.
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DESCRIPTION AND OPERATION (Continued) DTCs applicable to the fuel pump relay are shown in the following table. DTC P0230
Test Mode KOEO, Cont.
Fuel Injector Cross Section, Typical
Condition Relay primary circuit malfunction
Failure Mode If the Fuel Pump, Fuel Pump Relay or PCM Power Relay fail, the fuel pump will not operate.
Testing The fuel pump relay is tested continuously during vehicle operation (cont.) and whenever a Key On Engine Off (KOEO) test is performed. 1. Remove the relay from its socket in the relay/fuse box adjacent to the battery. 2. Check the condition of the relay. Replace the relay if faulty. 3. Check the harness for open circuits and short circuits.
Fuel Injectors 1-8 The fuel injectors are electronically operated valves, which deliver a metered amount of atomised fuel to the engine. The injectors are conventional solenoid operated injectors with a pintle type nozzle. The injector orifice is a fixed size and the fuel supply pressure to the injector is regulated by the fuel pressure regulator. Fuel flow to the engine, and thus the air-fuel ratio, is controlled by how long the injector solenoid is energised. The Injector Pulse Width is the time the solenoid is energised. Vehicles fitted with the I6 engine use 6 fuel injectors (INJ1-6),while V8 engines have 8 injectors (INJ1-8),one for each cylinder. CAUTION: The fuel injectors pulse open momentarily using a signal from the PCM. Applying battery voltage directly to the fuel injector’s electrical connector terminals will damage the internal solenoid. Battery voltage is applied to the positive side of the injector solenoid coil via the PCM Power Relay. The negative side of the injector solenoid is grounded, as required, by the Powertrain Control Module (PCM). The strategy the PCM uses to control the air-fuel ratio is described in Control Systems.
Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
Description O-ring Filter Adjusting Sleeve Weld Shells (2 of) Weld Weld Support Ring O-ring Seat & Spray Plate Assy. Tube Assy. Needle, Ball & Armature Assy. Spring Coil & Bobbin Assy. Plastic Body
Connections (I6) PCM PCM PCM PCM PCM G98133 en
Pin Pin Pin Pin Pin
A14................................. Injector 1 A7................................... Injector 2 A15................................. Injector 3 A4................................... Injector 4 A8................................... Injector 5 01/2003 2003.0 BA Falcon
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DESCRIPTION AND OPERATION (Continued) PCM Pin A3................................... Injector 6
Connections (V8) PCM Pin A14................................. Injector 1 PCM Pin A3................................... Injector 2 PCM Pin A8................................... Injector 3 PCM Pin A10................................. Injector 4 PCM Pin A4................................... Injector 5 PCM Pin A7................................... Injector 6 PCM Pin A15................................. Injector 7 PCM Pin A42................................. Injector 8
Circuit
DTC P0207 P0208
Test Mode KOEO, Cont. KOEO, Cont.
Condition INJ7 circuit malfunction INJ8 circuit malfunction
Failure Mode Should a fuel injector fail the engine may run rough, a Diagnostic Trouble Code (DTC) will be logged in memory for the failed injector and subsequent unexpected changes in the air-fuel ratio. In the unlikely event that all the fuel injectors fail simultaneously, the vehicle will not run. The appropriate DTC will be reported to indicate failure of the individual fuel injectors.
Testing The fuel injectors are tested continuously during vehicle operation (cont.) and whenever a Key On Engine Off (KOEO) test is performed. Injector Fouling Over time, sulphur and other trace elements in petrol can build-up on the injector spray plate and around the nozzle. The quality of the fuel plays an important part in minimising this fouling of the fuel injectors. Fouling affects both the spray pattern and the volume of fuel injected. Incorrect spray pattern will cause poor atomisation and vaporisation of the fuel, which results in poor combustion, rough idle and high hydrocarbon and carbon monoxide emissions. Maintenance The fuel rail must be removed to replace the fuel injectors. The procedure is described in Fuel Rail in the ‘Removal and Installation’ section. The fuel injectors have a fixed orifice size and cannot be adjusted
Fouling of the fuel injectors is a common condition that should be suspected if the engine is running rough or hesitation during cold acceleration. Injector Test
1. Disconnect the harness from the fuel injector connector. NOTE: If any, or all, of the fuel injectors are replaced, the Keep Alive Memory (KAM) must be reset to 2. Measure the resistance across the fuel injector ensure the adaptive idle strategy does not use the connector terminals using a suitable multimeter. previous adaptive values. Refer to Resetting The Replace the fuel injector if not within specification. Powertrain Control Module. Repeat the procedure for each fuel injector. Fuel Injector Solenoid Resistance Diagnosis Specification 13.5 to 16.0 Ω Diagnostic Trouble Codes (DTC) are retrieved through the diagnostic connector using the WDS tester. Fault 3. Turn the ignition key to the ON position. Do not Finding Tables for DTCs are in the ‘Diagnosis’ start the engine. Positive power should be applied section. to the fuel injectors from the PCM Power Relay. DTCs applicable to the fuel injectors are shown in the 4. On the harness, measure the voltage between the positive connector terminal (red wire) and ground following table. using a suitable multimeter. Repeat the procedure DTC Test Mode Condition for each fuel injector. P0201 KOEO, Cont. INJ1 circuit malfunction Fuel Injector Voltage Specification P0202 KOEO, Cont. INJ2 circuit malfunction 12 Volts DC P0203 KOEO, Cont. INJ3 circuit malfunction 5. Check the harness for open circuits and short circuits. P0204 KOEO, Cont. INJ4 circuit malfunction P0205 P0206
KOEO, Cont. KOEO, Cont.
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DESCRIPTION AND OPERATION (Continued) Fuel Injector Testing
Circuit
CAUTION: Care should be taken to avoid damaging the fuel injector tip. 1. Remove the fuel injector and place in a clean plastic bag to avoid contamination. Number each bag to identify the cylinder location of the injector spray plate. 2. Visually examine each fuel injector filter basket and protection sleeve for damage and contaminants using a suitable magnifying glass. NOTE: The injector spray pattern cannot be tested on the vehicle. 3. Mount the injector in a suitable commercial injector tester and inspect the spray pattern in accordance with the operating instructions. 4. Replace the injector if poor atomisation is found, ie: streaming, uneven spray pattern or dribbling.
Ignition Coils The ignition system is described in Control Systems section.
Connections (I6) PCM PCM PCM PCM PCM PCM
Pin Pin Pin Pin Pin Pin
A35................................. Ignition Coil 1 A24................................. Ignition Coil 2 A12................................. Ignition Coil 3 A23................................. Ignition Coil 4 A46................................. Ignition Coil 5 A34..................................Ignition Coil 6
Diagnosis Diagnostic Trouble Codes (DTC) are retrieved through the diagnostic connector using the WDS tester. Fault Finding Tables for DTCs are in the ‘Diagnosis’ section. DTCs applicable to the ignition coils are shown in the following table. DTC P0351
P0352
Connections (V8) PCM PCM PCM PCM PCM PCM PCM PCM
Pin Pin Pin Pin Pin Pin Pin Pin
A35................................. Ignition Coil 1 A24................................. Ignition Coil 2 A12................................. Ignition Coil 3 A1................................... Ignition Coil 4 A46................................. Ignition Coil 5 A34................................. Ignition Coil 6 A23................................. Ignition Coil 7 A11..................................Ignition Coil 8
P0353
P0354
P0355
P0356
P0357
P0358
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Test Mode Condition (I6) KOEO, Ignition Coil 1 KOER Cont Primary / Secondary Circuit Failure KOEO, Ignition Coil 5 KOER Cont Primary / Secondary Circuit Failure KOEO, Ignition Coil 3 KOER Cont Primary / Secondary Circuit Failure KOEO, Ignition Coil 6 KOER Cont Primary / Secondary Circuit Failure KOEO, Ignition Coil 2 KOER Cont Primary / Secondary Circuit Failure KOEO, Ignition Coil 4 KOER Cont Primary / Secondary Circuit Failure KOEO, KOER Cont KOEO, KOER Cont
Condition (V8) Ignition Coil 1 Primary / Secondary Circuit Failure Ignition Coil 3 Primary / Secondary Circuit Failure Ignition Coil 7 Primary / Secondary Circuit Failure Ignition Coil 2 Primary / Secondary Circuit Failure Ignition Coil 6 Primary / Secondary Circuit Failure Ignition Coil 5 Primary / Secondary Circuit Failure Ignition Coil 4 Primary / Secondary Circuit Failure Ignition Coil 8 Primary / Secondary Circuit Failure
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DESCRIPTION AND OPERATION (Continued)
Actuators
Connections
Intake Manifold Charge Control
PCM Pin B3......................................... IMCC Signal PCM Pin B34........................Vehicle Power (VPWR)
On I6 engines (except Turbo), the intake manifold has Circuit an Intake Manifold Charge Control (IMCC) system. The IMCC housing is an aluminium casting, situated below the plenum chamber. It has two intake air passages for each cylinder. The PCM opens vacuum control solenoid allowing the vacuum to pass to the vacuum actuator drawing the valve plates closed or releasing the vacuum allowing the actuator to push the valve plates open. The direct mounted vacuum actuator system and its return springs are located within the vacuum actuator assembly. The IMCC system is also described in Control Systems. The IMCC solenoid controls the vacuum signal line to the manifold servo control diaphragm. The solenoid is mounted on the front of the PCM bracket. Engine Speed 400 to 3,800 RPM above 3,800 RPM
IMCC Solenoid Specification Solenoid PCM Pin Butterfly Condition B3 Voltage Valves ON 12 Volts Closed OFF
IMCC Solenoid Location
0 Volts
Open
Diagnosis Diagnostic Trouble Codes (DTC) are retrieved through the diagnostic connector using the WDS tester. Fault Finding Tables for DTCs are in the ‘Diagnosis’ section. DTCs applicable to the IMCC solenoid are shown in the following table. DTC P1520
Test Mode KOEO, Cont.
Condition circuit malfunction
Failure Mode During self-test the PCM checks the electrical continuity of the IMCC circuit. If the circuit fails the self-test a DTC will be logged in the PCM memory. Should either the IMCC electrical or vacuum circuit fail, then the IMCC butterflies will remain open throughout the entire engine operating range. This will result in a noticeable lack of power and torque when operating the engine between 400 to 3,800 RPM.
Testing The IMCC solenoid is tested continuously during vehicle operation (cont.) and whenever a Key On Engine Off (KOEO) test is performed. Whenever the ignition key is in the ON position, positive power should be applied to the IMCC solenoid from the PCM Power Relay. 1. Connect a WDS tester to the diagnostic connector. 2. Initiate an Output Circuit Check as described in Diagnosis. 3. Check the Parameter Identification (PID) value of the IMCC. If the PID value is within specification, then check for other Diagnostic Trouble Codes (DTC) or component faults. G98133 en
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DESCRIPTION AND OPERATION (Continued) Connections
Sensor Test
4. Disconnect the engine harness from the IMCC PCM Pin B24................................................EDF1-2 solenoid electrical connector. PCM Pin B35............................….................EDF1-2 5. Connect the multimeter across the IMCC solenoid terminals and measure the resistance of the coil. Circuit IMCC Resistance Spesification 50 to 100 Ω 6. Check the harness for open circuits and short circuits.
Electro Drive Fans Electro Drive Fans 1 & 2 provide air flow over the radiator to remove heat from the engine coolant. Operation of the fans is controlled by the PCM. EDF1 and EDF2 PCM outputs control three relays to operate two electric cooling fans on the radiator. The relays are wired to switch the fans in series and parallel combinations to provide low and high speed operation as shown in the following table. Fan Speed Off Low Speed High Speed
EDF1 OFF ON ON
EDF2 OFF OFF ON
Diagnosis Diagnostic Trouble Codes (DTC) are retrieved through the diagnostic connector using the WDS tester. Fault Finding Tables for DTCs are in the ‘Diagnosis’ section. DTC P1474
Test Mode KOEO
P1479
KOEO
Condition EDF1 Fan Control Relay Circuit EDF2 Fan Control Relay Circuit
Failure Mode The PCM tests the EDF relay circuits during self test. If any circuit fails the test, then a Diagnostic Trouble Code (DTC) will be logged in the PCM memory.
Testing 1. Initiate an Output Circuit Check as described in Diagnosis. 2. Check the operation of the cooling fan EDF1-2. G98133 en
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DESCRIPTION AND OPERATION (Continued) 3. Check the harness for open circuits and short circuits. 4. Further testing of EDF1-2 is described in Section 303-03, Engine Cooling.
The camshaft timing is controlled by directing oil under pressure (from the engine oil pump) into one of two ports in the Phaser, one port will retard the cam timing (‘Retard port’) and the other will advance the timing (‘Advance port’). An Oil Control Valve (OCV), Variable Camshaft Timing one for each camshaft is used to control the flow of oil into the retard and advance ports of both cams. The I6 Engine OCV is controlled by the PCM. The I6 Engine is fitted with variable inlet and exhaust The PCM uses a pulse width modulated (PWM) camshaft timing. Both camshafts are variable over a voltage or ‘Duty Cycle’ (DC) to control each OCV to 60-degree crank angle. This is achieved by two attain the desired camshaft angle. VCT1 output separate hydraulic mechanisms called ‘Phasers’, controls the Bank1 camshaft OCV. VCT2 controls the which are integral with the intake and exhaust Bank2 camshaft OCV. camshaft drive sprockets. A 4 + 1 tooth wheel on the front of each camshaft with The camshaft timing is controlled by directing oil an associated sensor mounted on the intake and under pressure (from the engine oil pump) into one of exhaust sides of the cylinder head are used to two ports in the Phaser, one port will retard the cam calculate the ‘Actual cam angle’ for both camshafts. timing (‘Retard port’) and the other will advance the The two sensors, CID1 and CID2 measure the timing (‘Advance port’). An Oil Control Valve (OCV), camshaft angle on Bank 1 and Bank2 respectively. one for each camshaft is used to control the flow of oil The PCM uses engine rpm, throttle position and into the retard and advance ports of both cams. The engine load to determine the optimum camshaft OCV is controlled by the PCM. timing setting or ‘Desired Cam Angle’ for both The PCM uses a pulse width modulated (PWM) camshafts. voltage or ‘Duty Cycle’ (DC) to control each OCV to Once the PCM has determined the Desired Cam attain the desired camshaft angle. VCT1 output Angle, it will control the Duty Cycle output VCT1 and controls the inlet camshaft OCV. VCT2 controls the VCT2, to the intake and exhaust OCVs based on the exhaust camshaft OCV. difference between the Desired Cam Angle and the A 3 + 1 tooth wheel on the front of each camshaft with Actual Cam Angle. This difference is called the Cam an associated sensor mounted on the intake and Angle Error. The Cam Angle Error for each cam is exhaust sides of the cylinder head are used to calculated individually and used to control both calculate the ‘Actual cam angle’ for both camshafts. camshafts independently to a single Desired Cam The two sensors are called, intake cam position or Angle. ‘CID1’ and exhaust cam position or ‘CID2’. Intake and An engine oil temperature sensor, which measures oil exhaust cam positions are calculated separately. temperature in the oil sump, is used to compensate The PCM uses engine rpm, throttle position and for Phaser response with changing oil viscosity at engine load to determine the optimum camshaft different temperatures. timing setting or ‘Desired Cam Angle’ for both Modes of Operation camshafts. Once the PCM has determined the Desired Cam 1. Start-Up Mode Angle, it will control the Duty Cycle output VCT1 and In this mode the VCT phasers will be in the fully VCT2, to the intake and exhaust OCVs based on the advanced position or locked position. The Camshafts difference between the Desired Cam Angle and the are locked mechanically by a hydraulic ‘Locking Pin’ Actual Cam Angle. This difference is called the Cam which forms part of the phaser. The VCT1 and VCT2 Angle Error. The Cam Angle Error for each cam is duty cycle sent to the oil control valves will be 0%. calculated individually and used to control both Exit from startup mode is within 10 seconds of camshafts independently to a single Desired Cam starting. Angle. An engine oil temperature sensor, which measures oil 2. Idle Mode temperature in the oil gallery of the engine block, is At idle, the VCT Phasers are in the locked fully used to compensate for Phaser response with advance position as per Start-Up Mode. Exit from Idle changing oil viscosity at different temperatures. Mode occurs when the engine speed is above 1,050
5.4 L, 3 Valve V8 Engine
RPM and the throttle is open.
The 5.4, 3V, V8 Engine is fitted with variable inlet and exhaust camshaft timing on each cylinder head bank . The camshaft on each bank is variable over a 60-degree crank angle using two separate hydraulic ‘Phasers’, which are integral with the Bank1 and Bank2 camshaft drive sprockets.
3. Normal Drive Mode In this mode of operation the camshaft timing angle is controlled to a Desired Cam Angle which is determined by, Engine Speed, Engine Load, Throttle Position. In this condition the PCM VCT1 and VCT2 output duty cycle will be between 20% and 80% (0.2
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DESCRIPTION AND OPERATION (Continued) to 0.8) supplied to the OCVs.
VCT Sensor Location
4. Engine Shut down Mode When the vehicle is keyed off, (normally from idle) the VCT Phasers will remain in the Locked position. 5. Oil Overheat mode If the oil temperature becomes excessively high engine speed at which the VCT system enters Drive Mode will become higher. See specifications in this section. 6. System Malfunction Mode If a critical sensor or the VCT system fails the VCT system will be set to the fully advanced locked position. The VCT1 and VCT2 Duty cycle to the OCVs will be set to 0%. 7. Oil Control Valve Cleaning Mode The VCT system has an automatic Valve Cleaning Mode that is designed to keep the valve free of oil deposits and build up. This mode is activated when the throttle is closed during normal driving.
Connections PCM Pin A5…………………………………….VCT1 PCM Pin A6…………………………………….VCT2
Diagnosis Diagnostic Trouble Codes (DTC) are retrieved through the diagnostic connector using the WDS tester. Fault Finding Tables for DTCs are in the ‘Diagnosis’ section. DTCs applicable to the VCT solenoid are shown in the following table. DTC P0340
Test Type KOER Cont
P1340
KOER Cont
P1380
KOEO Cont
P1385
KOEO Cont
P1381
Cont
P1386
Cont
P1383
Cont
Circuit
Maintenance Maintenance of the VCT solenoid and mechanisms are described in the Variable Camshaft Timing section.
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Description of test Camshaft Position Sensor CID1 (I6 Intake Cam, V8 Bank 1) Camshaft Position Sensor CID2 (I6 Exhaust Cam, V8 Bank 2) Camshaft Position Actuator, VCT1 Circuit (I6 Intake OCV, V8 Bank 1 OCV) Camshaft Position Actuator, VCT2 Circuit (I6 Exhaust OCV, V8 Bank 2 OCV) Camshaft Position Timing Over Advanced (I6 Intake cam, V8 Bank 1) Camshaft Position Timing Over Advanced (I6 Exhaust Cam, V8 Bank 2) Camshaft Position Timing Over Retarded (I6 Intake cam, V8 Bank 1)
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DESCRIPTION AND OPERATION (Continued) DTC P1388
Test Type Cont
Description of test Camshaft Position Timing Over Retarded (I6 Exhaust Cam, V8 Bank 2)
PID VCTADV
Critical Sensors If the following sensors malfunction the VCT system will be disabled. Sensor Description CHT Cylinder head temperature sensor EOT Engine Oil Temperature Sensor MAP Manifold Absolute Pressure Sensor ACT Air Charge Temperature Sensor TP Throttle Position Sensor Check the relevant sections in this chapter to ensure these sensors are operating correctly, Before Performing any other diagnosis on the VCT system. Specifications / Modes of operation Cam Angle at fully advanced Position Cam Angle at Fully Retarded Position VCT Activation RPM Oil Temperature Normal 130° 140° 150°
I6, 4V 1000 RPM 1250 RPM 1500 RPM VCT off
I6 -10°
V8, 3V 0°
50°
60°
V8, 3V 1100 RPM 1100 RPM 1100 RPM 1100 RPM
VCTADV2
VCTADVERR
VCTADVERR2
Description cam_angle_0; The actual position in crankshaft degrees of the right or number 1 camshaft for VCT (Variable Camshaft Timing), where zero is the base camshaft timing. A decrease corresponds to an advance of the camshaft timing, while an increase corresponds (I6 Intake Cam, V8 Bank 1) cam_angle_1; The actual position in crankshaft degrees of the left or number 2 camshaft for VCT (Variable Camshaft Timing), where zero is the base camshaft timing. A decrease corresponds to an advance of the camshaft timing.(I6 Exhaust Cam, V8 Bank 2) cam_err_0; How far the actual position of the right camshaft is advanced (+) or retarded (-) in crankshaft degrees from the desired position for VCT (Variable Camshaft Timing ). (I6 Intake Cam, V8 Bank 1) cam_err_1; How far the actual position of the left or number 2 camshaft is advanced (+) or retarded (-) in crankshaft degrees from the desired position for VCT (Variable Camshaft Timing ). (I6 Exhaust Cam, V8 Bank 2)
Failure Diagnosis
Solenoid Test
If a fault develops in the VCT control system or a critical sensor, The VCT outputs from the PCM are disabled (the VCT system is turned off) and the appropriate trouble code will be logged in memory for retrieval during Self-test mode.
1. Disconnect the wiring harness from the VCT solenoid. 2. Using a suitable multimeter, measure the resistance of the solenoid coil across the terminals.
VCT PID Specification PID VCT1
VCT2
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Description cam_dc_0; Duty cycle of the VCT (Variable Camshaft Timing) solenoid output (I6 Intake Cam, V8 Bank 1) cam_dc_1; Duty cycle of the VCT (Variable Camshaft Timing) solenoid output (I6 Exhaust Cam, V8 Bank 2)
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DESCRIPTION AND OPERATION (Continued) VCT Solenoid Resistance Specification I6 7.0 Ω - 9.0 Ω V8, 3V 8.0 Ω - 10.0 Ω
Circuit
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DESCRIPTION AND OPERATION (Continued)
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DESCRIPTION AND OPERATION (Continued) Flow Problem Chart Output Number 1 VCT controller not at idle mode.
2
Possible Cause
Possible solution
Check for correct throttle pedal operation. Engine RPM is to Check and rectify high for entry into air leaks, throttle VCT idle mode. malfunction and other problems that allow engine to idle to be excessively high. Engine idle rough OCV is Remove valve, and/or high RPM contaminated, perform cleaning idle. One camshaft jammed or faulty. procedure and is retarded when the inspect. its OCV duty is PCM VCT output 1 or Check and repair equal to zero. 2 wiring is shorted to wiring/PCM. ground. (This problem will power up one of the OCVs).
Engine performance and/or Idle quality is poor. Camshaft is not at ‘Locked position’ when the OCV duty cycles are =0
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DTCs Additional comments that may be set
Throttle pedal is not fully closed.
VCT Phaser is jammed or faulty.
Remove and replace Phaser.
Camshaft or CID timing is incorrect or slipped, moved or damaged.
Check camshaft and engine timing including CID timing.
P1383 P1388
Ref: OCV Cleaning Procedure
P1383 P1388 P0340 P1340
Check by disconnecting both OCVs and re-running ‘VCT TEST1 IDLE’ in the diagnostic flow chart. Most problems can be attributed to the OCV, ensure that the OCV is checked and cleaned before replacing Phaser Ref: Engine Section 303-01a, b & c. Ref: Engine Section 303-01a, b & c.
P1383 P1388
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DESCRIPTION AND OPERATION (Continued) Flow Problem Chart Output Number 3 Engine stalls or runs poorly when throttle is opened. Engine operates normally for only 10sec after start. NOTE: Engine may recover 5sec after throttle is opened when the PCM Identifies a problem, turns VCT off and sets a DTC.
Possible Cause
Possible solution
VCT OCV or CID sensor wiring is connected back the front.
Check for correct OCV wiring orientation.
P1383 P1388 P1381 P1386
Open circuit/faulty OCV wiring.
Check VCT1 and VCT2 wiring.
One OCV is jammed in the fully closed position.
Remove and clean the OCV that is jammed or replace faulty valve. Check the oil filter in #1 cam cap.
P1381 P1386 P0340 P1340 P1381 P1386
Ref: OCV Cleaning Procedure.
P1381 P1386
Ref: Engine Section 303-01a, b & c.
P1381 P1386
This is not a very common fault ensure that the oil supply, OCV, wiring and PCM are operating correctly before replacing Phaser. Ref: Engine Section 303-01a, b & c for Phaser replacement.
Oil supply or filter blocked on one camshaft. VCT Phaser stuck in Replace VCT locked position i.e. Phaser. locking pin jammed. Phaser is therefore unable to move when a duty cycle is applied to the OCV.
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DTCs Additional comments that may be set This will only be a problem if the engine wiring has been removed and replaced, or the history of the vehicle is not known.
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DESCRIPTION AND OPERATION (Continued) Flow Problem Chart Output Number 4 Cam_dc_0_ or Cam_dc_1 is high, cam retard is slow or cam error is large.
5
Possible Cause
Remove OCV, perform cleaning procedure, inspect and re-install. Blocked VCT oil Remove OCVs and filter/s in #1 cam cap, cam caps inspect or blocked oil supply. and clean oil filters, oil galleries and OCV. Re-install and re-test. Cam_dc_0_ or OCV worn or faulty. Check condition of Cam_dc_1_ is low OCVs But not zero, cam Phaser return spring Check condition of error is large and is broken or faulty. Phaser return negative. spring. Cam friction is high. Check cam, journal and valve train condition. When throttle is A ‘Critical Sensor’ Run KOEO, KOER opened Both has failed and check DTCs Cam_dc_ are = 0, Check stored i.e. has been VCT is Failed PCM VCT outputs or wiring, i.e. DTCs for failed disabled OCVs not connected VCT outputs. or wiring damaged. Failed CID/Cam Check CID position sensor or sensors, Wiring associated wiring, and stored DTCs VCT control system Check OCVs, unable to move associated wiring, camshafts to desired and stored DTCs position. Poor VCT Oil condition is poor Change oil and oil performance. and/or engine oil filter filter. Causing poor is blocked. drivability. Engine runs well during Engine oil pressure is Check oil pressure cruise conditions. low. is within specification.
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OCV blocked, jammed, worn or faulty.
Possible solution
DTCs Additional comments that may be set P1381 P1386
Ref: OCV Cleaning Procedure.
P1381 P1386
Ref: Engine Section 303-01a, b & c.
P1388 P1383 P1388 P1383
Ref: Engine Section 303-01a, b & c. Ref: Engine Section 303-01a, b & c.
P1388 P1383
Ref: Engine Section 303-01a, b & c.
P1388 P1383 P1381 P1386 P0340 P1340 P1380 P1385 MAP EOT ACT CHT TP
Stop engine, check stored DTCs, and clear. Re-run flow chart tests. Check DTCs that indicate that the listed ‘critical sensors’ have failed. NOTE: During a test if a fault is found the VCT will be disabled and the stored DTC is set.
P1388 P1383 P1381 P1386 P1388 P1383 P1381 P1386
Ref: Engine Section 303-01a, b & c.
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DESCRIPTION AND OPERATION (Continued) Flow Problem Chart Output Number 6 Poor VCT performance. Causing poor drivability. Engine runs well during cruise conditions.
Possible Cause
VCT oil filters are blocked. Oil control valve is faulty/Worn out. VCT Phasers are worn/Faulty. #1 camshaft journal clearances are too high.
Electronic Throttle Body
Possible solution
Check and clean filters in cam journal caps. Check OCV condition and replace as necessary. Check Phasers and replace as necessary. Check journal clearances are within specification.
DTCs Additional comments that may be set P1381 P1386
Ref: Engine Section 303-01a, b & c.
P1381 P1386 P1388 P1383 P1381 P1386 P1388 P1383 P1381 P1386 P1388 P1383
Ref: Engine Section 303-01a, b & c. Ref: Engine Section 303-01a, b & c. Ref: Engine Section 303-01a, b & c.
Diagnosis
The PCM processes accelerator pedal and speed DTCs applicable to this output are shown on the control demand for the Electronic Throttle Body following table (ETB). The electric motor in the ETB moves the Test Mode Condition throttle plate through a gear set. The plate is adjusted DTC P2100 KOEO Cont. Throttle Actuator Control and monitored by the PCM in a closed control loop. Motor Circuit/Open The TP sensor provides the PCM with feedback on the actual position of the throttle plate. P2101 KOEO Cont. Throttle Actuator Control Motor Circuit CAUTION: The Electronic Throttle Body Range/Performance (ETB) must NOT be dismantled. No adjustments P2102 KOEO Cont. ETB motor current is can be made to the ETB. The only serviceable lower than expected item on the ETB is the Throttle Position Sensor P2103 KOEO Cont. ETB motor current is (TPS), which can be replaced. higher than expected NOTE: The preset stop-screw must not be adjusted P2105 Cont. Throttle Actuator Control as it is factory set and bonded tight. Adjustment will System - Forced Engine likely cause failure. Shutdown Connections P2107 Cont. Throttle Actuator Control System - Forced Engine PCM Pin A27…………………………………..ETCP into guard mode PCM Pin A28…………………………………..ETCN P2110 Cont ETC in Guard Mode. (Limp home mode) Circuit P2111 Cont. Throttle Actuator Control System - Higher throttle opening than driver demand P2112 Cont. Throttle Actuator Control System - Lower throttle opening than driver demand
Failure Mode If a fault develops in the electronic throttle control system, a standby function is carried out. The plate is spring loaded to a slightly open position allowing enough air to pass to provide limited engine operation. This spring-loaded position is preset during G98133 en
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DESCRIPTION AND OPERATION (Continued) manufacture and must not be adjusted in service. EVAP Solenoid Location, I6 When operating in this mode, rpm-limiting by cylinder cutout will occur and the warning light will be set. The appropriate trouble code will be logged in the memory for retrieval during Self-test mode.
Testing 1. Measure the resistance of the electronic throttle motor ETC Motor Resistance Specification 3 to 5 Ω
Evap Canister Purge Solenoid The Evaporator Canister Purge Solenoid (EVAP) controls purging of vapours from the carbon canister to the air intake system. The canister stores fuel vapours from the fuel tank. The Powertrain Control Module (PCM) monitors several systems to determine when to purge these vapours into the intake manifold with minimum impact on engine operation. The positive side of the EVAP solenoid is connected to Vehicle Power (VPWR). The PCM completes the electrical circuit by grounding the solenoid coil in a 10 Hz duty cycle. Once purge is initiated, the duty will gradually increase with engine speed to slowly draw the canister vapours in the intake manifold.
EVAP Solenoid Location, V8
Connections PCM Pin B22....................................EVAP Solenoid PCM Pin B34........................Vehicle Power (VPWR)
Circuit
Diagnosis Diagnostic Trouble Codes (DTC) are retrieved through the diagnostic connector using the WDS tester. Fault Finding Tables for DTCs are in the ‘Diagnosis’ section. DTCs applicable to the EVAP solenoid are shown in the following table. DTC P0443
Test Mode KOEO, Cont.
Condition circuit malfunction
Testing 1. Check the operation of the EVAP solenoid. 2. Measure the resistance of the solenoid. EVAP Solenoid Resistance Specification 50 to 70 Ω 3. Check the harness for open circuits and short circuits.
Turbocharger Westgate Control The PCM measures the boost pressure of the turbocharger using the boost pressure sensor (BPS). Boost pressure is controlled to a set pressure, which is dependent upon the engine load, temperature and RPM. The control system increases engine intake pressure by diverting excess pressure away from the G98133 en
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DESCRIPTION AND OPERATION (Continued) wastegate actuator, through a wastegate solenoid valve mounted underneath the battery. The solenoid is controlled by the PCM’s TURBO output.
Connections PCM Pin C21………………………………. TURBO
Circuit
cycle) allowing minimum mechanical boost to be delivered. The minimum mechanical boost is controlled by the spring-loaded position of the wastegate actuator. This is preset during manufacture and must not be adjusted in service. If the boost pressure is still higher than desired, torque limiting by cylinder cutout will occur. The appropriate trouble code will be logged in memory for retrieval during Self-test mode.
Testing The TURBO solenoid output is tested continuously during vehicle operation (cont.) and whenever Key On Engine Off (KOEO) or Key On Engine Running (KOER) test are performed. Testing TURBO control solenoid output 1. Connect a WDS tester to the diagnostic connector. 2. Check the Parameter Identification (PID) value of the WGATE. If the PID value is within specification, then check for other Diagnostic Trouble Code (DTC) or component faults PID Specification
Diagnosis DTCs applicable to this output are shown on the following table. DTC P0243
Test Mode KOEO, KOER Cont. Cont
Condition Wastegate Solenoid Circuit Malfunction P1227 Wastegate Control System Failed closed Over Pressure P1228 Cont Wastegate Control System Failed Open Under Pressure The P1227 and P1228 codes are total system performance codes, and may relate to a mechanical fault in the control system if P0243, P0236, P0237 and P0238 have not been set, possible causes are: Blocked or restricted wastegate solenoid ports Damaged or missing hose(s) between wastegate solenoid and turbo compressor or wastegate actuator. Failed wastegate actuator diaphragm, Stuck open/closed wastegate valve (in turbine housing). Loose, blocked or damaged hoses from turbo compressor outlet to throttle body Damaged intercooler Blocked or restricted intake to turbo compressor
Failure Mode If a fault develops in the turbo wastegate control system, a standby function is carried out. The wastegate solenoid is forced fully open (0% duty G98133 en
PID WGATE
Description Turbocharger Wastegate Control
Transmission Outputs If several Diagnostic Trouble Code (DTC) applicable to transmission are present, check for a short circuit to Vehicle Power (VPWR) or ground, or moisture in the transmission harness connector.
Shift Solenoid 1 Shift Solenoid 1 (SS1) is used on vehicles fitted with automatic transmission to control shifting of the gear ratios. The solenoid is wired to 12V within the transmission. The PCM applies 0 Volts to energise the coils of SS1 as required for gearshift operation. The automatic transmission gear shift strategy is described in Section 307-01, Automatic Transmission.
Connections PCM Pin A19......................................SS1 Solenoid Diagnosis Diagnostic Trouble Codes (DTC) are retrieved through the diagnostic connector using the WDS tester. Fault Finding Tables for DTCs are in the ‘Diagnosis’ section. DTCs applicable to the SS1 solenoid are shown in the following table.
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DESCRIPTION AND OPERATION (Continued) DTC P0752 P0753
Test Mode KOEO, KOER Cont KOEO, KOER Cont
Condition Shift Solenoid 1 (SS1) (Auto) stuck on Shift Solenoid 1 (SS1) electrical problem
Testing Solenoid Test 1. Disconnect the harness from the transmission connector. 2. Measure the resistance across the connector terminals using a suitable multimeter. Replace the solenoid if not within specification. SS1 Solenoid Resistance Specification 23 -45 Ω 3. Check the harness for open circuits and short circuits.
Shift Solenoid 2 Shift Solenoid 2 (SS2) is used on vehicles fitted with automatic transmission to control shifting of the gear ratios. The solenoid is wired to 12V within the transmission. The PCM applies 0 Volts to energise the coils of SS2 as required for gearshift operation. The automatic transmission gear shift strategy is described in Section 307-01, Automatic Transmission.
Connections PCM Pin A20.......................................SS2 Solenoid
Circuit
Testing Solenoid Test 1. Disconnect the harness from the transmission connector. 2. Measure the resistance across the connector terminals using a suitable multimeter. Replace the solenoid if not within specification. SS2 Solenoid Resistance Specification 23 -45 Ω 3. Check the harness for open circuits and short circuits.
Shift Solenoid 3 Shift Solenoid 3 (SS3) is used on vehicles fitted with automatic transmission to control shifting of the gear ratios. The solenoid is wired to 12V within the transmission. The PCM applies 0 Volts to energise the coils of SS3 as required for gearshift operation. The automatic transmission gear shift strategy is described in Section 307-01, Automatic Transmission.
Connections PCM Pin A17.......................................SS3 Solenoid Maintenance DTCs applicable to the SS3 solenoid are shown in the following table. DTC P0762 P0763
Test Mode KOEO, KOER Cont KOEO, KOER Cont
Condition Shift Solenoid 3 (SS3) (Auto) stuck on. Shift Solenoid 3 (SS3) electrical problem
Testing Solenoid Test 1. Disconnect the harness from the transmission connector. 2. Measure the resistance across the connector terminals using a suitable multimeter. Replace the solenoid if not within specification. SS3 Solenoid Resistance Specification 23 - 45 Ω 3. Check the harness for open circuits and short DTCs applicable to the SS2 solenoid are shown in the circuits. following table. DTC P0757 P0758
Test Mode KOEO, KOER Cont KOEO, KOER Cont
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Condition Shift Solenoid 2 (SS2) (Auto) stuck on. Shift Solenoid 2 (SS2) electrical problem
Shift Solenoid 4 Shift Solenoid 4 (SS4) is used on vehicles fitted with automatic transmission to control shifting of the gear ratios. The solenoid is wired to 12V within the transmission. The PCM applies 0 Volts to energise the coils of SS4 as required for gearshift operation. 01/2003 2003.0 BA Falcon
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DESCRIPTION AND OPERATION (Continued) The automatic transmission gear shift strategy is Connections described in Section 307-01, Automatic Transmission. PCM Pin A39......................................VPS Solenoid
Connections
PCM Pin A18.......................................SS4 Solenoid
Circuit
Circuit
DTCs applicable to the VPS solenoid are shown in the following table. DTCs applicable to the SS4 solenoid are shown in the following table. DTC P0768
Test Mode KOEO, KOER Cont
Condition Shift Solenoid 4 (SS4) electrical problem
Testing Solenoid Test
DTC P1746 P1747 P1748
Test Mode KOEO, KOER Cont KOEO, KOER Cont KOEO, KOER Cont
Condition Solenoid 5 (SS5) open circuit fault Solenoid 5 (SS5) short circuit fault Solenoid 5 (SS5) circuit fault
Testing
Solenoid Test 1. Disconnect the harness from the transmission connector. 1. Disconnect the harness from the transmission connector. 2. Measure the resistance across the connector terminals using a suitable multimeter. Replace the 2. Measure the resistance across the connector solenoid if not within specification. terminals using a suitable multimeter. Replace the solenoid if not within specification. SS4 Solenoid Resistance Specification 23 -45 Ω SS5 Solenoid Resistance Specification 3.8-6.2 Ω 3. Check the harness for open circuits and short circuits. 3. Check the harness for open circuits and short circuits.
Variable Pressure Solenoid 5
Variable Pressure Solenoid 5 (VPS) is used on vehicles fitted with automatic transmission to control the pressure to the clutches and bands for automatic gear shift. The solenoid is wired to 12V within the transmission. The PCM applies a PWM current to energise the coils of VPS as required for gearshift operation. The automatic transmission gearshift strategy is described in Section 307-01, Automatic Transmission.
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Power Control Solenoid 6 Power Control Solenoid 6 (PCS) is used on vehicles fitted with automatic transmission to control line pressure in the automatic transmission. The solenoid is wired to 12V within the transmission. The PCM applies 0 Volts to energise the coils of SS1 as required for gearshift operation. The automatic transmission gearshift strategy is described in Section 307-01, Automatic Transmission.
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DESCRIPTION AND OPERATION (Continued) Connections
Connections
PCM Pin A2.........................................PCS Solenoid
PCM Pin A43......................................LUS Solenoid
Circuit
Circuit
Maintenance Diagnosis Maintenance, removal and installation of PCS is Diagnostic Trouble Codes (DTC) are retrieved through described in Section 307-01, Automatic Transmission. the diagnostic connector using the WDS tester. Fault Finding Tables for DTCs are in the ‘Diagnosis’ DTCs applicable to the PCS solenoid are shown in section. the following table. DTC Test Mode Condition DTC Test Mode Condition P0743 KOEO, KOER Lock Up Solenoid 7 P0773 KOEO, KOER Shift Solenoid 6 (SS6) Cont (LUS) fault Cont electrical problem
Testing
Testing
Solenoid Test
Solenoid Test
1. Disconnect the harness from the transmission 1. Disconnect the harness from the transmission connector. connector. 2. Measure the resistance across the connector 2. Measure the resistance across the connector terminals using a suitable multimeter. Replace the terminals using a suitable multimeter. Replace the solenoid if not within specification. solenoid if not within specification. LUS Solenoid Resistance Specification PCS Solenoid Resistance Specification 23 -45 Ω 23 -45 Ω 3. Check the harness for open circuits and short 3. Check the harness for open circuits and short circuits. circuits.
Lock up Solenoid 7
LPG Fuel System Outputs
Lock Up Solenoid 7 (LUS) is used on vehicles fitted LPG Prime Solenoid PRIME with automatic transmission to control the automatic The LPG prime solenoid primes the LPG hoses and transmission torque converter lock-up clutch. the intake manifold with gas the facilitate engine The Powertrain Control Module (PCM) applies 12 starting. Volts to energise the coils of LUS as required. The automatic transmission gear shift strategy is described in Section 307-01, Automatic Transmission.
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DESCRIPTION AND OPERATION (Continued) Connections
Connections
PCM Pin C21............................…….. PRIME
PCM Pin C7..............................Gas Cut-Out (GCO)
Circuit
Circuit
Diagnosis Diagnostic Trouble Codes (DTC) are retrieved through the diagnostic connector using the WDS tester. Fault Finding Tables for DTCs are in the ‘Diagnosis’ section.
Diagnosis Diagnostic Trouble Codes (DTC) are retrieved through the diagnostic connector using the WDS tester. Fault Finding Tables for DTCs are in the ‘Diagnosis’ section.
DTCs applicable to the GCO relay are shown in the following table.
DTCs applicable to the GCO relay are shown in the following table.
DTC P1213
Test Mode KOEO, Cont.
Condition PRIME circuit malfunction
DTC P1182
Test Mode KOEO, Cont.
Condition relay circuit malfunction
Testing
Failure Mode
Solenoid Test
Should the GCO relay fail for any reason, LPG mode will not be available.
1. Remove the connector to the PRIME solenoid on the LPG converter. 2. Measure the resistance across the PRIME solenoid using a suitable multimeter. Prime Solenoid Resistance Specification 10-14 Ω 3. Check the harness for open circuits and short circuits.
Gas Cut-out Solenoid GCO In vehicles fitted with Ford factory SF LPG systems, three solenoids control LPG flow from the tank to the converter unit. The three solenoids are controlled by the Gas Cut-Out (GCO) relay. The GCO relay is energised by the PCM, energising the solenoid control relay, which then energises to activate the Tank Lock-off, Engine Bay Lock-off and Idle Circuit solenoids on the LPG fuel line. These solenoids are open when.
Testing Relay Test 1. Remove the GCO Relay. 2. Measure the resistance across the GCO relay coil terminals using a suitable multimeter. GCO Relay Coil Resistance Specification 60-120 Ω 3. Check the harness for open circuits and short circuits.
LPG Stepper Motor A-D LPG Stepper Motor A -D (GSCA-D) signals are used by the Powertrain Control Module (PCM) to control the air-fuel ratio when running in LPG mode. The LPG Stepper Motor moves in discrete steps from 0 (fully open) to 216 (fully closed).
Connections PCM Pin C24.............LPG Stepper Motor A (GSCA) PCM Pin C25.............LPG Stepper Motor B (GSCB) PCM Pin C26….........LPG Stepper Motor C (GSCC)
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DESCRIPTION AND OPERATION (Continued) PCM Pin C27............LPG Stepper Motor D (GSCD)
Circuit
DTCs applicable to GSMA-D are shown in the following table. DTC P1159
Test Mode LPG
Condition fault
Testing GSMA-D are tested whenever an LPG test is performed. 1. Connect a WDS tester to the diagnostic connector. 2. Check the Parameter Identification (PID) value of the GSM. If the PID value is within specification, then check for other Diagnostic Trouble Codes (DTC) or component faults. PID Specification LPG Stepper Motor Location
PID LPG SMP
Description LPG Stepper Motor Position
Units 100 - 160 Steps
Control Area Network (CAN) CAN is a bi-directional bus used in the vehicle for intermodule communications. A DLC connector in the fuse panel allows a WDS to be connected to the CAN for module diagnostics. CAN-H and CAN-L is a balanced pair of twisted wire on the CAN network. It is terminated at the PCM on one end and the instrument cluster on the other. In between the PCM and the instrument cluster are other modules that tap off or daisy chains the CAN-H and CAN-L wires on the wiring harness. CAN-H and CAN-L signals are complementary for EMC. A level of Diagnosis fault tolerance is provided should either line be Diagnostic Trouble Codes (DTC) are retrieved through shorted to ground or 12V. The PCM and the the diagnostic connector using the WDS tester. Fault instrument cluster must be connected for the CAN to Finding Tables for DTCs are in the ‘Diagnosis’ function. section.
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DESCRIPTION AND OPERATION (Continued) CAN Wiring Diagram
Signal Name Traction Control Module AC Compressor Clutch status AC Shed Load Speed control Telltale Engine Coolant Temperature Engine RPM Engine Temperature Warning Engine Type Engine Torque ETC Warning Lamp Fuel Usage Log DTC ODO Count Oil Pressure Warning Smartshield Security Codes Smartshield Warning Lamp Gear Position/ ratio Throttle position G98137 en
Body Electronics Module
Receiving ECU Audio/ Instrument Climate Cluster Control Module R R R R
R
R R
R R
R
R
R R
WDS Tester
R R R R R
R
R
Heater Integrated Module
R R
R R R R R R R R
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DESCRIPTION AND OPERATION (Continued) Signal Name Traction Control Module Transmission Fault Transmission Gear Transmission Mode Transmission Overheat Transmission Type Vehicle speed Diagnostics
Body Electronics Module
Receiving ECU Audio/ Instrument Climate Cluster Control Module R R R R R
R R
R
WDS Tester
R R
The PCM receives the following data from CAN for its operation: Signal Name Transmiting ECU Body Heater Instrument Traction Electronics Integrated Cluster Control Module Module Desired Torque T Command Evaporator temperature Blower voltage
T
A/C Clutch request
T
Park brake on Wheel Speed Immobilization Codes Diagnostics
Heater Integrated Module
Function WDS Tester
T
T T T T
Reduce engine torque to the commanded level during traction control events AC compressor protection calculations Cooling system load calculation to determine appropriate electro-drive fan speed Turns the AC compressor on and off to control the evaporator temperature Cancels speed control Vehicle speed calculation Smartshield Security Diagnostic Function
Connections
Smartshield Security
PCM PinB13………………….… …..……. CAN-H PCM Pin B14……………………………… CAN-L
The PCM forms part of the Smartshield immobilisation system with the BEM, instrument cluster.
Smartshield system diagram Diagnosis Diagnostic Trouble Codes (DTC) are retrieved through the diagnostic connector using the WDS tester. Fault Finding Tables for DTCs are in the ‘Diagnosis’ section. DTCs applicable to the CAN are shown in the following table. DTC U1900
Test Mode KOEO, KOER Cont
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Condition CAN Communication Bus Fault - Receive Error
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DESCRIPTION AND OPERATION (Continued) At key-on, the PCM transmit a code on the CAN line to the BEM to determine if the vehicle should be mobilized. The BEM will only respond with a correct code if the key transponder is recognized. The PCM immobilizes the engine if it does not receive the correct response code. The PCM immobilizes the car by deactivating: fuel injectors ignition system fuel pump starter motor The PCM controls the illumination of the Smartshield warning indicator on the instrument cluster using the CAN line. At key-off, the instrument cluster automatically flashes the warning jewel once every 2 seconds. At key-on, the PCM commands the warning jewel to illuminate for 2 seconds for system prove out. The lamp is commanded to flash if the system is immobilized. The lamp extinguishes after 2 seconds if the system is operational. Radio Security Code The PCM transmits a unique PCM ID code on the CAN for the radio’s security system to discourage theft.
DTC B2139
Test Mode KOEO Cont
PCM or BEM substituted on vehicle BEM does not recognise ignition key
Re-install original components or perform a Parameter Reset operation to train the immobilization system Check BEM DTCs Check KAPWR to PCM, BEM, and CAN lines then perform Parameter Reset Operation again. Check other DTCs. Check BEM and CAN operation
KOEO Cont
Incomplete PCM/BEM training.
P1260
KOEO Cont KOEO Cont
Vehicle Immobilized. Unsuccessful PCM/BEM ID training
U1147
The PCM Smartshield System operates by communicating codes on the CAN line with the BEM, the audio system and the instrument cluster.
Failure Mode
Maintenance Replacement of the PCM, BEM and keys will require a “Parameter Reset ” to be performed.
Start Relay
2. 3.
Action required
B2141
Connections
1.
Condition
Failure in any part of the Smartshield Security System will result in no vehicle operation.
The Smartshield and Smart Start function of the PCM Connect a WDS tester to the Data Link Connector strategy control the START relay. The START relay is enabled when the Smartshield immobilisation system (DLC). is not immobilised. After the vehicle starts, the START Turn the ignition to the RUN/START position relay is de-energise to prevent unintended starter Select “Service Bay Function” and follow the motor operation. menu directions to select “Parameter Reset” Connections Select “Enter Security Access” from the menu. PCM PinB4………………….… …..…….STRTEN There is a 10-minute access delay.
4. 5. 6. Select “Parameter Reset” from the menu. 7. When the BEM is trained correctly, the door locks will cycle twice. 8. Remove the WDS tester. 9. Cycle the ignition key OFF then RUN/START. 10. Verify that the Smartshield indicator turns on for 2 seconds and the vehicle will start. Replacement of the PCM will also require the audio system to be trained to the new PCM ID code. This procedure can be carried out by using the WDS tester. Diagnosis DTCs applicable to the PCM Smartshield system are shown on the following table. G98137 en
Testing 1. Observe that the Smartshield warning lamp operates for 2 seconds when the ignition is key is turned from the OFF to the RUN position. If the Smartshield warning lamp flashes, refer to the Smartshield section in this group. 2. Attempt to start the vehicle in the “P” and “N” positions. 3. Check that condition of the start relay located in the fuse/relay box adjacent to the battery. 4. Check the harness for open circuits and short circuits.
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DESCRIPTION AND OPERATION (Continued)
Diagnosis Diagnosis Diagnostic System A sophisticated on-board diagnostic system is integrated into the PCM software to monitor input and output components. The Powertrain Control Module (PCM) checks that sensors and calculated values are within specified operating parameters. The test varies according to the diagnosis mode and the component. Where a value falls outside of parameters, a Diagnostic Trouble Code (DTC) is reported and logged in the PCMs memory for retrieval. Components and circuits are tested in various ways depending on the hardware, function, and type of signal. Analogue inputs are typically checked for open or short circuits, and out-of-range values. Outputs are checked for open or short circuits by monitoring the circuit associated with the output driver when the output is energised or de-energised. Some outputs are also monitored for the proper function by measuring the reaction of the control system to a given output command.
Diagnostic Connector Diagnostics on the PCM are accessed through the diagnostic connected, situated in the fuse compartment below and to the right of the steering column. Connect a Worldwide Diagnostic System (WDS) tester to retrieve any Diagnostic Trouble Codes (DTC), initiate self-testing diagnostics, retrieve Parameter Identification (PID) values or reset the Keep Alive Memory (KAM) or adaptive values.
operation are logged in Keep Alive Memory (KAM) for later retrieval. On-demand tests are initiated as required to diagnose faults or check vehicle condition. During on-demand tests, the Powertrain Control Module (PCM) checks various sensors and circuits for faults or malfunctions.
Continuous Testing Continuous testing occurs throughout normal vehicle operation. Testing commences 4 seconds after the ignition key is moved to the ON position. Continuous testing does not occur whenever on-demand tests are being performed. When the Powertrain Control Module (PCM) detects a fault or malfunction a Diagnostic Trouble Code (DTC) is reported and stored in the PCMs Keep Alive Memory (KAM) memory. KAM has its own power supply that retains the codes even after the ignition is switched OFF. DTCs can be retrieved by the Worldwide Diagnostic System (WDS) testing tool. Continuous DTCs can be retrieved or cleared at any time using the WDS, independently of on-demand DTCs. To eliminate the storage of transient conditions, continuous fault codes are filtered. Only DTCs present for a specific duration are stored in memory. NOTE: Disconnecting the battery will clear the KAM and all DTCs stored in memory.
Once a DTC is stored, it remains in memory until manually cleared or the PCM is disconnected from the battery supply. If a stored continuous DTC does not occur for 80 subsequent key-ons, then the code is erased from memory. When a DTC is reported from a major input or output sensor or circuit, the PCM will log the DTC. A Failure Diagnostic Connector Location Mode Effects Management (FMEM) flag is set internally in the PCM, which then,if necessary, will implement a FMEM strategy to allow continued operation of the vehicle. The PCM performs the following continuous tests: Analogue/Digital Limit Check Air Conditioning System Tests CMP Test EDIS Test CMP Test VSS Test Auto Transmission Test Traction Control Test Output Circuit Check Diagnostic Modes Setting Of Failure Mode (FMEM) flags The PCM powertrain control management system has Servicing Warm-up Counters two diagnostic modes: Continuous Testing and On-Demand Tests. Fault Filter Calibration Continuous testing occurs during normal vehicle Analogue/Digital Limit Check operation. Faults or malfunctions which occur during The Analogue/Digital Limit Check tests the limits and G98137 en
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DESCRIPTION AND OPERATION (Continued) range of some analogue sensors. The check tests for VSS Test short or open circuit sensors and performs a range The Vehicle Speed Sensor Test checks the Vehicle test on each sensor to ensure it is within the expected Speed Sensor (VSS) signal and circuit. operating range. DTC P0500 is reported if the VSS sensor or its circuit Range checks are only performed where the sensor has malfunctioned. or circuit passes the limit test. The following sensor signal limits are checked during Automatic Transmission Tests the Analogue/Digital Limit Check and associated The Auto Transmission Tests check the operation and Diagnostic Trouble Codes (DTC) are reported if items circuit continuity of the Transmission Range Sensor tested are not within specification. Note that the (TRS-A1) , (SS1-4, VPS, LUS and PCS). VPWR test is designed to check continuity of the DTC P0706 is reported if the TR signal is either out of PCMs internal power circuit (IVPWR). VPWR does range or demonstrates a performance problem. DTC not test battery voltage. P0753 is reported if SS1 or its circuit have failed. Temperature and Manifold Absolute Pressure DTC P0758 is reported if SS2 or its circuit have failed. (T-MAP) DTC P0763 is reported if SS3 or its circuit have failed. Throttle Position Sensor (TP) DTC P0768 is reported if SS4 or its circuit have failed. Air Conditioner Refrigerant Discharge DTC P0748 is reported if Variable Pressure Solenoid Temperature (ACRT) 5 (VPS) or its circuit have failed. Transmission Fluid Temperature Sensor (TFT) DTC P0778 is reported if Power Control Solenoid 6 (PCS) or its circuit have malfunction. Transmission Range Sensor (TR) DTC P0743 is reported if the Lock Up Solenoid 7 Knock Sensor (KS) (LUS) or its circuit have failed. Vehicle Power (VPWR)
Air Conditioning System Tests Air Conditioning Compressor Integrity Failure The Air Conditioning Compressor Integrity Failure test checks the status of the air conditioning compressor clutch and reports a fault if the clutch does not engage, the clutch slips or the compressor output is insufficient.
Solenoids Electrical Fault Logic
When a transmission solenoid electrical fault is detected, the fault is latched:- remains set until next key-on event. Intermittent faults that do not trigger the latch mechanism are not reported.
Output Circuit Check The Output Circuit Check tests some outputs for a DTC P1463 is reported if there is insufficient pressure short or open circuit. change in the air conditioning pressure sensor. The following sensor signal limits are checked during Air Conditioning Low Refrigerant Charge the Output Circuit Check and associated Diagnostic Trouble Codes (DTC) are reported if items tested are The Air Conditioning Low Refrigerant Charge test checks the air conditioning charge and reports a fault not within specification. where the charge is below the specific limit, or if there Electro Drive Fan 1 (EDF1) is an A/C system blockage. Electro Drive Fan 2 (EDF2) DTC P0534 is reported if there is an air conditioning Fuel Pump (FP) refrigerant charge loss or blockage. Air Conditioning Request (ACR) Evaporative Canister Purge Solenoid (EVAP) COP Test The COP Test checks the test checks the continuity of Variable Cam Timing (VCT), the ignition coil circuits and verifies if a coil has fired since the test was last performed. Intake Manifold Runner Control (IMRC) Fuel Injectors 1-8 (INJ1-8) CMP Test The CMP Test checks the Camshaft Position Sensor Each time the engine is re-started from cold the warm-up counter is incremented by one. If the fault (Cylinder Identification) (CMP) signal and causing fault the code is not present after 80 warm-up circuit. cycles, the code is erased from memory. DTC P0340 is reported if the CMP sensor or its circuit Fault Filter Calibration have malfunctioned. Each continuous fault code has a fault filter to avoid DTC P0320 is reported if duration between CMP setting a DTC for transient (seen only for a split signal is greater than a specified value. G98137 en
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DESCRIPTION AND OPERATION (Continued) second) error conditions. When a particular fault occurs during operation the corresponding fault filter increments a background counter by one. For each key-on event the code is not present, the counter is reduced by one. If the counter reaches a specified limit, then a DTC is logged. Continuous DTCs stay in memory until cleared by Servicing Warm-up Counters or manually using the (WDS) tester, or by resetting the Keep Alive Memory (KAM).
On-Demand Testing On-demand testing is initiated to diagnose faults or check operating conditions. On-demand Testing can only commence 4 seconds after the ignition key is moved to the ON position. Continuous testing does not occur whenever on-demand tests are being performed. When the Powertrain Control Module (PCM) detects a fault or malfunction a Diagnostic Trouble Code (DTC) is reported and stored in the PCMs Keep Alive Memory (KAM) memory. KAM has its own power supply that retains the codes even after the ignition is switched OFF. DTCs can be retrieved by the Worldwide Diagnostic System (WDS) testing tool. On-demand DTCs can be retrieved or cleared at any time using the WDS, independently of continuous DTCs. If an on-demand test is requested and conditions are not correct for the test to run, a “conditions not correct” message is displayed on the WDS. On-demand test fault codes are only returned to the WDS tester if the test completes normally. On-demand tests exit the checking procedure under the following conditions: The test completes normally or runs to completion without interruption unless: The test is aborted by the operator; “Cancel” command is issued from the WDS The WDS test equipment is unplugged from the vehicle before the test procedure is complete Operational or vehicle conditions change so that conditions needed to continue the test are no longer met. The time taken to run the test exceeds a pre-set limit for the test. There are seven on-demand test modes. Each is described in further detail in the following sections. Key On Engine Off (KOEO) Key On Engine Running (KOER) Throttle Test Ignition Timing Test Cylinder Contribution Test Output Test Mode (OTM) LPG System Test, I6 engines, where fitted The KOEO and OTM tests are done with key on, engine off. G98137 en
All other on-demand tests are done with key on engine running, and the vehicle stationary. Key On Engine Off (KOEO) and Key On Engine Running (KOER) tests can only be run once during each key on event. The ignition key must be moved to the OFF position before the tests can be re-initiated. Key On Engine Off (KOEO) test NOTE: On manual transmission vehicles, the clutch pedal must be depressed during the whole test. The Key On Engine Off (KOEO) on-demand self-test is a functional test of the powertrain control system. The test checks various sensors and circuits with the ignition key in the ON position and the engine off:-not running. For a fault to be detected during this test the fault must be present at the time the test is initiated or running. Once a fault is detected a Diagnostic Trouble Code (DTC)will be logged in the Powertrain Control Modules (PCM)memory and output to the Diagnostic Link Connector (DLC) for retrieval by a Worldwide Diagnostic System (WDS) tester to the diagnostic tool. KOEO test is performed only once for each key on event. The ignition must be switched to the ON position for at least 4 seconds; do not move the ignition switch to the START position. When the conditions for KOEO test initiation are met, and the test has not already been performed during the current key on session, the PCM performs the following tests: PCM Processor and ROM/RAM Test Analogue/Digital Limit and Range Check Vehicle State Check Electronic Immobilisation Check Output Circuit Check Engine Cooling Fans Check
PCM Processor and ROM/RAM test PCM Processor and ROM/RAM Test checks the PCM Central Processing Unit (CPU), Random Access Memory (RAM), Keep Alive [Memory] Power (KAPWR) and Read Only Memory (ROM) checksum. If any item fails the test, a Diagnostic Trouble Code (DTC) is logged in memory and displayed on the Worldwide Diagnostic System (WDS) tester. DTC P0603 is reported if the KAPWR has been reset since the last key on event DTC P0605 is reported if the ROM checksum test fails DTC P0606 is reported if either the CPU or RAM check fails
Analogue/Digital Check The Analogue/Digital Limit Check tests the limits and range of some analogue sensors. The check tests for short or open circuit sensors and performs a range test on each sensor to ensure it is within the expected operating range. Range checks are only performed 01/2003 2003.0 BA Falcon
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DESCRIPTION AND OPERATION (Continued) where the sensor or circuit passes the limit test. The following sensor signal limits are checked during the Analogue/Digital Limit Check and associated Diagnostic Trouble Codes (DTC) are reported if items tested are not within specification. Temperature and Manifold Absolute Pressure (T-MAP) Throttle Position Sensor (TP) Air Conditioner Pressure Transducer (ACPT) (ACRT) Transmission Fluid Temperature Sensor (TFT) Transmission Range Sensor (TR) Vehicle Power (VPWR)
Vehicle State Check The Vehicle State Check tests that the Power Steering Pressure (PSP)switch is not active, that no Air Conditioner Demand (ACD) is present during KOEO, I6 engines, and for the Transmission Range Sensor (TR) (automatic transmission only) is in either Park or Neutral. DTC P1650 is reported the PSP is active DTC P1705 is reported if the TR is in any position other than Park or Neutral
1. Turning the steering wheel to open the Power Steering Pressure Switch (PSP) . 2. Depressing the brake pedal. Once a fault is detected a Diagnostic Trouble Code (DTC) will be logged in the Powertrain Control Modules (PCM) memory and outputs it to the Diagnostic Link Connector (DLC) for retrieval by a Worldwide Diagnostic System (WDS) tester to the diagnostic tool. KOER test is performed only once for each key on event. The ignition must be switched to the ON position for at least 4 seconds before a new test can be initiated. The test is initiated by the WDS when the vehicle stationary, engine running, transmission in either Park or Neutral, as appropriate; and test has not already been performed during the current key on session: Initialisation Analogue/Digital Limit Check High/Low Idle Speed Test Fuel Ramp Lean/Rich Test Spark Advance Test PSPS Operated Check I6 engines
Initialisation
The Initialisation phase prepares the vehicle for KOER test by switching off Evaporative Canister The Output Circuit Check tests some outputs for a Purge Solenoid (EVAP) , switching off any short or open circuit. The outputs are turned off before Air Conditioner Demand (ACD)Spark advance the check; each output is then switched on in turn for feedback is normally enabled during KOER testing, 50 milliseconds during the test. except during the Spark Advance, Ignition Timing and The following sensor signal limits are checked during Cylinder Contribution tests. During these tests spark advance feedback is disabled and the timing is fixed. the Output Circuit Check and associated Diagnostic Trouble Codes (DTC) are reported if items tested are Analogue/Digital Limit Check not within specification. The Analogue/Digital Limit Check tests the limits and Electro Drive Fan 1 (EDF1) range of some analogue sensors that are not covered Electro Drive Fan 2 (EDF2) by Key On Engine Off test. The check tests for short Fuel Pump (FP) or open circuit sensors and performs a range test on each sensor to ensure it is within the expected range Air Conditioning Request (ACR) under actual engine operating conditions. Range Evaporative Canister Purge Solenoid (EVAP) checks are only performed where the sensor or circuit passes the limit test. Variable Cam Timing (VCT) The following sensor signal limits are checked during Intake Manifold Runner Control (IMRC) . the Analogue/Digital Limit Check and associated Diagnostic Trouble Codes (DTC) are reported if items Key On Engine Running (KOER) test tested are not within specification. The Key On Engine Running (KOER) on-demand The Cylinder Head temperature Sensor (CHT) self-test is a functional test performed with the engine Temperature and Manifold Absolute Pressure operating in normal conditions and temperatures. The (T-MAP) test checks various sensors and circuits with the ignition key in the ON position and the engine Throttle Position Sensor (TP) on:-running. For a fault to be detected during this test High/Low Idle Speed Test the fault must be present at the time the test is initiated or running. This test calls for some operator The High/Low Idle Speed Test checks that the intervention to test additional sensor information. This Electronic Throttle Control (ETC) can properly control includes the idle speed. The test increases then decreases the idle speed and measures the change in engine speed.
Output Circuit Check
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DESCRIPTION AND OPERATION (Continued) DTC P0507 is reported if the idle speed is higher than table. the expected low idle speed Output Test Mode States DTC P0506 is reported if the idle speed is lower than the expected high idle speed State Description All On The following outputs are switched on (engine Fuel Ramp Lean/Rich Test cooling fans off): Air Conditioning Clutch Relay (ACR), The Fuel Ramp Lean/Rich Test varies the Fuel evaporative Emission Canister Purge (EVAP), Starter Injector Pulse Width and measures the Heated Relay (START), Fuel Pump (FP) relay, Intake Exhaust Gas Oxygen Sensors (HEGO) signal to Manifold Charge Control (IMCC) and Variable Cam detect if the Powertrain Control Module (PCM) can Timing (VCT)* All Off The outputs listed above, and successfully control the air fuel ratio between lean and engine cooling fans, are switched off. rich. Fans Low The engine cooling fans (EDF1-2) are If DTC P0131 or P0151, V8 engine, HEGO sensor switched on at low speed; all other outputs above short circuit is already set, the Fuel Ramp Lean/Rich switched off. Fans High The engine cooling fans Test will not be performed. (EDF1-2) are switched on at high speed; all other outputs above switched off. I6 Engines DTC P0172 is reported if the air fuel ratio is too rich LPG System Test during the lean phase of the test The LPG System Test checks the operation of the DTC P0171 is reported if the air fuel ratio is too lean complete LPG fuel control system on vehicles with during the rich phase of the test Ford Factory Fitted LPG systems.
Power Steering Pressure Switch Operated Check
The PCM uses the Heated Exhaust Gas Oxygen Sensor (HEGO) signal to detect that a change in the air fuel ratio occurs when the LPG stepper motor is actuated. The LPG stepper motor is ramped lean and then rich to force a change in the HEGO output. The test will fail if the system fails to switch either lean or rich within a set time or if the RPM drops below its predefined limits. A failure in this test can be caused by faulty stepper motor, wiring, PCM, HEGO sensor or LPG converter. Code P1159 is reports a fuel stepper motor malfunction if the air fuel ratio cannot be changed by the PCM during the test.
A requirement of KOER test is that the test operator moves the steering wheel to either left or right hand extreme lock to operate the Power Steering Pressure Switch (PSP) . The PCM checks that the power steering pressure switch changes state during the KOER test. DTC P1651 is reported if the PSP does not change state during the test.
Ignition Test The Ignition Test sets the ignition spark advance to a fixed value so that ignition timing can be manually checked using a timing light. Fixed timing mode stays in effect for 2 minutes or less if cancelled from the WDS. Fixed timing can be performed more than once during the same Key On Engine Running (KOER) test session.
Output Test Mode The Output Test Mode (OTM), No. 84, allows some Powertrain Control Module (PCM) outputs to be switched on and off manually using the Worldwide Diagnostic System (WDS) tester. Either an audible sound or visually verification of a device can confirm its operation. The OTM may be performed more than once during a KOEO event. TM can only be entered with the key in the ON position and the engine off:-not running. There are no fault codes reported following this test. The test will time out and abort if the test time in any one state exceeds a specified limit.
No fault codes are reported from the ignition test.
V8 Engines DTC P0172 is reported if the air fuel ratio is too rich on cylinder bank 1 during the lean phase of the test DTC P0175 is reported if the air fuel ratio is too rich on cylinder bank 2 during the lean phase of the test DTC P0171 is reported if the air fuel ratio is too lean on cylinder bank 1 during the rich phase of the test DTC P0174 is reported if the air fuel ratio is too lean on cylinder bank 2 during the rich phase of the test
Once OTM has been entered, there are 4 states that can be manually selected, as shown in the following G98137 en
Parameter Identification A Parameter Identification (PID) represents an internal Powertrain Control Module (PCM) parameter. PIDs accessed using the Worldwide Diagnostic System (WDS) tester are displayed as parameter names with operating values of analogue and digital inputs/outputs, calculated values and system status information. The WDS PID data monitor and record data function can display values and data dynamically during normal running and can also record the data for detailed diagnosis. 01/2003 2003.0 BA Falcon
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DESCRIPTION AND OPERATION (Continued) Input PID values can immediately confirm the status of a sensor and its associated circuit to the Powertrain Control Module (PCM). Similarly output PID values can monitor the operation of an output device or signal being sent from the PCM. Use of PIDs minimises the need to perform pin out tests. Circuit continuity and a sensor’s actual operating value can be read directly from the WDS. PIDs can optimize diagnostic time by quickly identifying faulty components or circuits.
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DIAGNOSIS AND TESTING Diagnostic Communications
Powertrain Control Management Powertrain Control Management Diagnostic Trouble Codes The PCM diagnostic system monitors the condition of various sensors and circuits associated with control of the powertrain. A Diagnostic Trouble Code (DTC) is reported and logged in memory to identify the specific area where a fault has been reported to the Powertrain Control Module (PCM).
Retrieving Diagnostic Trouble Codes Diagnostic data is accessible with the Worldwide Diagnostic System (WDS) tester to assist in diagnosing faults and operating conditions on the vehicle. The system is accessed through the diagnostic connector situated in the fuse box, below and to the right of the steering column. The functions and operation of the WDS are described in the Worldwide Diagnostic System (WDS) Tester Instruction Manual.
DTC Description AC Compressor Clutch A979 KOEO, KOER cycling due to ACPT cutout. Cont Incorrect BEM Response B2139 KOEO, Cont. Code.
B2141 KOEO, Cont.
Incomplete PCM/BEM training.
The PCM communicates with the Worldwide Diagnostic System (WDS) tester through the diagnostic connector using the Control Area Network (CAN).
Resetting The Powertrain Control Module NOTE: Do not disconnect the battery to clear the Keep Alive Memory (KAM) or Diagnostic Trouble Codes (DTC) unless absolutely necessary. Disconnecting the battery will clear the PCM memory, including the adaptive values. Clearing Diagnostic Trouble Codes (DTC) Once a system fault has been rectified, the diagnostic trouble codes must be cleared from the PCM memory using the Worldwide Diagnostic System (WDS) tester. 1. Connect the Worldwide Diagnostic System (WDS) tester to the diagnostic connector. 2. Initiating Retrieve/Clear Continuous DTCs. 3. After the codes appear on the screen, press “CLEAR”, to erase DTCs from memory. 4. Verify the codes have been erased by test-driving the vehicle and then repeat Step 2. Possible Causes
Refer to AC section
IMMOBILIZATION SYSTEM CONDITION PCM or BEM substituted on vehicle BEM does not recognise ignition key IMMOBILIZATION SYSTEM CONDITION Unsuccessful PCM/BEM ID training
Temperature And P0107 SENSOR CONDITION KOEO, KOER, ManifoldAbsolute Pressure Sensor damaged or faulty Cont. (T-MAP) circuit low input DTC P0107 is reported if the manifold pressure sensor in the T-MAP Sensor is less than the self- test range.
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ACTION REQUIRED Perform a Parameter Reset operation to train the immobilization system Check BEM DTCs ACTION REQUIRED Check KAPWR to PCM, BEM operation, and CAN line operation then perform Parameter Reset operation again ELECTRICAL CONDITION Improper connection, signal open circuit or shorted to ground, low Vehicle Reference Voltage (VREF), VREF open circuit OTHER CONDITION Manifold pressure has changed but signal from Throttle Position Sensor (TP) remains steady, PCM damaged or faulty
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DIAGNOSIS AND TESTING (Continued) DTC Description Temperature And P0108 KOEO, KOER, ManifoldAbsolute Pressure Cont. (T-MAP) circuit high input DTC P0108 is reported if the manifold pressure sensor in the T- MAP Sensor is greater than the self-test range.
Intake air temperature signal P0112 KOEO, KOER, (T-MAP sensor) circuit low Cont. input. DTC P0112 is reported if the air temperature signal is less than the self-test range.
Intake air temperature signal P0113 KOEO, KOER, (T- MAP) Cont. DTC P0113 is reported if the air temperature signal is greater than the self-test range.
Throttle Position Sensor (TP) P0121 KOEO, KOER circuit range/ performance problem DTC P0121 is reported if the TP sensor signal is out of the self-test range.
Throttle Position Sensor P0122 KOEO, KOER, (TP1) circuit low input Cont. DTC P0122 is reported if the TP sensor signal is less than the self-test range.
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Possible Causes MECHANICAL CONDITION ELECTRICAL CONDITION Vacuum leak at manifold, Improper connection, signal sensor loose or not installed shorted to Vehicle Power on manifold (VPWR), high Vehicle Reference Voltage (VREF) SENSOR CONDITION Sensor damaged or faulty OTHER CONDITION Manifold pressure has changed but signal from Throttle Position Sensor (TP) remains steady, PCM damaged or faulty SENSOR CONDITION ELECTRICAL CONDITION Faulty or malfunctioning Improper connection, sensor incorrect Reference Voltage (VREF), sensor signal or Signal Return (SIGRTN) shorted to ground OTHER CONDITION Extreme low ambient temperature, faulty or damaged PCM MECHANICAL CONDITION ELECTRICAL CONDITION Clogged air filter Improper connection, incorrect Reference Voltage SENSOR CONDITION Faulty or malfunctioning (VREF),T-MAP sensor signal sensor shorted to VREF or Vehicle Power (VPWR), T-MAP sensor signal open circuit, Signal Return (SIGRTN) open circuit OTHER CONDITION Extreme high ambient temperature, PCM damaged or faulty MECHANICAL CONDITION ELECTRICAL CONDITION Binding or bent throttle shaft Improper connection, throttle plate below closed corrosion on contacts or position, throttle plate or base connectors, Reference idle screw maladjustment, TP Voltage (VREF) too low, TP sensor not properly secured sensor signal or VREF open or loose circuit, TP signal shorted to Signal Return (SIGRTN) or SENSOR CONDITION TP sensor loose or incorrectly ground installed. TP sensor damaged OTHER CONDITION or faulty; corrosion on TP PCM faulty or damaged. sensor brush, contaminated TP sensor brush SENSOR CONDITION ELECTRICAL CONDITION TP1 sensor faultyor damaged. Improper connection, Check Throttle Position corrosion on contacts or Sensor Connector. connectors, Reference Voltage (VREF) too low, TP sensor signal or VREF open circuit, TP signal shorted to Signal Return (SIGRTN) or ground OTHER CONDITION PCM damaged or faulty 01/2003 2003.0 BA Falcon
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DIAGNOSIS AND TESTING (Continued) DTC Description Throttle Position Sensor P0123 KOEO, KOER, (TP1) circuit high input Cont. DTC P0123 is reported if the TP sensor signal is greater than the self-test range.
Possible Causes SENSOR CONDITION ELECTRICAL CONDITION TP1 sensor faulty or Improper connection, TP damaged. Check Throttle sensor signal shorted to Position Sensor Connector. Reference voltage (VREF) or Vehicle Power (VPWR), Signal Return (SIGRTN) open circuit, Reference Voltage (VREF) shorted to Vehicle Power (VPWR) Throttle/Pedal Position P0124 SENSOR CONDITION ELECTRICAL CONDITION KOEO, KOER, Sensor Intermittent TP1 sensor faulty or Improper connection, TP Cont. DTC P0124 is reported if the damaged. Check Throttle sensor signal shorted to TP sensor signal is Position Sensor Connector. Reference voltage (VREF) or intermittent Vehicle Power (VPWR), Signal Return (SIGRTN) open circuit, Reference Voltage (VREF) shorted to Vehicle Power (VPWR) Fuel System too lean (I6, P0171 FUEL SYSTEM CONDITION INTAKE AIR CONDITION KOEO, KOER bank 1-V8) External leak at fuel injectors, Defective positive crankcase Cont DTC P0171 is reported to externally leaking fuel ventilation system, faulty indicate the air fuel ratio is pressure regulator, leaking Evaporative Purge (EVAP) incorrect, too lean. The fuel rail, inadequate pressure Canister or Solenoid adaptive fuel control strategy from fuel pump, fuel injectors ELECTRICAL CONDITION has reached the limit of contaminated with foreign Heated Exhaust Gas Oxygen available mixture correction. material, blocked or restricted Sensor (HO2S) signal shorted fuel filter to ground; moisture in harness connectors, blown CAUTION: A leaking HO2S heater fuse fuel system poses a OTHER CONDITION potential fire hazard. Leaking exhaust system; leak at manifold slip joint, leaking SENSOR CONDITION joint between engine pipe and Sensor damaged or faulty catalyst converter, leak at engine pipe to manifold joint, damaged or leaking exhaust Fuel System too rich (I6, P0172 FUEL SYSTEM CONDITION INTAKE AIR CONDITION KOEO, KOER bank 1- V8) Internally leaking fuel Faulty or damaged Cont DTC P0172 is reported to injectors, damaged fuel Evaporative Canister Purge indicate the air fuel ratio is pressure regulator, obstructed Solenoid (EVAP) , incorrect, too rich. The fuel return line, low or no EVAP canister saturated with adaptive fuel control strategy vacuum to fuel pressure fuel has reached the limit of regulator; leaking, damaged ELECTRICAL CONDITION available mixture correction. or missing vacuum hose to Heated Exhaust Gas Oxygen fuel pressure regulator. Sensor (HO2S) signal shorted to Vehicle Power (VPWR), CAUTION: A leaking blown HO2S heater fuse. fuel system poses a OTHER CONDITION potential fire hazard. Restricted exhaust system, Engine Cylinder Head SENSOR CONDITION Temperature Sensor (CHT) or Sensor damaged or faulty cooling system fault
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DIAGNOSIS AND TESTING (Continued) DTC Description Fuel System too lean (bank P0174 KOEO, KOER 2-V8) Cont DTC P0174 is reported to indicate the air fuel ratio is incorrect, too lean. The adaptive fuel control system has reached the limit of available mixture correction.
Possible Causes FUEL SYSTEM CONDITION INTAKE AIR CONDITION External leak at fuel injectors, Defective positive crankcase externally leaking fuel ventilation system, faulty pressure regulator, leaking Evaporative Purge (EVAP) fuel rail, inadequate pressure Canister or Solenoid from fuel pump, fuel injectors ELECTRICAL CONDITION contaminated with foreign Heated Exhaust Gas Oxygen material, blocked or restricted Sensor (HO2S) signal shorted fuel filter to ground; moisture in harness connectors, blown CAUTION: A leaking HO2S heater fuse fuel system poses a OTHER CONDITION potential fire hazard. Leaking exhaust system; leak at manifold slip joint, leaking SENSOR CONDITION joint between engine pipe and Sensor damaged or faulty catalyst converter, leak at engine pipe to manifold joint, damaged or leaking exhaust Fuel System too rich (bank P0175 FUEL SYSTEM CONDITION INTAKE AIR CONDITION KOEO, KOER 2-V8) Internally leaking fuel faulty or damaged Cont DTC P0175 is reported to injectors, damaged fuel Evaporative Canister Purge indicate the air fuel ratio is pressure regulator, obstructed Solenoid (EVAP) P, incorrect, too rich. The fuel return line, low or no EVAP canister saturated with adaptive fuel control system vacuum to fuel pressure fuel has reached the limit of regulator; leaking, damaged ELECTRICAL CONDITION available mixture correction. or missing vacuum hose to Heated Exhaust Gas Oxygen fuel pressure regulator. Sensor (HO2S) signal shorted to Vehicle Power (VPWR), CAUTION: A leaking blown HO2S heater fuse. fuel system poses a OTHER CONDITION potential fire hazard. restricted exhaust system, Engine Cylinder Head SENSOR CONDITION Temperature Sensor (CHT) or Sensor damaged or faulty. cooling system fault ngine Oil Temperature P0196 SENSOR CONDITION ELECTRICAL CONDITION KOER Sensor Circuit Sensor damaged or faulty; Improper wiring connection to Range/Performance sensor. EOT wiring circuit EDTC P0196 is reported if shorted to VPWR, VREF or the EOT Sensor temperature PWRGND. is inconsistent with engine OTHER CONDITION temperature. CHT sensor faulty. Injector Circuit / Open P0201 ELECTRICAL CONDITION OTHER CONDITION KOEO, KOER Cylinder 1 Improper connection, injector Faulty fuel injector; fuel Cont DTC P0201 is reported if the shorted to ground or Vehicle injector field coil not fuel injector for cylinder 1 is Power (VPWR), short or open continuous malfunctioning or fails the circuit in injector coil KOEO self-test Injector Circuit / Open P0203 ELECTRICAL CONDITION OTHER CONDITION KOEO, KOER Cylinder 3 Improper connection, injector Faulty fuel injector; fuel Cont DTC P0203 is reported if the shorted to ground or Vehicle injector field coil not fuel injector for cylinder 3 is Power (VPWR), short or open continuous malfunctioning or fails the circuit in injector coil KOEO self-test
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DIAGNOSIS AND TESTING (Continued) DTC Description Injector Circuit / Open P0204 KOEO, KOER Cylinder 4 Cont DTC P0204 is reported if the fuel injector for cylinder 4 is malfunctioning or fails the KOEO self-test Injector Circuit / Open P0205 KOEO, KOER Cylinder 5 Cont DTC P0205 is reported if the fuel injector for cylinder 5 is malfunctioning or fails the KOEO self-test Injector Circuit / Open P0206 KOEO, KOER Cylinder 6 Cont DTC P0206 is reported if the fuel injector for cylinder 6 is malfunctioning or fails the KOEO self-test Injector Circuit / Open P0207 KOEO, KOER Cylinder 7 Cont DTC P0207 is reported if the fuel injector for cylinder 7 is malfunctioning or fails the KOEO self-test Injector Circuit / Open P0208 KOEO, KOER Cylinder 8 Cont DTC P0208 is reported if the fuel injector for cylinder 8 is malfunctioning or fails the KOEO self-test TP2-PS fails - Out-of-range P0221 KOEO, KOER, at commanded settings. Cont. DTC P0221 is reported if the TP sensor signal is invalid at the commanded throttle position.
Possible Causes ELECTRICAL CONDITION OTHER CONDITION Improper connection, injector Faulty fuel injector; fuel shorted to ground or Vehicle injector field coil not Power (VPWR), short or open continuous circuit in injector coil ELECTRICAL CONDITION Improper connection, injector shorted to ground or Vehicle Power (VPWR), short or open circuit in injector coil
OTHER CONDITION Faulty fuel injector; fuel injector field coil not continuous
ELECTRICAL CONDITION Improper connection, injector shorted to ground or Vehicle Power (VPWR), short or open circuit in injector coil
OTHER CONDITION Faulty fuel injector; fuel injector field coil not continuous
ELECTRICAL CONDITION Improper connection, injector shorted to ground or Vehicle Power (VPWR), short or open circuit in injector coil
OTHER CONDITION Faulty fuel injector; fuel injector field coil not continuous
ELECTRICAL CONDITION Improper connection, injector shorted to ground or Vehicle Power (VPWR), short or open circuit in injector coil
OTHER CONDITION Faulty fuel injector; fuel injector field coil not continuous
MECHANICAL CONDITION Binding or bent throttle shaft throttle plate below closed position, throttle plate or base idle screw maladjustment, TP sensor not properly secured or loose SENSOR CONDITION TP sensor loose or incorrectly installed. TP sensor faulty or damaged. TP sensor damaged or faulty; corrosion on TP sensor brush, contaminated TP sensor brush Throttle Position Sensor P0222 SENSOR CONDITION KOEO, KOER, (TP2) circuit low input TP sensor loose or incorrectly Cont. DTC P0222 is reported if the installed.TP sensor faulty or TP sensor signal is less than damaged. Check Throttle the self- test range. Position Sensor Connector.
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ELECTRICAL CONDITION Improper connection, corrosion on contacts or connectors, Reference Voltage (VREF) too low, TP sensor signal or VREF open circuit, TP signal shorted to Signal Return (SIGRTN) or ground OTHER CONDITION PCM damaged or faulty
ELECTRICAL CONDITION Improper connection, corrosion on contacts or connectors, Reference Voltage (VREF) too low, TP sensor signal or VREF open circuit, TP signal shorted to Signal Return (SIGRTN) or ground OTHER CONDITION PCM damaged or faulty
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DIAGNOSIS AND TESTING (Continued) DTC Description Throttle Position Sensor P0223 KOEO, KOER, (TP2) circuit high input Cont. DTC P0223 is reported if the TP sensor signal is greater than the self-test range.
Throttle/Pedal Position P0224 KOEO, KOER, Sensor Intermittent Cont DTC P0224 is reported if the TP sensor signal is intermittent
Fuel Pump (FP) relay P0230 KOEO, KOER primary circuit malfunction Cont DTC P0230 is reported if a malfunction develops in the fuel pump, fuel pump relay or fuel pump circuit Turbo Charger Boost Sensor P0236 KOEO, KOER, Circuit Range/Performance Cont.
Turbo Charger Boost Sensor P0237 KOEO, KOER, Circuit Low Cont. Turbo Charger Boost Sensor P0238 KOEO, KOER, Circuit High Cont. Engine Speed Input Circuit P0320 KOEO, KOER DTC P0320 is reported if Cont duration between two successive PIP signals is greater than specified value resulting in a possible engine stall or misfire
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Possible Causes SENSOR CONDITION ELECTRICAL CONDITION TP sensor loose or incorrectly Improper connection, TP installed. TP sensor faulty or sensor signal shorted to damaged. Check Throttle Reference voltage (VREF) or Position Sensor Connector. Vehicle Power (VPWR), Signal Return (SIGRTN) open circuit, Reference Voltage (VREF) shorted to Vehicle Power (VPWR) OTHER CONDITION PCM damaged or faulty SENSOR CONDITION ELECTRICAL CONDITION TP sensor loose or incorrectly Improper connection, TP installed. TP sensor faulty or sensor signal shorted to damaged. Check Throttle Reference voltage (VREF) or Position Sensor Connector. Vehicle Power (VPWR), Signal Return (SIGRTN) open circuit, Reference Voltage (VREF) shorted to Vehicle Power (VPWR) OTHER CONDITION PCM damaged or faulty ELECTRICAL CONDITION RELAY CONDITION Improper connection, fuel Open circuit to fuel pump pump circuit open or shorted relay, open circuit within fuel circuit between fuel pump pump relay improper relay and FP, Vehicle Power connection to fuel pump relay (VPWR) open circuit to fuel OTHER CONDITION pump, fuel pump circuit PCM damaged or faulty shorted to VPWR SENSOR CONDITION ELECTRICAL CONDITION Sensor damaged or faulty. Intermittent electrical connection to T-MAP sensor. Intermittent short circuit to VPWR, VREF or PWRGND. SIGRTN shorted to PWRGND. SENSOR CONDITION ELECTRICAL CONDITION Sensor damaged or faulty. Improper connection, signal shorted to Vehicle Power (VPWR), high Vehicle Reference Voltage (VREF) SENSOR CONDITION ELECTRICAL CONDITION Sensor damaged or faulty. Improper connection, signal shorted to Vehicle Power (VPWR), high Vehicle Reference Voltage (VREF) ELECTRICAL CONDITION OTHER CONDITION Improper connection, short or Interference from on open circuit in harness boardtransmitter such as a two way radio, faulty or SENSOR CONDITION Faulty Crankshaft Position damaged PCM Sensor (CK), faulty or damaged reluctor (toothed wheel)
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Powertrain Control Management
303-14-77
DIAGNOSIS AND TESTING (Continued) DTC Description Knock Sensor (KS) circuit P0325 KOEO, KOER malfunction Cont DTC P0325 is reported if the KS is out of the self-test range. Camshaft Position Sensor P0340 KOEO, KOER CID1 (I6 Intake Cam, V8 Cont Bank 1)
P0351 I6 Engine KOEO, KOER Ignition Coil 1 Cont Primary/Secondary Circuit Failure V8 Engine Ignition Coil 1 Primary/Secondary Circuit Failure.
P0352 I6 Engine KOEO, KOER Ignition Coil 5 Cont Primary/Secondary Circuit Failure V8 Engine Ignition Coil 3 Primary/Secondary Circuit Failure.
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Possible Causes ELECTRICAL CONDITION SENSOR CONDITION Improper connection, open or Sensor damaged or faulty. short circuit, KS shorted to General background noise not ground, KS shorted to Vehicle within expected range Power (VPWR) OTHER CONDITION PCM damaged or faulty MECHANICAL CONDITION ELECTRICAL CONDITION Inlet camshaft (I6) or Bank1 Improper connection to CID1 (V8) camshaft incorrectly Sensor. installed. Reluctor incorrectly installed on camshaft Sensor loose or incorrectly secured. SENSOR CONDITION Sensor damaged or faulty; IGNITION SYSTEM OTHER CONDITION Crankshaft Position Sensor CONDITION Fouled spark plugs, incorrect (CKP) or reluctor (toothed spark plug gap, worn or wheel) faulty or damaged, damaged spark plugs, faulty PCM excessive carbon deposits on spark plugs, coil faulty or damaged ELECTRICAL CONDITION coil signal shorted to ground, Vehicle Power (VPWR) or Signal Return (SIGRTN), faulty or improper coil signal connection, improper signal from Crankshaft Position Sensor (CKP) to PCM, wiring fault. IGNITION SYSTEM OTHER CONDITION Crankshaft Position Sensor CONDITION Fouled spark plugs, incorrect (CKP) or reluctor (toothed spark plug gap, worn or wheel) faulty or damaged, damaged spark plugs, faulty PCM excessive carbon deposits on spark plugs, coil faulty or damaged ELECTRICAL CONDITION coil signal shorted to ground, Vehicle Power (VPWR) or Signal Return (SIGRTN), faulty or improper coil signal connection, improper signal from Crankshaft Position Sensor (CKP) to PCM, wiring fault.
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Powertrain Control Management
303-14-78
DIAGNOSIS AND TESTING (Continued) DTC Description P0353 I6 Engine KOEO, KOER Ignition Coil 3 Cont Primary/Secondary Circuit Failure V8 Engine Ignition Coil 7 Primary/Secondary Circuit Failure.
P0354 I6 Engine KOEO, KOER Ignition Coil 6 Cont Primary/Secondary Circuit Failure V8 Engine Ignition Coil 2 Primary/Secondary Circuit Failure.
P0355 I6 Engine KOEO, KOER Ignition Coil 2 Cont Primary/Secondary Circuit Failure V8 Engine Ignition Coil 6 Primary/Secondary Circuit Failure.
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Possible Causes IGNITION SYSTEM OTHER CONDITION Crankshaft Position Sensor CONDITION Fouled spark plugs, incorrect (CKP) or reluctor (toothed spark plug gap, worn or wheel) faulty or damaged, damaged spark plugs, faulty PCM excessive carbon deposits on spark plugs, coil faulty or damaged ELECTRICAL CONDITION coil signal shorted to ground, Vehicle Power (VPWR) or Signal Return (SIGRTN), faulty or improper coil signal connection, improper signal from Crankshaft Position Sensor (CKP) to PCM, wiring fault. IGNITION SYSTEM OTHER CONDITION Crankshaft Position Sensor CONDITION Fouled spark plugs, incorrect (CKP) or reluctor (toothed spark plug gap, worn or wheel) faulty or damaged, damaged spark plugs, faulty PCM excessive carbon deposits on spark plugs, coil faulty or damaged ELECTRICAL CONDITION Coil signal shorted to ground, Vehicle Power (VPWR) or Signal Return (SIGRTN), faulty or improper coil signal connection, improper signal from Crankshaft Position Sensor (CKP) to PCM, wiring fault. IGNITION SYSTEM OTHER CONDITION Crankshaft Position Sensor CONDITION Fouled spark plugs, incorrect (CKP) or reluctor (toothed spark plug gap, worn or wheel) faulty or damaged, damaged spark plugs, faulty PCM excessive carbon deposits on spark plugs, coil faulty or damaged ELECTRICAL CONDITION Coil signal shorted to ground, Vehicle Power (VPWR) or Signal Return (SIGRTN), faulty or improper coil signal connection, improper signal from Crankshaft Position Sensor (CKP) to PCM, wiring fault.
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Powertrain Control Management
303-14-79
DIAGNOSIS AND TESTING (Continued) DTC Description P0356 I6 Engine KOEO, KOER Ignition Coil 4 Cont Primary/Secondary Circuit Failure V8 Engine Ignition Coil 5 Primary/Secondary Circuit Failure.
P0357 V8 Engine KOEO, KOER Ignition Coil 4 Cont Primary/Secondary Circuit Failure.
P0358 V8 Engine KOEO, KOER Ignition Coil 8 Cont Primary/Secondary Circuit Failure.
Evaporative Emission P0443 KOEO, KOER System Purge Control Cont Valve Circuit malfunction
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Possible Causes IGNITION SYSTEM OTHER CONDITION Crankshaft Position Sensor CONDITION Fouled spark plugs, incorrect (CKP) or reluctor (toothed spark plug gap, worn or wheel) faulty or damaged, damaged spark plugs, faulty PCM excessive carbon deposits on spark plugs, coil faulty or damaged ELECTRICAL CONDITION Coil signal shorted to ground, Vehicle Power (VPWR) or Signal Return (SIGRTN), faulty or improper coil signal connection, improper signal from Crankshaft Position Sensor (CKP) to PCM, wiring fault. IGNITION SYSTEM OTHER CONDITION Crankshaft Position Sensor CONDITION Fouled spark plugs, incorrect (CKP) or reluctor (toothed spark plug gap, worn or wheel) faulty or damaged, damaged spark plugs, faulty PCM excessive carbon deposits on spark plugs, coil faulty or damaged ELECTRICAL CONDITION Coil signal shorted to ground, Vehicle Power (VPWR) or Signal Return (SIGRTN), faulty or improper coil signal connection, improper signal from Crankshaft Position Sensor (CKP) to PCM, wiring fault. IGNITION SYSTEM OTHER CONDITION Crankshaft Position Sensor CONDITION Fouled spark plugs, incorrect (CKP) or reluctor (toothed spark plug gap, worn or wheel) faulty or damaged, damaged spark plugs, faulty PCM excessive carbon deposits on spark plugs, coil faulty or damaged ELECTRICAL CONDITION Coil signal shorted to ground, Vehicle Power (VPWR) or Signal Return (SIGRTN), faulty or improper coil signal connection, improper signal from Crankshaft Position Sensor (CKP) to PCM, wiring fault. SOLENOID CONDITION ELECTRICAL CONDITION Solenoid open or short circuit Improper connection, CANP output wiring shorted to Vehicle Power (VPWR) or Ground.
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303-14-80
DIAGNOSIS AND TESTING (Continued) DTC Description Vehicle Speed signal fault P0500 KOEO, KOER DTC P0500 is reported if the Cont vehicle speed signal is not received at the Powertrain Control Module (PCM). The signal may be missing or intermittent.
Vehicle Speed signal fault P0503 KOEO, KOER DTC P0503 is reported if the Cont vehicle speed signal is not received at the Powertrain Control Module (PCM). The signal may be missing or intermittent.
P0505 KOER
Idle Air Control System DTC P0506 is reported if the idle speed cannot be controlled to a specified speed during self-test
P0532 KOEO, Cont.
Air Conditioner PressureTransducer (ACPT) sensor circuit low input DTC P0532 is reported if the ACPT sensor is less than the self- test range.
Air Conditioner P0532 KOEO, KOER PressureTransducer (ACPT) Cont sensor circuit low Input DTC P0532 is reported if the ACPT sensor is greater than the self-test range.
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Possible Causes ASR Equipped Vehicle OSS Equipped Vehicle Check ASR warning lamp. Check VSS wiring between Rectify ASR faults if required. PCM and OSS on Check other DTCs. Rectify as transmission for open circuit, required. short circuit to VPWR and Ground. ABS Equipped Vehicle Check ABS warning lamp. Check condition of OSS and Rectify ABS faults if required. driven gears Check VSS wiring between OTHER CONDITION PCM and ABS module for PCM VID block incorrectly open circuit, short circuit to configuredPCM damaged or VPWR and Ground. faulty ASR Equipped Vehicle OSS Equipped Vehicle Check ASR warning lamp. Check VSS wiring between Rectify ASR faults if required. PCM and OSS on Check other DTCs. Rectify as transmission for open circuit, required. short circuit to VPWR and Ground. ABS Equipped Vehicle Check ABS warning lamp. OTHER CONDITION Rectify ABS faults if required. PCM damaged or faulty Check VSS wiring between PCM and ABS module for open circuit, short circuit to VPWR and Ground. MECHANICAL CONDITION ELECTRICAL CONDITION Extreme blockage of the air Electronic throttle body wiring inlet system or air cleaner. open circuit or, short circuit to Improper adjustment of VPWR or Ground throttle stop screw. Damaged OTHER CONDITION throttle stop screw; faulty PCM damaged or faulty throttle body or gasket. Throttle body loose; sticking or binding throttle plate; Faulty or damaged positive crankcase ventilation system, leaking o-ring at fuel injector. Vacuum leak in manifold; hole in inlet manifold, damaged gasket at inlet manifold, damaged, broken or missing vacuum hose. ELECTRICAL CONDITION AIR CONDITIONING Improper connection, Air SYSTEM Conditioner Pressure Refer to Section 412-03, Transducer (ACPT) sensor AirConditioning for air open circuit or shorted to conditioner diagnosis ground. OTHER CONDITION PCM damaged or faulty ELECTRICAL CONDITION AIR CONDITIONING Improper connection, Air SYSTEM Conditioner Pressure Refer to section 412-03, Air Transducer (ACPT) shorted to Conditioning for air ground or SIGRTN conditioner diagnosis OTHER CONDITION PCM damaged or faulty
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DIAGNOSIS AND TESTING (Continued) DTC Description Air Conditioner P0533 KOEO, KOER PressureTransducer (ACPT) Cont sensor circuit high input DTC P0533 is reported if the ACPT sensor is greater than the self-test range. A/C Refrigerant Charge Loss P0534 KOEO, KOER Cont Battery / System voltage low DTC P0562 is reported if the battery voltage is below 9.0 Volts System Voltage High Cont. DTC P0563 is reported if the battery voltage is above 16.0 Volts Powertrain Control Module KOER Vehicle ID block Programming Error
P0562 KOEO, Cont.
P0563 KOEO,
P0602 KOEO, Cont
Keep Alive Memory (KAM test failed. Internal control module failure DTC P0603 is reported if the KAM has been reset since the last key on event Powertrain Control Module Read Only Memory (ROM) Error DTC P0605 is reported if the ROM checksum test fails Powertrain Control Module (PCM) Central Processing Unit (CPU) fault DTC P0606 is reported if either the CPU or Read Only Memory (RAM) check fails Transmission Range Sensor KOER (TRSA1) sensor circuit low input (Auto) DTC P0707 is reported if the TSA1 sensor signal is less than the self-test range.
P0603 KOEO, Cont
P0605 KOEO
P0606 KOEO
P0707 KOEO, Cont
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Possible Causes ELECTRICAL CONDITION AIR CONDITIONING Improper connection, Air SYSTEM Conditioner Pressure Refer to section 412-03, Air Transducer (ACPT) shorted to Conditioning for air Vehicle Power (VPWR), conditioner diagnosis Vehicle Reference Voltage OTHER CONDITION (VREF) PCM damaged or faulty Refer to section 412-03. AIR CONDITIONING SYSTEM Insufficient gas charge in A/C system or A/C system blockage. ELECTRICAL CONDITION CHARGING SYSTEM Improper connections at Faulty charging system. Refer battery or ground, faulty or to Group 13, Charging damaged battery System for diagnosis ELECTRICAL CONDITION CHARGING SYSTEM Improper connections at Faulty charging system. Refer battery or ground, faulty or to Group 13, Charging damaged battery System for diagnosis POWERTRAIN CONTROL MODULE CONDITION VID block is not configured correctly. Refer to PCM configuration section SENSOR CONDITION ELECTRICAL CONDITION OTHER CONDITION Improper connection; Keep PCM has been disconnected Alive Power (KAPWR) open from wiring harness; circuit to PCM, PCMfusible intermittent connection at link blown battery POWERTRAIN CONTROL MODULE CONDITION Faulty Powertrain Control Module (PCM), ROM has failed POWERTRAIN CONTROL MODULE CONDITION Faulty PCM: -RAM, or CPU has failed
ELECTRICAL CONDITION Improper connection; TR sensor shorted to ground
SENSOR CONDITION Faulty sensor, moisture in sensor AUTOMATIC TRANSMISSION Refer to Group 7, Automatic Transmission for more information on the transmission control system.
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Powertrain Control Management
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DIAGNOSIS AND TESTING (Continued) DTC Description Transmission Range Sensor P0708 KOEO, KOER (TRSA1) circuit Cont high input (Auto) DTC P0708 is reported if the TRSA1 sensor signal is greater than the self-test range. Transmission Fluid P0712 KOEO, KOER TemperatureSensor (TFT) Cont sensor circuit low input (Auto) DTC P0712 is reported if the TFT sensor is less than the self-test range. Transmission Fluid P0713 KOEO, KOER Temperature Sensor (TFT) Cont sensor circuit high input (Auto) DTC P0713 is reported if the TFT sensor is greater than the self-test range. Lock Up Solenoid 7 (LUS) P0743 KOEO, KOER (Auto) fault Cont DTC P0743 is reported if LUS or its circuit have failed
Shift Solenoid 1 (SS1) (Auto) P0752 KOEO, KOER stuck on. Cont DTC P0752 is reported if SS1 solenoid is stuck on
Shift Solenoid 1 (SS1) P0753 KOEO, KOER electrical problem Cont DTC P0753 is reported if SS1 or its circuit have failed
Shift Solenoid 2 (SS2) (Auto) P0757 KOEO, KOER stuck on. Cont DTC P0757 is reported if SS2 solenoid is stuck on
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Possible Causes ELECTRICAL CONDITION SENSOR CONDITION Improper connection; TRSA1 Faulty sensor, moisture in sensor shorted to Vehicle sensor Power (VPWR) or Vehicle AUTOMATIC Reference Voltage (VREF), TRANSMISSION sensor open circuit Refer to Group 7, Automatic Transmission for more information on the transmission control system. ELECTRICAL CONDITION SENSOR CONDITION Improper connection; TFT Faulty sensor, moisture in sensor shorted to ground sensor AUTOMATIC TRANSMISSION Refer to Group 7, Automatic Transmission for more information on the transmission control system. ELECTRICAL CONDITION SENSOR CONDITION Improper connection; TFT Faulty sensor, moisture in sensor shorted to Vehicle sensor Power (VPWR) or Vehicle AUTOMATIC Reference Voltage (VREF), TRANSMISSION sensor open circuit Refer to Group 7, Automatic Transmission for more information on the transmission control system. ELECTRICAL CONDITION AUTOMATIC Improper connection; LUS TRANSMISSION shorted to Vehicle Power Faulty solenoid (VPWR), Vehicle Reference Refer to Group 7, Automatic Voltage (VREF) or ground, Transmission for more solenoid open circuit information on the transmission control system. AUTOMATIC TRANSMISSION SS1 hydraulic fault Refer to Group 7, AutomaticTransmission for more information on the transmission control system. ELECTRICAL CONDITION AUTOMATIC Improper connection; SS1 TRANSMISSION shorted to Vehicle Power Faulty solenoid (VPWR), Vehicle Reference Refer to Group 7, Automatic Voltage (VREF) or ground, Transmission for more solenoid open circuit information on the transmission control system. AUTOMATIC TRANSMISSION SS2 hydraulic fault Refer to Group 7,AutomaticTransmission for more information on the transmission control system.
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303-14-83
Powertrain Control Management
303-14-83
DIAGNOSIS AND TESTING (Continued) DTC Description Shift Solenoid 2 (SS2) P0758 KOEO, KOER electrical problem Cont DTC P0758 is reported if SS2 or its circuit have failed
Possible Causes ELECTRICAL CONDITION AUTOMATIC Improper connection; SS2 TRANSMISSION shorted to Vehicle Power Faulty solenoid (VPWR), Vehicle Reference Refer to Group 7, Automatic Voltage (VREF) or ground, Transmission for more solenoid open circuit information on the transmission control system. Shift Solenoid 3 (SS3) (Auto) AUTOMATIC P0762 KOEO, KOER stuck on. TRANSMISSION Cont DTC P0762 is reported if SS3 hydraulic fault SS3 solenoid is stuck on Refer to Group 7, Automatic Transmission for more information on the transmission control system. Shift Solenoid 3 (SS3) P0763 ELECTRICAL CONDITION AUTOMATIC KOEO, KOER electrical problem Improper connection; SS3 TRANSMISSION Cont DTC P0763 is reported if shorted to Vehicle Power Faulty solenoid SS3 or its circuit have failed (VPWR), Vehicle Reference Refer to Group 7, Automatic Voltage (VREF) or ground, Transmission for more solenoid open circuit information on the transmission control system. Shift Solenoid 4 (SS4) P0768 ELECTRICAL CONDITION AUTOMATIC KOEO, KOER electrical problem Improper connection; SS4 TRANSMISSION Cont DTC P0763 is reported if shorted to Vehicle Power Faulty solenoid SS4 or its circuit have failed (VPWR), Vehicle Reference Refer to Group 7, Automatic Voltage (VREF) or ground, Transmission for more solenoid open circuit information on the transmission control system. Shift Solenoid 6 (SS6) P0773 ELECTRICAL CONDITION AUTOMATIC KOEO, KOER electrical problem Improper connection; SS6 TRANSMISSION Cont DTC P0763 is reported if shorted to Vehicle Power Faulty solenoid SS6 or its circuit have failed (VPWR), Vehicle Reference Refer to Group 7, Automatic Voltage (VREF) or ground, Transmission for more solenoid open circuit information on the transmission control system. Reverse Gear Input Circuit P0812 ELECTRICAL CONDITION OTHER CONDITION KOEO, KOER Improper connection; RGS Both reverse lamps faulty. Cont wiring open circuit or shorted Check reverse lamp operation to Vehicle Power (VPWR), SWITCH CONDITION Manual transmission reverse gear switch faulty. Check reverse lamp operation Electronic sport shift Switch Check DTC0827 and 0828 P0826 OTHER CONDITION KOEO, KOER Input Circuit Performance This DTC is not applicable to SENSOR CONDITION Cont ESS switching detected when column-shift automatic. TRSA-1 is not in “DRIVE” position. TRS-A2 printed circuit board loose or incorrectly installed in ESS shift assembly. Electronic sport shift P0827 ELECTRICAL CONDITION OTHER CONDITION KOEO, KOER Switch Input Circuit Low Improper connection, signal This DTC is not applicable to Cont shorted to PWRGND or column-shift automatic. SIGRTN SENSOR CONDITION Sensor damaged or faulty
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303-14-84
DIAGNOSIS AND TESTING (Continued) DTC Description Electronic sport shift P0828 KOEO, KOER Switch Input Circuit High Cont
Possible Causes ELECTRICAL CONDITION OTHER CONDITION Improper connection, signal This DTC is not applicable to shorted to Vehicle Power column-shift automatic. (VPWR), high Vehicle Reference Voltage (VREF) SENSOR CONDITION Sensor damaged or faulty KOER Not Able to Complete, OTHER CONDITION P1001 KOER KOER Aborted Check other DTCs and re-run test. Throttle Position Sensor P1124 OTHER CONDITION KOEO, KOER A Out Of Self Test Range Driver pressed on accelerator pedal or throttle position at unexpected position during self-test. Key-off, Key-on and Re-run test. NOTE: If throttle system in RPM guard mode during KOER test, it is likely that you will get this P-code. Additionally if engine stops while in RPM guard and KOEO test run w/o cycling ignition, it is likely to get this P-code despite foot off pedal during this test. Upstream HO2S Sensors P1128 ELECTRICAL CONDITION KOEO, KOER Swapped (V8 only) Connection for Bank1 and Cont DTC P1128 is reported if the Bank2 HO2S sensors Bank 1 and Bank2 HO2S swapped. sensors are swapped. Lack Of HO2S11 Switches - FUEL SYSTEM CONDITION INTAKE AIR CONDITION P1130 KOEO, KOER Fuel Trim At Limit External leak at fuel injectors, Defective positive crankcase Cont externally leaking fuel ventilation system, faulty pressure regulator, leaking Evaporative Purge (EVAP) fuel rail, inadequate pressure Canister or Solenoid from fuel pump, fuel injectors ELECTRICAL CONDITION contaminated with foreign Heated Exhaust Gas Oxygen material, blocked or restricted Sensor (HO2S) signal shorted fuel filterInternally leaking fuel to ground or VPWR; moisture injectors, damaged fuel in harness connectors, blown pressure regulator, obstructed HO2S heater fuse fuel return line, low or no OTHER CONDITION vacuum to fuel pressure Leaking exhaust system; leak regulator; leaking, damaged at manifold slip joint, leaking or missing vacuum hose to joint between engine pipe and fuel pressure regulator. catalyst converter, leak at engine pipe to manifold joint, CAUTION: A leaking damaged or leaking exhaust fuel system poses a potential fire hazard. SENSOR CONDITION Sensor damaged or faulty
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303-14-85
Powertrain Control Management
303-14-85
DIAGNOSIS AND TESTING (Continued) DTC Description Lack Of HO2S11 Switches P1131 KOEO, KOER Sensor Indicates Lean Cont
Lack Of HO2S11 Switches P1132 KOEO, KOER Sensor Indicates Rich Cont
Lack Of HO2S21 Switches P1150 KOEO, KOER Fuel Trim At Limit Cont
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Possible Causes FUEL SYSTEM CONDITION INTAKE AIR CONDITION External leak at fuel injectors, Defective positive crankcase externally leaking fuel ventilation system, faulty pressure regulator, leaking Evaporative Purge (EVAP) fuel rail, inadequate pressure Canister or Solenoid from fuel pump, fuel injectors ELECTRICAL CONDITION contaminated with foreign Heated Exhaust Gas Oxygen material, blocked or restricted Sensor (HO2S) signal shorted fuel filter to ground; moisture in harness connectors, blown CAUTION: A leaking HO2S heater fuse fuel system poses a OTHER CONDITION potential fire hazard. Leaking exhaust system; leak at manifold slip joint, leaking SENSOR CONDITION joint between engine pipe and Sensor damaged or faulty catalyst converter, leak at engine pipe to manifold joint, damaged or leaking exhaust FUEL SYSTEM CONDITION INTAKE AIR CONDITION Internally leaking fuel Faulty or damaged injectors, damaged fuel Evaporative Canister Purge pressure regulator, obstructed Solenoid (EVAP) , fuel return line, low or no EVAP canister saturated with vacuum to fuel pressure fuel regulator; leaking, damaged ELECTRICAL CONDITION or missing vacuum hose to Heated Exhaust Gas Oxygen fuel pressure regulator. Sensor (HO2S) signal shorted to Vehicle Power (VPWR), CAUTION: A leaking blown HO2S heater fuse. fuel system poses a OTHER CONDITION potential fire hazard. Restricted exhaust system, Engine Cylinder Head SENSOR CONDITION Temperature Sensor (CHT) or Sensor damaged or faulty. cooling system fault FUEL SYSTEM CONDITION INTAKE AIR CONDITION External leak at fuel injectors, Defective positive crankcase externally leaking fuel ventilation system, faulty pressure regulator, leaking Evaporative Purge (EVAP) fuel rail, inadequate pressure Canister or Solenoid from fuel pump, fuel injectors ELECTRICAL CONDITION contaminated with foreign Heated Exhaust Gas Oxygen material, blocked or restricted Sensor (HO2S) signal shorted fuel filter to ground or VPWR; moisture Internally leaking fuel in harness connectors, blown injectors, damaged fuel HO2S heater fuse pressure regulator, obstructed OTHER CONDITION fuel return line, low or no Leaking exhaust system; leak vacuum to fuel pressure at manifold slip joint, leaking regulator; leaking, damaged joint between engine pipe and or missing vacuum hose to catalyst converter, leak at fuel pressure regulator. engine pipe to manifold joint, damaged or leaking exhaust CAUTION: A leaking fuel system poses a potential fire hazard. SENSOR CONDITION Sensor damaged or faulty
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Powertrain Control Management
303-14-86
DIAGNOSIS AND TESTING (Continued) DTC Description Lack Of HO2S21 Switches P1151 KOEO, KOER Sensor Indicates Lean Cont
Possible Causes FUEL SYSTEM CONDITION INTAKE AIR CONDITION External leak at fuel injectors, Defective positive crankcase externally leaking fuel ventilation system, faulty pressure regulator, leaking Evaporative Purge (EVAP) fuel rail, inadequate pressure Canister or Solenoid from fuel pump, fuel injectors ELECTRICAL CONDITION contaminated with foreign Heated Exhaust Gas Oxygen material, blocked or restricted Sensor (HO2S) signal shorted fuel filter to ground; moisture in harness connectors, blown CAUTION: A leaking HO2S heater fuse fuel system poses a OTHER CONDITION potential fire hazard. Leaking exhaust system; leak at manifold slip joint, leaking SENSOR CONDITION joint between engine pipe and Sensor damaged or faulty catalyst converter, leak at engine pipe to manifold joint, damaged or leaking exhaust Lack Of HO2S21 Switches - FUEL SYSTEM CONDITION INTAKE AIR CONDITION P1152 Cont Sensor Indicates Rich Internally leaking fuel Faulty or damaged injectors, damaged fuel Evaporative Canister Purge pressure regulator, obstructed Solenoid (EVAP) , fuel return line, low or no EVAP canister saturated with vacuum to fuel pressure fuel regulator; leaking, damaged ELECTRICAL CONDITION or missing vacuum hose to Heated Exhaust Gas Oxygen fuel pressure regulator. Sensor (HO2S) signal shorted to Vehicle Power (VPWR), CAUTION: A leaking blown HO2S heater fuse. fuel system poses a OTHER CONDITION potential fire hazard. Restricted exhaust system, Engine Cylinder Head SENSOR CONDITION Temperature Sensor (CHT) or Sensor damaged or faulty. cooling system fault LPG Stepper Motor A-D P1159 FUEL SYSTEM CONDITION LPG SYSTEM LPG (GSCA- D) fault (I6 LPG) Improper connection; Refer to the LPG section of DTC P1159 is reported if GSCA-D open circuit, shorted this manual for details on the GSCA-D fails the self-test or to Vehicle Power (VPWR) or Ford factory fitted LPG if the air fuel ratio cannot be ground systems changed by the PCM during the test Gas Cut-Out Solenoid P1182 ELECTRICAL CONDITION LPG SYSTEM KOEO, KOER (GCO) relay circuit Improper connection; GCO Refer to the LPG section of Cont malfunction, I6 engine solenoid open circuit, shorted this manual for details on the DTC P1182 is reported if the to Vehicle Power (VPWR) or Ford factory fitted LPG GCO solenoid or its circuit ground, blown fuse systems have failed Engine Oil Temperature P1183 SENSOR CONDITION ELECTRICAL CONDITION KOEO, KOER Sensor Circuit Sensor damaged or faulty. Improper connection. Sensor Cont DTC P1183 is reported if the wiring open circuit or short sensor voltage is out of circuit to VPWR or PWRGNF, range VREF or SIGRTN.
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DIAGNOSIS AND TESTING (Continued) DTC Description Possible Causes Engine Oil Temperature P1184 SENSOR CONDITION ELECTRICAL CONDITION KOEO, KOER Sensor Out Of Self Test Sensor damaged or faulty. Improper connection. Sensor Cont Range wiring open circuit or short DTC P1184 is reported if the circuit to VPWR or PWRGND, sensor voltage is out of VREF or SIGRTN. range during self test OTHER CONDITION Engine cold or overheated during self-test. Operate engine to normal operating temperature and re-run test. LPG Prime Solenoid Circuit P1213 ELECTRICAL CONDITION OTHER CONDITION KOEO, KOER DTC P1213 is reported if the Improper connection. PCM damaged or faulty Cont LPG prime solenoid is Solenoid wiring open circuit or malfunctioning short circuit to VPWR or PWRGND. Wastegate Control System P1227 TURBOCHARGER KOEO, KOER Failed closed - Over CONDITION Cont Pressure Blocked or restricted wastegate solenoid ports. Damaged or missing hose(s) between wastegate solenoid and turbo compressor or wastegate actuator. Failed wastegate actuator diaphragm,Stuck open/closed wastegate valve (in turbine housing). Loose, blocked or damaged hoses from turbo compressor outlet to throttle body. Damaged intercooler. Blocked or restricted intake to turbo compressor. Wastegate Control System P1228 TURBOCHARGER KOEO, KOER Failed Open - Under CONDITION Cont Pressure Blocked or restricted wastegate solenoid ports. Damaged or missing hose(s) between wastegate solenoid and turbo compressor or wastegate actuator. Failed wastegate actuator diaphragm,Stuck open/closed wastegate valve (in turbine housing). Loose, blocked or damaged hoses from turbo compressor outlet to throttle body. Damaged intercooler. Blocked or restricted intake to turbo compressor. Theft Detected, Vehicle P1260 SMARTSHIELD CONDITION KOEO, KOER Immobilized A theft condition has been Cont DTC P1260 is reported if the detected. The PCM has Smartshield immobilization immobilised the vehicle. system is in an immobilised Refer to DTC B2139, 2141 state and U1147 for diagnosis.
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303-14-88
Powertrain Control Management
303-14-88
DIAGNOSIS AND TESTING (Continued) DTC Description Engine RPM or Vehicle P1270 KOEO, KOER Speed Limiter Reached Cont DTC P1270 is reported if the engine rpm limit or vehicle speed limit has been reached, resulting in torque intervention by the PCM. Cylinder Head Over P1285 KOEO, KOER, temperature Condition Cont. DTC P1285 is reported if the CHT sensor indicates over-temperature Cylinder Head Temperature P1288 KOEO, KOER Sensor Out Of Self Test Range DTC P1288 is reported if the CHT sensor temperature is out of range during self test.
P1289 KOER Cont
Cylinder Head Temperature Sensor Circuit High Input DTC P01289 is reported if the CHT sensor signal is greater than the self-test range.
Cylinder Head Temperature P1290 KOEO, KOER Sensor Circuit Low Input Cont DTC P0190 is reported if the CHT sensor signal is lower than the self-test range. Cylinder Head Over P1299 KOEO, KOER Temperature Protection Cont Active DTC P1299 is reported if the PCM is activating the fail-safe cooling strategy. Camshaft Position Sensor P1340 KOEO, KOER CID2 (I6 Exhaust Cam, V8 Cont Bank 2)
Possible Causes OTHER CONDITION Driver induced condition NOTE: This code can also get set if forced shutdown is activated after RPM guard mode (P2105 and P2110) ENGINE CONDITION Engine over-heated SENSOR CONDITION Sensor damaged or faulty.
ELECTRICAL CONDITION Improper connection. Sensor wiring open circuit or short circuit to VPWR or VREF.
SENSOR CONDITION Sensor damaged or faulty.
ELECTRICAL CONDITION Improper connection. Sensor wiring open circuit or short circuit to VPWR or PWRGND, VREF or SIGRTN. OTHER CONDITION Engine too hot or cold during self-test. Operate engine to normal operating temperature and re-run test. ELECTRICAL CONDITION Improper connection. Sensor wiring open circuit or short circuit to VPWR or VREF. OTHER CONDITION Engine is at extreme low temperature ELECTRICAL CONDITION Improper connection. Sensor wiring short circuit to PWRGND or SIGRTN.
SENSOR CONDITION Sensor damaged or faulty.
SENSOR CONDITION Sensor damaged or faulty.
ENGINE CONDITION Engine over-heating SENSOR CONDITION Sensor damaged or faulty;
MECHANICAL CONDITION Exhaust camshaft (I6) or Bank2 (V8) camshaft incorrectly installed. Reluctor incorrectly installed on camshaft Sensor loose or incorrectly secured. SENSOR CONDITION Sensor damaged or faulty;. Camshaft Position Actuator, ACTUATOR CONDITION P1380 KOEO, KOER VCT1 Circuit (I6 Intake OCV, Oil control valve solenoid Cont V8 Bank 1 OCV) open circuit or short circuit
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ELECTRICAL CONDITION Improper connection. Sensor wiring open circuit or short circuit to VPWR or VREF.
ELECTRICAL CONDITION Improper connection to CID12 Sensor.
ELECTRICAL CONDITION Improper connection Sensor circuit open circuit or shorted to VPWR or PWRGND. OTHER CONDITION PCM damaged or faulty
01/2003 2003.0 BA Falcon
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Powertrain Control Management
303-14-89
DIAGNOSIS AND TESTING (Continued) DTC Description Camshaft Position Timing P1381 KOEO, KOER Over Advanced (I6 Intake Cont cam, V8 Bank 1) Camshaft Position Timing P1383 KOEO, KOER Over Retarded (I6 Intake Cont cam, V8 Bank 1) Camshaft Position Actuator, P1385 KOEO, KOER VCT2 Circuit (I6 Exhaust Cont OCV, V8 Bank 2 OCV)
P1386 KOER Cont P1388 KOER Cont P1463 KOER Cont
Camshaft Position Timing Over Advanced (I6 Exhaust Cam, V8 Bank 2) Camshaft Position Timing Over Retarded (I6 Exhaust Cam, V8 Bank 2) A/C Pressure Sensor Insufficient Pressure Change when AC compressor commanded on
AC Compressor Relay P1465 KOEO, KOER, Cont
EDF1 Fan Control Relay P1474 KOEO, KOER, Cont
EDF2 Fan Control Relay P1479 KOEO, KOER, Cont
Idle Air Control Over Speed P1506 KOEO, KOER Error Cont Idle Air Control Under Speed P1507 KOEO, KOER Error Cont Restraint Deployment P1534 Cont Indicator Circuit
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Possible Causes MECHANICAL CONDITION Camshaft incorrectly installed. MECHANICAL CONDITION Camshaft incorrectly installed. ACTUATOR CONDITION Oil control valve solenoid open circuit or short circuit
ELECTRICAL CONDITION Improper connectionSensor circuit open circuit or shorted to VPWR or PWRGND. OTHER CONDITION PCM damaged or faulty
MECHANICAL CONDITION Camshaft incorrectly installed. MECHANICAL CONDITION Camshaft incorrectly installed. AIR CONDITIONER Refer to the Air Conditioner section of this manual. ELECTRICAL CONDITION ACR relay coil open circuit or short circuit. Relay not inserted correctly into socket. PCM wiring to relay open or shorted to ground. ELECTRICAL CONDITION AC Relay coil open circuit or short circuit. Relay not inserted correctly into socket. PCM wiring to relay open or shorted to ground. ELECTRICAL CONDITION EDF1 Relay coil open circuit or short circuit. Relay not inserted correctly into socket. PCM wiring to relay open or shorted to ground. ELECTRICAL CONDITION EDF2 Relay coil open circuit or short circuit. Relays not inserted correctly into socket. PCM wiring to relay open or shorted to ground. Refer to other DTCs for diagnosis.
SENSOR CONDITION ACPT sensor damaged or faulty OTHER CONDITION PCM damaged or faulty Compressor or Compressor clutch fault
OTHER CONDITION PCM damaged or faulty
OTHER CONDITION PCM damaged or faulty
OTHER CONDITION PCM damaged or faulty
Refer to other DTCs for diagnosis. Faulty RCM, check Section 501-20b, open circuit TAS signal to pin B6 of PCM
01/2003 2003.0 BA Falcon
303-14-90
Powertrain Control Management
303-14-90
DIAGNOSIS AND TESTING (Continued) DTC Description Intake Manifold P1549 KOEO, KOER Communication Control Cont Circuit (IMCC) circuit malfunction, I6 engine DTC P1549 is reported to indicate a fault in the IMCC circuit. P1565 KOEO, KOER Cont
P1566 KOEO, KOER Cont
P1572 KOEO, KOER Cont
P1635 KOEO, KOER Cont
P1639 KOEO, KOER Cont
P1650 KOEO
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Possible Causes ELECTRICAL CONDITION OTHER CONDITION IMCC control signal open Faulty or damaged IMCC circuit, IMCC signal shorted to solenoid, faulty or damaged Vehicle Power (VPWR) or PCM ground, loose or improper harness connections, intermittent short to VPWR or PWRGND. Speed Control Command SWITCH CONDITION ELECTRICAL CONDITION Switch Out Of Range High Speed control switch Improper connection, ground DTC P1565 is reported if the assembly damaged or faulty circuit open circuit; SCRS-A sensor signal is SCRS-A signal wire open greater than the self-test circuit or short circuit to VREF range. or VPRWR Speed Control Command SWITCH CONDITION ELECTRICAL CONDITION Switch Out Of Range Low Speed control switch SCRS-A signal wire short DTC P1566 is reported if the assembly damaged or faulty circuit to PWRGND or SCRS-A sensor signal is SGRTN greater than the self-test range. Brake Pedal Switch Circuit MECHANICAL CONDITION ELECTRICAL CONDITION DTC P1572 is reported if the Brake switch bracket loose or Improper connection to BOO BOO and RBS brake switch distorted. and RBS switch. Fusible link status are different when the SWITCH CONDITION to RBS blown. Switch wiring brake pedal is depressed. BOO or RBS switch damaged open circuit or short circuit to or faulty VPWR or PWRGND OTHER CONDITION No speed control option fitted to vehicle. This DTC is not applicable to vehicles without speed control. Tire/Axle Out of Acceptable PCM CONDITION Range VID block incorrectly DTC P1572 is reported if the configured. tyre and axle data entered into the VID block is out of range Vehicle ID Block Corrupted, PCM CONDITION Not Programmed VID block incorrectly DTC P1572 is reported if the configured VID block is corrupted not programmed Power Steering Pressure ELECTRICAL CONDITION MECHANICAL CONDITION Switch (PSP) Improper connection, PSP Refer to Group 3 Suspension, failure open circuit Steering, Wheels & Tyre for DTC P1650 is reported if the SENSOR CONDITION power steering information PSP has failed in the open Sensor damaged or faulty. OTHER CONDITION position Switch contacts may be stuck PCM damaged or faulty open, improper operation threshold of switch.
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Powertrain Control Management
303-14-91
DIAGNOSIS AND TESTING (Continued) DTC P1651 KOER
Description Power Steering Pressure Switch (PSP) did not switch, 6 engine DTC P1651 is reported if the switch fails in the closed position. This code is also reported if the PSP does not change state during KOER self-test
P1703 KOER
Brake Switch Out Of Self Test Range
P1705 KOEO
P1708 KOEO
P1709 KOEO
P1746 KOEO, Cont
Not in Park or Neutral during self- test (Auto) DTC P1705 is reported if the Transmission Range Sensor (TRS-A1) is in any position other than Park or Neutral Clutch Switch was not depressed during self-test (Manual) DTC P1708 is reported if the Clutch Engagement Switch (CES) indicates that the clutch pedal was not depressed Not in Park or Neutral during self- test (Auto) DTC P1709 is reported if theTransmission Range Sensor (TRS-A1) is in any position other than Park or Neutral Solenoid 5 (SS5) KOER open circuit fault DTC P1746 is reported if SS5 or its circuit have failed
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Possible Causes ELECTRICAL CONDITION MECHANICAL CONDITION Improper connection, PSP Power steering fluid low or shorted to Vehicle Power loss, mechanical or hydraulic (VPWR) fault in power steering system. SENSOR CONDITION Faulty or malfunctioning Refer to Group 3 Suspension, sensor, switch contacts may Steering, Wheels & Tyres for be stuck closed, improper power steering information operation threshold of switch OTHER CONDITION Steering wheel was not moved during KOER self-test, Faulty or damaged PCM MECHANICAL CONDITION ELECTRICAL CONDITION Brake switch bracket loose or Improper connection to BOO distorted. and RBS switch. Fusible link to RBS and/or BOO blown. SWITCH CONDITION BOO or RBS switch damaged Switch wiring open circuit or or faulty short circuit to VPWR or PWRGND OTHER CONDITION Brake switch was not depressed and released during KOER self-test. No speed control option fitted to vehicle. This DTC is not applicable to vehicles without speed control. TEST CONDITION OTHER CONDITION Transmission was not in Park Faulty TR sensor or wiring or Neutral positions during the Key On Engine Off self-test. Move the gear selector to either Park or Neutral and re-run the test TEST CONDITION OTHER CONDITION Clutch pedal was not Faulty CES switch or wiring depressed during the Key On Engine Off self-test. Depress the clutch pedal and re-run the test
TEST CONDITION Transmission was not in Park or Neutral positions during the Key On Engine Off self-test. Move the gear selector to either Park or Neutral and re-run the test ELECTRICAL CONDITION Improper connection; SS5 shorted to PWRGND, solenoid open circuit
OTHER CONDITION Faulty TR sensor or wiring
AUTOMATIC TRANSMISSION Faulty solenoid Refer to Group 7, Automatic Transmission for more information on the transmission control system.
01/2003 2003.0 BA Falcon
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Powertrain Control Management
303-14-92
DIAGNOSIS AND TESTING (Continued) DTC Description Solenoid 5 (SS5) P1747 KOEO, KOER short circuit fault Cont DTC P1747 is reported if SS5 or its circuit have failed
Solenoid 5 (SS5) P1748 KOEO, KOER circuit fault Cont DTC P1748 is reported if SS5 or its circuit have failed
Throttle Actuator Control P2100 KOEO, KOER Motor Circuit /Open Cont
P2101 KOEO, KOER Cont P2102 KOEO Cont
Throttle Actuator Control Motor Circuit Range/Performance ETB motor current is lower than expected
P2103 KOEO Cont
ETB motor current is higher than expected
Throttle Actuator Control P2105 KOEO, KOER System - Forced Engine Cont Shutdown Throttle Actuator Control P2107 KOEO, KOER System - Internal TPPC Cont Fault
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Possible Causes ELECTRICAL CONDITION AUTOMATIC Improper connection; SS5 TRANSMISSION shorted to VPWR, solenoid Faulty solenoid short circuit Refer to Group 7, Automatic Transmission for more information on the transmission control system. ELECTRICAL CONDITION AUTOMATIC Improper connection; SS5 TRANSMISSION shorted to VPWR or Faulty solenoid PWRGND, solenoid open Refer to Group 7, Automatic circuit or short circuit Transmission for more information on the transmission control system. ELECTRONIC THROTTLE OTHER CONDITION Refer to other DTCs for CONDITION Motor open circuit. Check diagnosis. Throttle Motor Connector. This code may also get set by entry into RPM Guard mode (P2110). OTHER CONDITION PCM damaged or faulty ELECTRONIC THROTTLE CONDITION ETB motor faulty.Throttle Damaged. Check Throttle Motor Connector. SENSOR CONDITION TP sensor incorrectly installed ELECTRONIC THROTTLE CONDITION ETB motor faulty. Throttle Damaged. Check Throttle Motor Connector. ETB HARDWARE Check ETB for Stuck Throttle Plate. SENSOR CONDITION TP sensor incorrectly installed Refer to other DTCs for diagnosis.
ELECTRICAL CONDITION Improper ETB wiring connection OTHER CONDITION PCM damaged or faulty
ELECTRICAL CONDITION Improper ETB wiring connection OTHER CONDITION PCM damaged or faulty
Refer to other DTCs for OTHER CONDITION diagnosis. This code may PCM damaged or faulty. also get set by entry into RPM Guard mode (P2110).
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Powertrain Control Management
303-14-93
DIAGNOSIS AND TESTING (Continued) DTC Description Throttle Actuator Control P2110 KOEO, KOER System - Forced Limited Cont RPM
Throttle Actuator Control P2111 KOEO, KOER System - Higher throttle Cont opening than driver demand Throttle Actuator Control P2112 KOEO, KOER System - Lower throttle Cont opening than driver demand Pedal Position Sensor P2122 KOEO, KOER (PPS1) Low Input Cont Pedal Position Sensor P2123 KOEO, KOER (PPS1) High Input Cont Pedal Position Sensor P2124 KOEO, KOER (PPS1) Intermittent Input Cont Pedal Position Sensor P2127 KOEO, KOER (PPS2) Low Input Cont Pedal Position Sensor P2128 KOEO, KOER (PPS2) High Input Cont Pedal Position Sensor P2129 KOEO, KOER (PPS2) Intermittent Input Cont Pedal Position Sensor P2132 KOEO, KOER (PPS3) Low Input Cont
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Possible Causes SENSOR CONDITION OTHER CONDITION Accelerator pedal and/or PCM damaged or faulty. throttle position sensor damaged or faulty. Throttle motor damaged or connector/wiring faulty. Check other DTCs. ETB HARDWARE Check ETB for Stuck Throttle Plate. ETB HARDWARE Check ETB for Stuck Throttle Plate. Refer to other DTCs for diagnosis. ETB HARDWARE Check ETB for Stuck Throttle Plate. Refer to other DTCs for diagnosis. SENSOR CONDITION ELECTRICAL CONDITION Accelerator Pedal Sensor Improper connection to PPS. damaged or faulty. Check PPS wiring open circuit or Connector. short circuit to PWRGND or SIGRTN. SENSOR CONDITION ELECTRICAL CONDITION Accelerator Pedal Sensor Improper connection to PPS. damaged or faulty. Check PPS wiring open circuit or Connector. short circuit to VPWR or VREF. SENSOR CONDITION ELECTRICAL CONDITION Accelerator Pedal Sensor Improper connection to PPS. damaged or faulty. Check PPS wiring open circuit or Connector. short circuit to VPWR, VREF, PWRGND or SIGRTN. SENSOR CONDITION ELECTRICAL CONDITION Accelerator Pedal Sensor Improper connection to PPS. damaged or faulty. Check PPS wiring open circuit or Connector. short circuit to PWRGND or SIGRTN. SENSOR CONDITION ELECTRICAL CONDITION Accelerator Pedal Sensor Improper connection to PPS. damaged or faulty. Check PPS wiring open circuit or Connector. short circuit to VPWR or VREF. SENSOR CONDITION ELECTRICAL CONDITION Accelerator Pedal Sensor Improper connection to PPS. damaged or faulty. Check PPS wiring open circuit or Connector. short circuit to VPWR, VREF, PWRGND or SIGRTN. SENSOR CONDITION ELECTRICAL CONDITION Accelerator Pedal Sensor Improper connection to PPS. damaged or faulty. Check PPS wiring open circuit or Connector. short circuit to PWRGND or SIGRTN.
01/2003 2003.0 BA Falcon
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Powertrain Control Management
303-14-94
DIAGNOSIS AND TESTING (Continued) DTC Description Pedal Position Sensor P2133 KOEO, KOER (PPS3) High Input Cont
P2134 KOEO, KOER Cont
P2135 KOEO, KOER Cont
P2138 KOEO, KOER Cont
P2139 KOEO, KOER Cont
P2140 KOEO, KOER Cont
U1147 KOEO, KOER Cont
U1900 KOEO, KOER Cont
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Possible Causes SENSOR CONDITION ELECTRICAL CONDITION Accelerator Pedal Sensor Improper connection to PPS. damaged or faulty. Check PPS wiring open circuit or Connector. short circuit to VPWR or VREF. Pedal Position Sensor SENSOR CONDITION ELECTRICAL CONDITION (PPS3) Intermittent Input Accelerator Pedal Sensor Improper connection to PPS. damaged or faulty. Check PPS wiring open circuit or Connector. short circuit to VPWR, VREF, PWRGND or SIGRTN. Throttle Position Sensor 1 & SENSOR CONDITION ELECTRICAL CONDITION 2 Voltage Correlation Fault Throttle Position Sensor Improper connection to TPS. damaged or faulty. Check TPS wiring open circuit or Connector. short circuit to VPWR, VREF, PWRGND or SIGRTN. OTHER CONDITION PCM damaged or faulty Pedal Position Sensor 1 and SENSOR CONDITION ELECTRICAL CONDITION 2 correlation fault Accelerator Pedal Sensor Improper connection to PPS. damaged or faulty. Check PPS wiring open circuit or connector. short circuit to VPWR, VREF, PWRGND or SIGRTN. OTHER CONDITION PCM damaged or faulty Pedal Position Sensor 1 and SENSOR CONDITION ELECTRICAL CONDITION 3 correlation fault Accelerator Pedal Sensor Improper connection to PPS. damaged or faulty. Check PPS wiring open circuit or connector. short circuit to VPWR, VREF, PWRGND or SIGRTN. OTHER CONDITION PCM damaged or faulty Pedal Position Sensor 2 and SENSOR CONDITION ELECTRICAL CONDITION 3 correlation fault Accelerator Pedal Sensor Improper connection to PPS. damaged or faulty. PPS wiring open circuit or short circuit to VPWR, VREF, PWRGND or SIGRTN. OTHER CONDITION PCM damaged or faulty Invalid or Missing Data for IMMOBILIZATION SYSTEM ACTION REQUIRED Vehicle Security. Check BEM and CAN line CONDITION PCM did not receive the operation. correct response codes from the BEM CAN Communication Bus Missing CAN messages from ELECTRICAL CONDITION Fault - Receive Error HIM, instrument cluster, BEM CAN wiring open circuit or and/or traction control (where short circuit to VPWR, VREF, fitted) PWRGND or SIGRTN. Check other DTCs
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Powertrain Control Management
303-14-95
DIAGNOSIS AND TESTING (Continued) Glossary ABS APPS APPSVREF APPSRTN ASR Absolute Pressure ACC ACD ACP ACPT ACR Actuator AEAT Air Conditioning
acronym for Anti-lock Brake System. Prevents wheel lockup during an emergency stop by modulating brake pressure. Allows the driver to maintain steering control and stop the vehicle in the shortest possible distance under most conditions acronym for Accelerator Pedal Position Sensor. The pedal position sensor has 3 independent outputs, APPS1, APPS2 and APPS3 acronym for Accelerator Pedal Position Sensor VREF. A 5V supply. Two are used for the pedal sensor acronym for Accelerator Pedal Position Sensor Return. A 0V supply. Two are used for the pedal sensor acronym for Acceleration Slip Control system. Also known as the traction control system The pressure referenced to a perfect vacuum
acronym for Air Conditioning Clutch in this section acronym for Air Conditioner Demand. acronym for Air Conditioning Pressure acronym for Air Conditioner Pressure Transducer acronym for Air Conditioning Clutch Relay A mechanism for moving or controlling something indirectly instead of by hand acronym for Air Conditioner Evaporator Temperature A vehicular system that modifies the passenger compartment environment by cooling and drying the air Analogue Signals are signals that vary within a certain range (ie.0 - 5 volts). An analogue signal is infinitely variable within the rage. The Throttle Position Sensor (TP) produces an analogue signal acronym for After Top Dead Centre ATDC Spark advance in degrees before top dead centre of the base engine without any Base Timing control from the PCM An electrical storage device designed to produce a DC voltage by means of an Battery electrochemical reaction acronym for Broad Band Manifold, see IMCC BBM acronym for Body Electronic Module BEM acronym for Blower Fan Speed BFS A device designed to supply a current of air at a moderate pressure. A blower usually Blower consists of an impeller assembly,a motor and a suitable case. The blower case is designed as part of the ventilation system Acronym for the Brake On Off Switch. BOO acronym for Boost Pressure Sensor. Measures the boost pressure of the turbocharger. BPS acronym for Before Top Dead Centre - relating to the position of the piston within the BTDC cylinder A shaft on which phased cams are mounted. The camshaft is used to regulate the Camshaft opening and closing of the intake and exhaust valves Acronym for Control Area Network. An intermodule communications network comprising CAN a twisted pair wire, CAN-H and which have complementary output. CAN-L A device designed to hold dry material. An evaporative emission canister contains Canister activated charcoal that absorbs fuel vapours and holds them until the vapours can be purged at an appropriate time Controls purging of the EVAP canister Canister Purge acronym for PCM Case Ground CASEGN G98120 en
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303-14-96
Powertrain Control Management
303-14-96
DIAGNOSIS AND TESTING (Continued) Catalytic Converter CD1..8 CHT Circuit CKP Closed Loop Clutch CMP CO CO2 Coil
An in-line exhaust system device used to reduce the level of engine exhaust emissions acronym for Coil Driver. The PCM’s Coil On Plug output drivers. acronym for Cylinder Head Temperature sensor. A complete electrical path or channel, usually includes the source of electrical energy. Circuit may also describe the electrical path between two or more components. May also be used with fluids, air or liquids acronym for Crankshaft Position Sensor A control system that uses a signal from an oxygen sensor mounted in the exhaust system to control the ratio of air and fuel provided to the engine. Also known as the Lambda loop A mechanical device that uses mechanical, magnetic or friction type connections to facilitate engaging or disengaging of two shafts or rotating members acronym for Camshaft Position. Indicates camshaft position. Provides camshaft position information for fuel injection synchronisation Carbon Monoxide. A colourless, odourless, gas toxic gas formed by combustion within the cylinder Carbon Dioxide. A colourless, odourless, incombustible gas formed during combustion A device consisting of windings of conductors around an iron core, designed to increase the voltage and for use in a spark ignition system The portion of KAM used to store DTCs generated during Continuous Memory Self-Test
Continuous Memory A continuous test of the EEC system conducted by the PCM whenever the vehicle is Continuous Memory Self-Test operating A means or a device to direct and regulate a process or guide the operation of a Control machine, apparatus system A fluid used for heat transfer. Coolants usually contain additives such as rust inhibitors Coolant and antifreeze The part of an engine that converts the reciprocating motion of the pistons to rotary Crankshaft motion General term for information, usually represented by numbers, letters, or symbols Data Digital signals have only one of two values, either on or off. Some systems measure the Digital duration between the on and off signals to determine a value. The vehicle speed sensor (VSS)is produces a digital signal acronym for Data Link Connector. Connector providing access and/or control of the DLC vehicle information, operating conditions, and diagnostic information acronym for Diagnostic Trouble DTC An alpha/numeric identifier for a fault condition identified by the On-Board Diagnostic Code System acronym for Electro Drive Fan 1. Controls the engine cooling fans at low Speed EDF1 acronym for Electro Drive Fan 2. Controls the engine cooling fans at high Speed EDF2 acronym for Electro-Magnetic Compatibility EMC A machine designed to convert thermal energy into mechanical energy to produce force Engine or motion acronym for Engine Oil Temperature EOT acronym for Electronic Throttle Body ETB acronym for Electronic Throttle Control. ETC acronym for Electronic Throttle Control Negative. The negative of the ETC motor. ETCN acronym for Electronic Throttle Control Positive. The positive of the ETC motor. ETCP acronym for Evaporative Emission Evaporative Emission (EVAP) - A system to prevent EVAP fuel vapour from escaping into the atmosphere. Typically includes a charcoal canister to store fuel vapours G98120 en
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Powertrain Control Management
303-14-97
DIAGNOSIS AND TESTING (Continued) Fan FEPS FMEM FP Freeze Frame Fuel Fuel Rich/Lean
GCO GLVL GLVL-RTN GRND GSCA-D Hall Effect HC HO2S Hz IAC IAT IDM Ignition IGNSNS IMCC INJ1-8 Injector Intake Air Intermittent KAM KAPWR Knock KOEO KOER KS L Lean LONGFT
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A device designed to supply a current of air. A fan may also have a frame, motor, wiring harness and the like acronym for Flash EEPROM Power Supply acronym for Failure Mode Effects Management. An alternative vehicle operation strategy that protects vehicle function from the adverse effect of a system failure acronym for Fuel Pump. A pump used to deliver fuel to the engine A block of memory containing the vehicle operating conditions for a specific time Any combustible substance burned to provide heat or power. Typical fuels include gasoline and diesel fuel. Other types of fuel include ethanol, methanol, natural gas, propane or in combination A qualitative evaluation of air-fuel ratio based on an A/F ratio known as stoichiometry or 14.64:1. In the EEC system, rich/lean is determined by a voltage signal from the H02S. An excess of oxygen (lean) is indicated by an H02S voltage of less than 0.4 volts; a rich condition is indicated by an H02S voltage of greater than 0.6 volts acronym for Gas Cut-out acronym for Gas Tank Level Sensor acronym for Gas Tank Level Sensor Return Ground. The ground, or common side of a DC electrical circuit acronym for LPG Stepper Motor A to D A process where current is passed through a small slice of semi-conductor material at the same time as a magnetic field to produce a small voltage in the semi-conductor Hydrocarbon. A compounds that contains only carbon and hydrogen acronym for Heated Oxygen Sensor. An Oxygen Sensor (02S) that is electrically heated Hertz. The measure of a frequency - equal to one cycle per second. Defined by Heinrich Rudolf Hertz acronym for Idle Air Control. Electrical control of throttle bypass air acronym for Intake Air Temperature. The temperature of the intake air acronym for Ignition Diagnostic Monitor System used to provide high voltage spark for internal combustion engines Acronym for Ignition Sense input. acronym for intake Manifold Charge Control acronym for Fuel Injectors 1 to 8 A device for delivering metered pressurised fuel to the intake system or the cylinders Air drawn through a cleaner and distributed to each cylinder for use in combustion A fault that may not be present or identifiable at the present time acronym for Keep Alive Memory. A portion of the memory within the PCM that must maintain power even when the vehicle is not operating acronym for Keep Alive memory Power. Dedicated, unswitched power circuit that maintains KAM The sharp metallic sound produced when two pressure fronts collide in the combustion chamber of an engine acronym for Key On Engine Off Self-Test. A test of the EEC system conducted by the PCM with power applied and the engine at rest acronym for Key On Engine Running Self-Test. A test of the EEC system conducted by the PCM with the engine running and the vehicle at rest acronym for Knock Sensor. Detects engine knock Litres excess air (or too little fuel) in the air- fuel ratio being supplied to the combustion process acronym for Long Term Fuel Trim
01/2003 2003.0 BA Falcon
303-14-98
Powertrain Control Management
303-14-98
DIAGNOSIS AND TESTING (Continued) LPG LUS M/T Manifold MAP Module Multiplexing NC NO NOx OCV OHC OSS PCM PCS PCV Phaser PID PIP Power Steering Powertrain PSPS Pulse Width Modulation PRIME Pump PWRGND PWRSTN Relay RBS RGS Rich RPM SCRSA Short Circuit G98120 en
acronym of Liquefied Propane Gas. Used as an alternative to petroleum fuel in combustion engines acronym for Lock up Solenoid Manual Transmission A device designed to collect or distribute fluid, air or the like acronym for Manifold Absolute Pressure. The absolute pressure of the intake manifold air A self-contained group of electrical/electronic components, which is designed as a single renewable unit the simultaneous transmission of two or more signals over a single circuit. The EEC-V uses multiplexing to communicate with the NGS acronym for Normally Closed electrical Contact acronym for Normally Open electrical Contact Oxides of Nitrogen acronym for Oil Control Valve. Also known as a Camshaft Position Actuator. Used on the VCT to control oil pressure to the phaser. acronym for Overhead Camshaft. An engine configuration that uses a camshaft positioned above the valves Open Circuit - A circuit which does not provide a complete path for flow of current acronym for Output Shaft Speed Sensor. A sensor which provides driveshaft speed information acronym for Powertrain Control Module acronym for Power Control Solenoid acronym for Positive Crankcase Ventilation. Positive ventilation of crankcase emissions a mechanism used on VCT to vary camshaft angle acronym for Parameter Identification. Identifies an address in memory which contains vehicle operating information acronym for Profile Ignition Pick-up. Provides crankshaft or camshaft position information for ignition synchronisation A system which provides additional force to the steering mechanism, reducing the driver’s steering effort The elements of a vehicle by which motive power is generated and transmitted to the driven axles acronym for Power Steering Pressure Switch. Indicates the pressure in the power steering system a continually changing digital signal turned on and off or a percentage of the available on pulse off cycle time. A signal on for 30% and off 70% of the time is a 30% On PWM signal acronym for the LPG PRIME solenoid. A device used to raise, transfer, or compress fluids by suction, pressure or both Power Ground. The main ground circuit in the EEC-V system acronym for Power Sustain. A PCM output that powers the VPWR relay on for a short delay after the ignition is keyed OFF. A generally electromechanical device in which connections in one circuit are opened or closed by changes in another circuit acronym for Redundant Brake Switch used for the cruise control feature Acronym for the Reverse Gear Switch used on manual transmissions. an inadequate amount of air (or too much fuel) in the air-fuel ratio being supplied to the combustion process Engine speed in revolutions per Minute Acronym for Speed Control Range Sensor (Analogue signal). An undesirable connection between a circuit and any other point 01/2003 2003.0 BA Falcon
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Powertrain Control Management
303-14-99
DIAGNOSIS AND TESTING (Continued) SHRTFT Signal SIGRTN Solenoid Speed SS x STRTEN Switch System Tachometer TAS TDC Test TFT Throttle Timing T-MAP TP TPS_VREF TPS_RTN TRS-A1 TRS-A2 Transient Transmission TURBO Variable Reluctance Valve
VCT VPS VPWR VREF
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acronym for Short Term Fuel Trim A fluctuating electric quantity, such as voltage or current, whose variations represent information acronym for Signal Return. A dedicated sensor ground circuit that is common to two or more sensors A device consisting of an electrical coil which, when energised, produces a magnetic field in a plunger that is pulled to a central position. A solenoid may be used as an actuator in a valve or switch The magnitude of velocity (regardless of direction) acronym for Shift Solenoid. A device that controls shifting in an automatic transmission Acronym for Start Enable relay output. A device for making, breaking, or changing the connections in an electrical circuit A group of interacting mechanical or electrical components serving a common purpose A meter that provides a measure of engine speed in RPM Acronym for Travel Assistance Service, the signal recieved by the PCM from the Restraint Control Module, RCM, when it detects deployment level impact events. acronym for Top Dead Centre - relating to the position of the piston within the cylinder A procedure whereby the performance of a product is measured under various conditions acronym for Transmission Fluid Temperature. Indicates temperature of transmission fluid A valve for regulating the supply of a fluid, usually air or an air-fuel mix, to an engine Relationship between spark plug firing and piston position usually expressed in crankshaft degrees before (BTDC) or after (ATDC) top dead centre of the compression stroke acronym for Temperature and Manifold Absolute Pressure Sensor acronym for Throttle Position sensor. Indicates the position of the throttle plate. The TP sensor assembly has two independent sensor outputs acronym for Throttle Position sensor VREF. The 5V supply for the sensor acronym for Throttle Position sensor RTN. The 0V supply for the sensor acronym for Transmission Range Sensor - (Analogue signal) 1. The transmission mounted sensor gear position. acronym for Transmission Range Sensor - (Analogue signal) 2. The centre console mounted electronic Sport Shift sensor. Remaining only for a brief time A device which selectively increases or decreases the ratio of relative rotation between its input and output shafts. acronym for Turbocharger A process of passing a magnetic field through wire windings and inducing a voltage A device by which the flow of liquid, gas, vacuum, or loose material in bulk may be started, stopped or regulated by a movable part that opens, shuts or partially obstructs one or more ports or passageways. A “Valve” is also the moveable part of such a device acronym for Variable Camshaft Timing acronym for Variable Pressure Control Solenoid 5 acronym for Vehicle Power. A switched circuit that provides power to the EEC system. Compare “Battery Positive Voltage (B+).” acronym for Reference Voltage. A dedicated circuit that provides a 5.0 volt signal used as a reference by certain sensors
01/2003 2003.0 BA Falcon
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Powertrain Control Management
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DIAGNOSIS AND TESTING (Continued) VSOUT VSS WOT
acronym for Vehicle Speed Output. An output which provides speed information as a frequency signal proportional to vehicle speed acronym for Vehicle Speed Sensor. A sensor which provides vehicle speed information acronym for Wide Open Throttle. A condition of maximum airflow through the throttle body
The glossary is a list of technical terms or acronyms and their definitions. It is not intended to be a dictionary of components and their functions. If a detailed description of a specific component is desired, refer to the related Workshop Manual Group.
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GENERAL PROCEDURES
Powertrain Control Module Accessing vehicle speed signal for installation of taximeters
3. Locate 565B-W (Black wire with white stripe) and splice the wire at the back of connector C-119. Refer to Connector Views chapter 700-07-00-9.
CAUTION: Vehicle speed signal must NOT be accessed via the ABS system as this may compromise system integrity. NOTE: The Power Control Module (PCM) generates the vehicle speed signal which can be accessed by taximeters. The B36VSOUT is a pulsed 12V signal of approximately 5000 pulses/km which is used by SATNAV (Refer to chapter 419-07 for further SATNAV information) to measure speed. This outputted signal should be accessed by taximeters to monitor vehicle speed. 1. Remove outer front LHS scuff plate.
4. Check integrity of taximeter. Taximeters to be used with the PCM should have an input resistance to ground of between 4.7kOhm and 15kOhm 5. Re-install scuff plates.
Intake Manifold Charge Control Adjustment
2. Remove inner front LHS scuff plate. This will expose the B36VSOUT wiring which includes the 565B-W wire and C-119 connector.
1. Using a suitable vacuum pump and gauge, apply a 40kPa vacuum to IMCC actuator. 2. Adjust IMCC set screw to achieve the specified clearance between the set screw and the actuator arm. IMCC Clearance Specification 1. 0.65 - 0.80 mm
VCT Solenoid Valve Cleaning Procedure Items required. 1. Aerosol can of suitable cleaning fluid such as CO electrical cleaning fluid, Compressed air or similar. 2. Clean Rag. 3. Wiring Loom. G98141 en
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GENERAL PROCEDURES (Continued) 4. 12V Vehicle Battery. 5. Safety Glasses. Procedure. 1. Remove jammed Oil Control Valve (OCV) Ref. Engine Section 303-01a, b & c. 2. Place valve on a clean cloth. 3. Connect 12V onto valve through a push button momentary switch. 4. Hold valve upright on clean cloth. 5. Spray cleaning Fluid into ports of valve while pressing momentary switch 3 - 4 times per second. 6. Clean down the center of the valve using a similar process. 7. Repeat process until the obstruction is removed. 8. Re-fit valve and test.
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REMOVAL AND INSTALLATION
Crankshaft Position (CKP) Sensor (I6 Engine) Removal 1. Remove the crankshaft position (CKP) sensor. 1. Disconnect the electrical connector 2. Remove the retaining bolt 3. Remove the sensor
Camshaft Position Sensor (I6 Engine) Removal 1. Remove the camshaft position (CMP) sensor. 1. Disconnect the electrical connector 2. Remove the retaining bolt 3. Remove the sensor
Installation NOTE: Be sure the sensor wiring is routed away from 1. To Install, reverse the removal procedure. the battery cable. Installation 1. To Install, reverse the removal procedure.
Crankshaft Position (CKP) Sensor (V8 Engine) Removal 1. Remove the A/C compressor. For additional information, refer to Section 412-03. 2. Remove the crankshaft position (CKP) sensor. 1. Disconnect the electrical connector 2. Remove the bolt 3. Remove the sensor
Camshaft Position Sensor (V8 Engine)
Removal 1. Disconnect the battery ground cable. For additional information, refer to Section 414-01. 2. Disconnect the camshaft position (CID) sensor electrical connector. 3. Unscrew the retaining bolt and remove the CID sensor.
Installation 1. To Install, reverse the removal procedure.
Knock Sensor (I6 Engine) Installation 1. To Install, reverse the removal procedure.
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Removal 1. Disconnect the knock sensor (KS) electrical connector.
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REMOVAL AND INSTALLATION (Continued) 2. Remove the bolt and the KS.
4. Remove the CHT sensor.
Installation 1. To Install, reverse the removal procedure.
Installation 1. To Install, reverse the removal procedure.
Cylinder Head Temperature (CHT) Sensor (I6 Engine)
Throttle Position (TP) Sensor (I6, LPG & Turbo Engines)
Removal 1. Disconnect the cylinder head temperature (CHT) sensor electrical connector. 2. Using a ring spanner, remove the CHT sensor.
Removal 1. Ensure the ignition has been switched off and the battery disconnected. For additional information, refer to Section 414-01. 2. Remove the inlet duct from the throttle body. 3. Remove the TP sensor. 1. Disconnect the electrical connector from the TP sensor by sliding the red locking tab out and pressing the clip release. 2. Remove the 2 TP sensor retaining bolts. 3. Remove the TP sensor from the throttle body. I6 & Turbo
Installation 1. To Install, reverse the removal procedure.
Cylinder Head Temperature (CHT) Sensor (V8 Engine) Removal 1. Disconnect the battery ground cable. For additional information, refer to Section 414-01. 2. Disconnect the electrical connector and remove the alternator. 3. Disconnect the CHT sensor electrical connector.
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REMOVAL AND INSTALLATION (Continued) LPG Engine
Installation 1. Fit the new bolts provided with the new TP sensor and tighten them to 2 - 4Nm. 2. Reconnect the electrical connector ensuring there is a positive “click” as the safety clip engages. 3. Slide the red locking tab into position. 4. Refit the inlet duct to the throttle body. 5. Reconnect the battery. 6. Switch on the ignition then fully depress the accelerator pedal and release it. 7. Perform key-on, engine-off test to ensure no TP sensor codes are present. 8. Start the car and ensure normal operation.
Throttle Position (TP) Sensor (V8 Engine) Removal 1. Ensure the ignition has been switched off and the battery disconnected. For additional information, refer to Section 414-01. 2. Remove the inlet duct from the throttle body. 3. Disconnect the 4 way electrical connector from the TP sensor by sliding the red locking tab out and pressing the clip release. 4. Disconnect the 2 way electrical connector from the throttle body motor by sliding the red locking tab and pressing the clip release. 5. Remove the 4 bolts retaining the throttle body to the inlet manifold. 6. Note the throttle body orientation, then remove the throttle body, being careful with the gasket.
7. Remove the throttle TP sensor. 1. Remove the 2 TP sensor retaining bolts. 2. Remove the TP sensor from the throttle body.
Installation 1. Fit the new TP sensor to the throttle body, ensuring that the locating pin on the TP sensor aligns with the hole in the throttle body. 2. Fit the new bolts provided with the new TP sensor and tighten them to 2 - 4Nm. 3. Refit the gasket and the throttle body to the inlet manifold and tighten the bolts to 8 -12Nm. 4. Reconnect both electrical connectors ensuring there is a positive “click” as the safety clips engage. 5. Slide the red locking tabs into position. 6. Refit the inlet duct to the throttle body. 7. Reconnect the battery. 8. Switch on the ignition then fully depress the accelerator pedal and release it. 9. Perform key-on, engine-off test to ensure no TP sensor codes are present. 10. Start the car and ensure normal operation.
Powertrain Control Module (PCM) (I6 Engine) The PCM is installed in the engine compartment on the bracket over the front nearside strut tower. Three security bolts secure the PCM to the PCM bracket. Removal 1. Ensure the ignition has been switched off and the battery disconnected. For additional information, refer to Section 414-01. 2. Use a small high-speed grinding tool with a small circular grinding disc to cut slots on the 3 security bolts holding the PCM to the bracket. CAUTION: This operation produces sparks and debris that can cause fire and personal injury. Perform this operation in a well-ventilated area.
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REMOVAL AND INSTALLATION (Continued) Ensure that that there are no fuel leaks in the engine compartment, the engine, fuel injectors and fuel lines. Ensure that there are no flammable liquids and fumes present in the work area. Eg solvents, inks, paints, thinners, cleaning fluids, open fuel containers etc. Use necessary precautions to confine debris from the grinder. Use protective goggles and gloves for personal safety. 3. Use a blade screwdriver to unscrew the security bolts. 4. Release the wiring harness locking bar and remove the harness from the PCM.
9. Torque the security bolts on the PCM until the heads break off.
HEGO Sensor (I6 & V8 Engines) Removal 1. Remove the HEGO sensor. 1. Disconnect the electrical connector 2. Remove the screws 3. Using a 22mm ring spanner, remove the sensor I6 Engine
V8 Engine Item 1 2
Description PCM Module Security bolt
5. Remove the PCM. Installation 1. Secure the wiring harness to the correct PCM connector pockets. They are keyed so that they only fit one way and both the A and B pocket connectors are different. 2. For new PCMs, perform the Module Configuration operation in the "Module Programming" section. 3. For new PCMs, perform the Parameter Reset operation as detailed in this section to re-train the Smartshield security system. 4. For new PCMs, retrain the audio system to the new PCM ID code. This procedure can be carried out by using the WDS tester. 5. Temporarily secure the PCM to the bracket with new security bolts. DO NOT BREAK THE HEADS OFF YET. 6. Clear the PCM fault codes 7. Remove the WDS and test-drive the vehicle. 8. Reconnect the WDS tester and run a KOEO and KOER test on the PCM. Rectify faults if required.
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Item 1 2
Description HEGO Sensor (LHS only) HEGO Sensor (LHS & RHS)
Installation 1. To Install, reverse the removal procedure. NOTE: Make sure the thread is cleaned and that a suitable anti-seize compound is applied to the thread before installing the sensor. NOTE: Make sure the sensor’s flylead is routed away from the steering intermediate shaft. Check for any exhaust leakage around the sensor.
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REMOVAL AND INSTALLATION (Continued)
HEGO Sensor (Turbo) Removal 1. Remove the HEGO sensor. 1. Disconnect the electrical connector 2. Remove the screws 3. Using a 22mm ring spanner, remove the sensor I6 Engine
Installation 1. To Install, reverse the removal procedure. NOTE: Make sure the thread is cleaned and that a suitable anti-seize compound is applied to the thread before installing the sensor. NOTE: Make sure the sensor’s flylead is routed away from the steering intermediate shaft. Check for any exhaust leakage around the sensor.
Boost Pressure Sensor (Turbo Engine) Removal 1. Disconnect the wire harness from the BPS connector. 2. Unscrew the retaining bolt. 3. Gently pull the sensor out vertically from the aluminum duct.
Installation 1. Push the BPS into the aluminum duct. 2. Refit the retaining bolt and tighten. 3. Reconnect the harness to the BPS.
Turbocharger Wastegate Control Solenoid Removal 1. Remove the Wastegate Control Solenoid. 1. Disconnect the electrical connector. 2. Slide solenoid up and away from its retaining bracket.
Installation 1. To Install, reverse the removal procedure.
Reverse Gear Switch Removal 1. Remove the Reverse Gear Switch 1. Disconnect the electrical connector 2. Remove the retaining bolt 3. Remove the sensor
Installation 1. To Install, reverse the removal procedure.
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REMOVAL AND INSTALLATION (Continued)
Temperature and Manifold Absolute Pressure (T-MAP) Sensor Removal 1. Remove the Electronic Throttle Body and then disconnect the engine wiring harness from the T-MAP connector. 2. Remove the two screws securing the T-MAP sensor to the inlet manifold. 3. Carefully withdraw the sensor from the manifold. 4. Plug the aperture in the inlet manifold to prevent the ingress of foreign material. Installation 1. Install new o-rings on the T-MAP sensor, if necessary. 2. Install the T-MAP sensor into the inlet manifold with the connector at the bottom. 3. Align the holes and install the T-MAP sensor retaining screws. Tighten the screws to 3Nm. 4. Reconnect the harness to the T-MAP sensor. 5. Run the engine and check for vacuum leaks around the sensor. Rectify any leaks found. I6 Engine
V8 Engine
Fuel Rail (I6 Engine) Removal 1. Ensure the area of the fuel rail and intake manifold injectors are clean of all dirt, grit etc. Prior to the removal of injectors. 2. Relieve fuel system residual pressure. 3. Remove intake air duct. 4. Disconnect the wiring harness from the fuel injectors at the connector. 5. Tag and disconnect fuel supply and return lines at the quick-connect fittings. 6. Disconnect vacuum hose from pressure regulator. 7. Disconnect the wiring loom from the fuel rail. 8. Remove the screws attaching the fuel rail brackets to the intake manifold. 9. Remove the fuel injector to fuel rail retaining clips and withdraw each injector. Place each injector in a clean plastic bag to prevent the injectors from being contaminated with foreign material. Number each bag according to injector position. Plug the apertures in the intake manifold to prevent the ingress of foreign material. Installation 1. Ensure the fuel rail injector mounting apertures are clean, smear the fuel injector sealing rings with a light coating of engine oil. DO NOT use petroleum jelly. Insert the injectors into the fuel rail and install retaining clips. 2. Ensure the intake manifold injector apertures and the fuel injector tips are clean, smear the injector sealing rings with a light coating of engine oil. DO NOT use petroleum jelly. Insert the injectors into the manifold and position the fuel rail, install the retaining screws and torque screws to 19Nm. 3. Attach the injector wiring loom at the fuel rail and connect the injector clamp. 4. Reconnect the fuel supply and return lines as tagged. 5. Start and run engine. Check for any leaks. Rectify any faults found.
Fuel Rail (V8 Engine) Removal 1. Ensure the area of the fuel rail and intake manifold injectors are clean of all dirt, grit etc. Prior to the removal of injectors. 2. Relieve fuel system residual pressure. 3. Remove intake air duct from the air cleaner and throttle body. 4. Disconnect wiring connectors from the Throttle Position Sensor (TP) and Idle Air Control Valve (IAC) sensors. 5. Disconnect vacuum hoses and lines from the PCV system and fuel pressure regulator. G98156 en
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REMOVAL AND INSTALLATION (Continued) 6. Disconnect the throttle cable from the throttle linkage. 7. Remove the upper intake manifold. 8. Tag and is connect the fuel supply and return lines using quick-connect fittings. 9. Disconnect the fuel injector wiring connectors. 10. Remove the screws securing the fuel rail. 11. Remove the fuel rail and injectors as an assembly. 12. Remove the fuel injector from the fuel rail. Place each injector in a clean plastic bag to prevent the injectors from being contaminated with foreign material. Number each bag according to injector position. Plug the apertures in the intake manifold to prevent the ingress of foreign material. Installation 1. Ensure the fuel rail injector mounting apertures are clean, smear the fuel injector sealing rings with a light coating of engine oil. DO NOT use petroleum jelly. Insert the injectors into the fuel rail. 2. Ensure the intake manifold injector apertures and the fuel injector tips are clean, smear the injector sealing rings with a light coating of engine oil. DO NOT use petroleum jelly. Insert the injectors into the manifold and position the fuel rail, press down on the fuel rail and install the retaining screws. Torque screws to 12Nm. 3. Connect the fuel supply and return lines. 4. Install the upper intake manifold as described in Group 8-3, Eight Cylinder Engine. 5. Connect PCV hoses and all vacuum lines. 6. Connect throttle cable to the throttle linkage. 7. Connect wiring connectors to the TP and ISC sensors. 8. Install intake air duct to the air cleaner and throttle body. 9. Start and run engine. Check for any leaks. Rectify any faults found.
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Brake Switches Refer to Section 206-06 for more information.
Clutch Engagement Switch, (Manual Transmission) Removal 1. Gently twist the switch 45 degrees anti clockwise. 2. Withdraw the switch from the bracket.
3. Unplug the wire harness connector from the switch. Installation 1. Plug the wire harness connector to the switch. 2. Insert the switch into to the bracket. 3. While pushing the switch home into the bracket, gently twist the switch 45 degrees clockwise to lock the switch into the bracket.
Pedal Position Sensor Removal Refer to Adjustable pedal section. Installation Refer to Adjustable pedal section.
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REMOVAL AND INSTALLATION (Continued)
Air Conditioning Relay
Phaser removal
Refer to Sections 412-03 & 412-04.
Refer to Section 303-01a for more information.
Air Conditioner Pressure Transducer
OCV removal
Refer to Section 412-03.
Refer to Section 303-01a for more information.
Transmission Fluid Temperature Sensor
CID sensor removal
Refer to Section 307-01.
Fuel Pump Refer to Section 310-00.
Transmission Range Sensor (TRSA1)
Refer to Section 303-01a for more information.
VCT oil filter removal Refer to Section 303-01a for more information.
EVAP Canister Purge Solenoid
Refer to Section 307-01.
Transmission Range Sensor (TRSA2) Refer to Section 307-01.
Intake Manifold Charge Control Refer to Section 307-01. IMCC Installation
Power Steering Pressure Switch PSP Switch Location, I6
Item 1 2
Description Vacuum motor Intake manifold
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REMOVAL AND INSTALLATION (Continued) PSP Switch Location, V8
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SECTION : 307-01 Automatic Transmission VEHICLE APPLICATION : 2003.0 BA Falcon CONTENTS
PAGE
SPECIFICATIONS Specifications .........................................................................................................................307-01-3 DESCRIPTION AND OPERATION Automatic Transmission .........................................................................................................307-01-4 BTR Model 93/97LE Automatic transmission general description .......................................307-01-4 The Electronic Control System ..........................................................................................307-01-10 Adaptive Shift Strategy ......................................................................................................307-01-13 DIAGNOSIS AND TESTING 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 ............................................................................................................................307-01-47 Air Pressure checks .............................................................................................................307-01-48 Transmission fluid level adjustment .....................................................................................307-01-49 Filling a drained/dry transmission and convertor to determine the correct fluid level ..........307-01-50 Gear shift cable adjustment .................................................................................................307-01-51 Band adjustment ..................................................................................................................307-01-51 Oil cooler flushing ................................................................................................................307-01-51 REMOVAL AND INSTALLATION Inhibitor Switch .....................................................................................................................307-01-53 Radiator Oil Cooler ..............................................................................................................307-01-53 Oil Cooler Tube ....................................................................................................................307-01-53 Gear Shift — Column Shift ..................................................................................................307-01-54 Gear Shift — Floor Mounted ................................................................................................307-01-56 Cross Shaft Seals ................................................................................................................307-01-58 Mass Damper / Extension Housing .....................................................................................307-01-58 Speedometer drive gear (Non-ABS vehicles only) ..............................................................307-01-59 Extension housing seal .......................................................................................................307-01-60 Extension housing bush .......................................................................................................307-01-60 Oil Pan and Filter .................................................................................................................307-01-60 01/2003 2003.0 BA Falcon
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(Continued) Valve Body Assembly ..........................................................................................................307-01-60 Front Servo ..........................................................................................................................307-01-61 Rear Servo ...........................................................................................................................307-01-61 Transmission ........................................................................................................................307-01-62 DISASSEMBLY Transmission ........................................................................................................................307-01-67 Transmission Case ..............................................................................................................307-01-67 DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES Forward Clutch Cylinder ......................................................................................................307-01-69 C3 Clutch Cylinder ...............................................................................................................307-01-70 Planet Carrier & Centre Support ..........................................................................................307-01-71 Pump ....................................................................................................................................307-01-71 Valve Body ...........................................................................................................................307-01-71 ASSEMBLY Transmission ........................................................................................................................307-01-73 Output Shaft & Gear Assembly ............................................................................................307-01-76 Rear Band ............................................................................................................................307-01-78 Rear Servo ...........................................................................................................................307-01-78 Planet Carrier and Centre Support ......................................................................................307-01-78 Extension Housing ...............................................................................................................307-01-79 Front Servo ..........................................................................................................................307-01-79 Front Band ...........................................................................................................................307-01-79 C2/C4 Clutch ........................................................................................................................307-01-79 C3 Clutch, Reverse Sun Gear & Forward Sun Gear Assembly ..........................................307-01-83 C1 Clutch Overdrive Shaft & Input Shaft .............................................................................307-01-85 Clutch ...................................................................................................................................307-01-86 Pump Cover & Converter Support .......................................................................................307-01-87 Valve Bodies ........................................................................................................................307-01-94 Oil Filter and Pan Assembly ................................................................................................307-01-99 Torque Converter & Housing .............................................................................................307-01-100
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SPECIFICATIONS Oil Specification Description Automatic Transmission Fluid
Specification CASTROL TQ-95
NOTE: When adding fluid use only CASTROL TQ-95 ATF. The use of incorrect fluids will cause a reduction in performance and durability of the transmission. Torque Specifications Description Nm Transmission Assembly Screws T. C. housing to case M12 x 32 54-68 Extension housing to case - M93 M12 54-68 x 32 Extension housing to case - M97 M8 x 35-40 25 Rear servo cover to case M8 x 25 30-35 Pan to case M6 x 16 4-6 Cooler connector 40-45 Valve body to case M6 x 26 8-13 Valve body to case M6 x 45 8-13 Detent spring M8 x 16 20-22 Centre support to case M10 x 34 20-27 Cam plate to case M8 x 16 16-22 Position sensorswitch 10-24 x 13 4-6 Shipping strap to converter housing 11-16 M93, M8 x 13 OR M8 x 30 (TAPTITE) Shipping strap to converter housing 11-16 M97, M8 x 13 Shipping strap to converter housing 13-18 M97, M8 x 50 Shipping cap - cooler connector M16 0.15-0.35 Service fill plug M20 30-35 Pump Cover Assembly Screws Pump to pump cover M8 x 55 24-27 Pump to pump cover M8 x 40 24-34 Pump cover to case M8 x 58 24-34 Pump cover plate to pump cover M6 x 13-16 16 Pump cover plate to crescent M6 x 54 13-16 Valve Body Body Assembly Screws Upper valve body to lower M6 x 30 11-16 Line pressure plug M6 4-7 Solenoids (ON/OFF & VPS including 8-12 S7) M6 x 16
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DESCRIPTION AND OPERATION gear states or modes, Park, Reverse, Neutral, Drive (Adaptive Mode), Manual ‘3’, Manual ‘2’ and Manual ‘1’. BTR Model 93/97LE Automatic Shift scheduling is controlled by the Adaptive (mode) transmission general description Shift Schedule or the Performance (mode) Shift The Model 93/97LE is an electronically controlled four Schedule System. The Adaptive mode monitors how speed transmission with overdrive fourth gear and a the driver uses the throttle and adjusts the shift torque converter lockup clutch. strategy to meet driving requirements. The Of primary significance is the microprocessor based Performance mode is optimised to achieve maximum control system which employs a single proportional vehicle performance. In certain vehicles this mode is solenoid multiplexed to three regulator valves to optimised for towing operations instead. control all shift feel aspects. This solenoid is The 93LE (6 cylinder) and 97LE (8 cylinder) controlled as a function of transmission sump transmissions are controlled by Powertrain Control temperature to maintain consistent shift feel Module (PCM). The PCM utilizes throttle position, throughout the operating range. engine speed, engine torque, transmission range Transmission gear state is selected by the driver via sensor, transmission output speed, transmission the position selector. There are two sump temperature and communication to the engine vehicle/transmission position selector mechanism controller inputs, to control all shift feel and shift variants available, these are Sequential Sports Shift schedule aspects. and Column Shift. A reverse lockout feature is also incorporated into the The Sequential Sports Shift variant has the following transmission design. This feature is intended to selection of gear states or modes: Park, Reverse, protect the transmission from being exposed to Neutral, Drive (Adaptive Mode), Performance Mode, excessive torque in the event that Reverse gear is ‘+’ and ‘-’ in Sequential Sports Shift Mode. The engaged at speed. Column Shift variant has the following selection of
Automatic Transmission
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DESCRIPTION AND OPERATION (Continued) Model 93LE Automatic Transmission (Non-ABS shown)
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DESCRIPTION AND OPERATION (Continued) Model 97LE Automatic Transmission
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DESCRIPTION AND OPERATION (Continued) In the case where Reverse is selected inappropriately, solenoids 1 and 3 both have the supply output This system is comprised of various input sensors, a pressure exhausted, the RLO spring biases the RLO PCM and seven solenoids. The PCM simply reads the valve to the B2 band exhausted position, reverse oil is inputs and activates the outputs as per the software prevented from feeding the B2 band. and table values stored in the Read Only Memory (ROM). Mechanical Arrangement The PCM drives the hydraulic valve body via the The mechanical arrangement consists of four clutch seven electromagnetic solenoids. Six of the seven assemblies, two bands, two sprag (or one way) solenoids are ON/OFF solenoids used to: boost the clutches and a planetary gear set. line pressure, operate shift valves and turn on and off two regulator valves to control shift feel. The seventh Power Flow solenoid is the proportional or Variable Pressure First gear is accomplished by applying the C2 clutch Solenoid (VPS). and regulating the front band off, the reaction torque
Electronic Control
Hydraulic Control The hydraulic control system consists of a primary regulator valve for line pressure, a solenoid supply regulator, a lockup clutch regulator valve, a band apply regulator valve, a clutch apply regulator valve, a servo exhaust valve, C1 bias valve for converter lockups, a 4-3 sequence valve, three shift valves, a manual valve and the previously mentioned solenoids. All upshifts are accomplished by simultaneously switching: a shift valve or valves, the band and/or clutch regulator valve and controlling the VPS output pressure. The event is completed by switching the regulator off concurrent with sending the VPS to maximum pressure. All downshifts are accomplished by simultaneously switching on one or both of the regulators and controlling the VPS output pressure. The event is completed by concurrently; switching the regulator off, switching the shift valve and sending the VPS to maximum pressure. The exception to this is a downshift to Auto 1st where the VPS is reduced to minimum pressure while switching the shift valve, the regulator remains on while in Auto 1st. Neutral to ‘D’ shifts while the vehicle speed is below approximately 6 km/hr results in a shift to Garage 1st to improve garage shift quality. Above 6 km/hr the transmission shifts to Auto 1st. Garage 1st is identical to Auto 1st hydraulically except solenoid 1 is energised, this results in the C4 clutch not being supplied with oil. Downshifts to Manual 1st gear state are accomplished in the same manner as other downshifts, however the gear state is achieved by exhausting the output pressures of solenoids 1, 2 & 3. This results in the 1-2 Shift Valve toggling to the Manual 1st position supplying oil to the C4 clutch and B2 band. The Reverse gear state is accomplished by the driver positioning the manual valve into the reverse position, the manual valve supplies oil to the C3 clutch and to the reverse lockout valve (RLO). To obtain Reverse gear state either solenoids 1 or 3 supply output pressure to the RLO valve, this biases the valve to the B2 Band applied position where reverse oil is fed to the B2 band. G73081 en
is taken by the 1-2 One Way Clutch (OWC). The C2 clutch is applied in all forward gears. The 1-2 shift is accomplished by applying the B1 band and overrunning the 1-2 OWC (Only the outer B1 servo apply area is used). The 2-3 shift is accomplished by applying the C1 clutch concurrent with releasing the B1 band. The 3-4 shift is accomplished by applying the B1 band and overrunning the 3-4 OWC. (Both inner and outer B1 servo apply areas are used). The C3 clutch and the B2 band are applied to accomplish Reverse. (Both inner and outer B2 servo apply areas are used). The C4 clutch is applied in Sequential Sports Shift/manual ranges 3, 2 and 1 to provide engine braking. In addition the C4 clutch is applied in Adaptive and Performance mode for 2nd and 3rd gears to prevent objectionable ‘freewheel’ coasting. Note in Auto 1st the C4 clutch is applied but due to the B2 band not being applied the 1-2 OWC is able to overrun this enables the vehicle to ‘freewheel’. B2 band is applied in Sequential Sports Shift/manual range 1 to achieve engine braking shift. The servo is a dual area design which allows smooth overrun shifts at high vehicle speeds without the addition of a regulator valve (i.e. servo is applied with line pressure). Only the inner B2 area is used for manual 1st. The B1 servo is also a dual area design to provide additional clamping force on the B1 band in fourth gear. The mechanical arrangement utilizes non-asbestos friction materials for all members. These paper composites were selected based upon their performance with a specially formulated Automatic Transmission Fluid.
Converter Lockup Clutch The Converter Lockup Clutch is a conventional clutch with a spring damper arrangement to reduce engine torsional disturbances. Located in the torque converter, its function is to couple the turbine (driven member) to the impeller (drive member) to eliminate slippage. It is generally functional in 3rd gear and 4th 01/2003 2003.0 BA Falcon
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DESCRIPTION AND OPERATION (Continued) gear. The apply schedule and feel are modulated with The Torque Converter - 97LE throttle position, engine torque and vehicle speed. To enable lockup at high engine torque, line pressure is supplied to the converter clutch regulator valve. The Torque Converter - 93LE
Item 1 2 3 4 5 6 7 8 9 10 11 12
Description Turbine Impeller Stator Thrust Bearing Stator One Way Clutch Converter Cover Clutch Plate Torsion Damper Springs Preload Spring Turbine Hub Clutch Hub Friction Surface
Item 1 2 3 4 5 6 7 8 9 10 11 12
Description Turbine Impeller Stator Thrust Bearing Stator One Way Clutch Converter Cover Clutch Plate Torsion Damper Springs Preload Spring Turbine Hub Clutch Hub Friction Surface
Diagnostics Diagnostic activities of the control module are divided into two categories.
Real-Time Self Check This is an automatic monitoring of all inputs and outputs for malfunctions during normal operation of the vehicle. If any INPUTS malfunction, the transmission assumes one of a number of ‘temporary limp home’ (default) G73081 en
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DESCRIPTION AND OPERATION (Continued) modes until the malfunction ceases, at which time the unit will return to normal operation either while driving or after the module is re-initialised (vehicle turned off and restarted). If solenoids 1 to 6 OUTPUTS malfunction the transmission assumes a ‘permanent limp home’ mode. Even if the output malfunction corrects itself, the module must be re-initialised to return to normal operation. The exception to this is a hydraulic solenoid 1 or 3 fault where normal operation is not restored until reverse is successfully engaged at vehicle startup. If solenoid 7 output malfunctions then this solenoid is disabled resulting in the torque converter always unlocked.
Limp Home Mode There are now a number of ‘Limp Home’ modes available depending on the type of fault which has occurred. The target gear state in most cases is third gear, if solenoid 2 is faulty above a certain speed fourth gear is the target gear state. Several Limp Home modes will result in the speed limiting of the vehicle, in the event of a speedo fault the vehicle will be limited to 140 km/hr, a solenoid 1 to 6 fault will limit to 120 km/hr and multiple solenoid 1 to 6 faults will limit to 45 km/hr. These speeds are approximate and depend on the vehicle axle/wheel configuration. Limp Home modes that noticeably limit driveability also result in the PRNDL display being flashed. Reverse gear is available.
Active Diagnostics This aspect is dedicated for service technician use. Error codes are displayed by digital output to the diagnostic terminals.
Selector Lever Positions 1. Sequential Sports Shift Selector Lever A four position detent mechanism is used to select ranges ‘D’, ‘N’, ‘R’, ‘P’. In the ‘D’ position, Adaptive mode is selected. The lever can then be moved to the left to obtain the ‘PERF’ range, or Performance mode. In this position the lever can be nudged up for ‘-’ or down for ‘+’, this initiates Sequential Sports Shift mode. A spring returns the lever to the central position, the transmission will remain in Sequential Sports Shift mode until the lever is moved back to ‘D’. RANGE ‘P’ (PARK): No bands or clutches are engaged. The transmission output shaft is locked. The inhibitor switch will allow engine start. RANGE ‘R’ (REVERSE): Reverse gear operation, when selected outside appropriate vehicle and engine speed limits reverse is inhibited. Reversing lights on. RANGE ‘N’ (NEUTRAL): No bands or clutches are engaged. The inhibitor switch will allow engine start. During a N-D or N-PERF shift and while the vehicle is stationary, a N-Garage 1st-Auto 1st shift will be G73081 en
performed. This feature is to improve garage shift quality. RANGE ‘D’ (ADAPTIVE MODE): Auto 1st, 2nd, 3rd and 4th gear operation. 1-2, 2-3, 3-4, 4-3, 4-2, 4-1, 3-2, 3-1 and 2-1 shifts are all available as a function of vehicle speed, throttle position and the time rate of change of the throttle position (forced downshift, inhibited upshifts). Lockup clutch available in 3rd and 4th. RANGE ‘PERF’ (PERFORMANCE MODE): Auto 1st, 2nd, 3rd and 4th gear operation. 1-2, 2-3, 3-4, 4-3, 4-2, 4-1, 3-2, 3-1, and 2-1 shifts are all available as a function of vehicle speed, throttle position and the time rate of change of the throttle position (forced downshift, inhibited upshifts). Lockup clutch available in 3rd and 4th. In some vehicle this mode is replaced with Towing mode. Range ‘+’ (MANUAL ‘2’, ‘3’, ‘4’): This position initiates an upshift. Each gear state has a vehicle speed range, if the target gear is outside of this range an upshift is inhibited. Lockup clutch available in third and fourth, application. RANGE ‘-’ (MANUAL ‘1’, ‘2’, ‘3’): This position initiates a downshift. Each gear state has a vehicle speed range, if the target gear is outside of this range a downshift is inhibited. Lockup clutch available in 3rd. Manual 1st is only available by this means. 2. Column Shift Selector Lever A seven position detent mechanism is featured to select ranges ’1’, ’2’, ’3’, ’D’, ’N’, ’R’, ’P’. Range ‘1’ (MANUAL ‘1’): Manual 1st gear only with an inhibited engagement as a function of excess vehicle speed. Manual 1st is only available in this range. RANGE ‘2’ (MANUAL ‘2’): Auto 1st and 2nd gear operation with an inhibited engagement of second at high vehicle speed. RANGE ‘3’ (MANUAL ‘3’): Auto 1st, 2nd and 3rd gear operation with an inhibited 3rd gear engagement at high vehicle speed. Lockup clutch available in 3rd. RANGE ‘D’: Auto 1st, 2nd, 3rd and 4th gear operation. 1-2, 2-3, 3-4, 4-3, 4-2, 4-1, 3-2, 3-1, and 2-1 shifts are all available as a function of vehicle speed, throttle position and the time rate of change of the throttle position (forced downshift, inhibited upshifts). Lockup clutch available in 3rd and 4th. RANGE ‘N’ (NEUTRAL): No bands or clutches are engaged. The inhibitor switch will allow engine start. During a N-D or N-PERF shift and while the vehicle is stationary, a N-Garage 1st-Auto 1st shift will be performed. This feature is to improve garage shift quality. RANGE ‘R’ (REVERSE): Reverse gear operation, when selected outside appropriate vehicle and engine speed limits reverse is inhibited.. Reversing lights on.
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DESCRIPTION AND OPERATION (Continued) RANGE ‘P’ (PARK): No bands or clutches are for manual 1st. Both areas are applied for reverse engaged. The transmission output shaft is locked. The operation. inhibitor switch will allow engine start.
Friction Members All friction materials are non-asbestos. ‘C1’ CLUTCH: 3-4 clutch . . . engaged in third and fourth gears. ‘C2’ CLUTCH: Forward clutch . . . engaged in all forward gears. ‘C3’ CLUTCH: Reverse clutch . . . engaged in reverse gear only. ‘C4’ CLUTCH: Overrun clutch . . . primary function is to provide engine braking in manual 1st, 2nd and 3rd. In 2nd and 3rd gears to prevent objectionable ‘freewheel coasting’. ‘B1’ BAND: 2-4 band . . . engaged in second and fourth gears. There are two apply areas on the servo piston. The outer area is applied in second gear. Both areas are applied in fourth gear. ‘B2’ BAND: Low/reverse band. There are two apply areas on the servo piston. The inner area is applied
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The Electronic Control System
The transmission control unit is combined within the Powertrain Control Unit (PCM). Input signals received from the pedal position sensor, ignition system, speedometer transducer, range sensor, transmission temperature sensor and the Sequential Sports Shift selector switch are processed by the PCM to provide output signals to control the shift schedule, shift feel and line pressure. This control is achieved by the use of six ON/OFF solenoids and one proportional or variable pressure solenoid. The PCM has a diagnostic ‘Self Test’ capability whereby any malfunctions are recorded in the memory. The Diagnostic Test Codes (DTC’s) codes are displayed by digital output at the diagnostic terminals and may be read by the technician with the Worldwide Diagnostic System (WDS) tester. Refer to chapter 303-14 for PCM diagnostics.
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DESCRIPTION AND OPERATION (Continued) Solenoids
Engine Speed The engine speed signal is taken from the tachometer signal line.
Road Speed The road speed signal is taken from the speedometer transducer to speedometer line (ABS model only). On non-ABS models, the speed signal is taken from the speedometer transducer on the output shaft.
Transmission Sump Temperature This sensor takes the form of a thermistor located in the solenoid wiring loom within the transmission. Above certain temperatures, overheat strategies are invoked as indicated in the table below. Temp (°C) Overheat Strategy Item Description 115 Fan engaged. 1 Exhaust No driver alert. 2 Line 500 In Adaptive mode, Solenoids Nos. 1 to 6 are mounted in the valve body. 120 power shift schedule Solenoid No. 7 is mounted in the pump cover. is selected. Solenoids 1 and 2 are normally open ON/OFF Engine temperature solenoids that combine with other solenoids to set the jewel will appear. selected gear. PRNDL indicator will Solenoids 3 and 4 are normally open ON/OFF flash. solenoids that combine to control shift quality 125 Torque converter sequencing. They also combine with other solenoids lock-up invoked in to obtain certain gear states. 2nd, 3rd and 4th Solenoid 5 is a variable pressure solenoid (VPS) that gears above certain ramps the pressure during gear changes to control calibratable shaft shift quality. It is also used to obtain certain gear speed points. states in combination with other solenoids. 135 Vehicle restricted to a Solenoid 6 is a normally open ON/OFF solenoid that calibratable constant sets the high/low level of line pressure. torque. Solenoid 7 is a normally open ON/OFF solenoid that Transmission Range Sensor controls the application of the converter clutch. The transmission range TR sensor is incorporated in Accelerator Pedal Position (APP) Sensor the inhibitor switch mounted on the side of the The APP is part of the Electronic Throttle Control ETC transmission case and provides discrete resistance system. ETC provides direct throttle control by values indicating the gear selected by the gear shift eliminating the throttle cable. A spring is contained in lever. the APP to proved pedal resistance. The APP contains three potentiometers: one reverse slope full ratio, one forward slope full-ratio and one forward slope half-ratio. This allows an accurate picture of both the accelerator pedal position and rate of change to be sent to the PCM, while providing a failsafe backup if one of the potentiometers fails. The APP is not serviceable, if faulty replace the APP as an assembly.
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DESCRIPTION AND OPERATION (Continued) Temperature Sensor Location in Solenoid Loom
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DESCRIPTION AND OPERATION (Continued) Adaptive Shift Strategy
Override Function
The PCM features an adaptive shift strategy, which is controlled by the software within the PCM. By continuously monitoring the driver’s accelerator inputs (via the Throttle Position Sensor - measuring throttle position and rate of change, and vehicle speed-VSS), the PCM determines the driving style being used and modifies the gearshift points to suit that style. The PCM selects from 6 graduated shift maps. The maps are selected automatically by the PCM dependent on the driving style being used at the time.
The adaptive shift strategy allows for an immediate change to maximum performance shifting when the pedal application is greater than 85%. When the pedal falls below 85%, the adaptive shift level will return to the level used prior to the 85% pedal application.
Kickdown Strategy A ‘kickdown’, or forced downshift feature, is controlled by the PCM. The PCM reads pedal position, rate of pedal application, engine speed and road speed signals to determine and select the required gear.
Keep alive memory data retention
The Shift maps are essentially sets of tables which dictate the speeds at which the transmission will change gear, based on vehicle speed and throttle position.
Operation The PCM monitors what pedal position is used for upshifts and/or downshifts and compiles a composite score which reflects a particular driver’s behaviour. If the composite score is higher than the current “library” score then it will move to the next more aggressive “shift map”, or vice versa. There are two parameters that the adaptive shift routine continuously monitors to determine the best suited “shift map” to suit the driver’s driving behaviour. Parameters monitored are as follows:
The 93/97LE PCM contains a ‘Keep Alive Memory’ capability. When in Adaptive Mode, this enables the module to maintain a score of various engine/ transmission parameters and optimise the transmission shift points. The Keep Alive Memory also stores the fault data for service technician use in diagnosis. This data is stored for 40 warm up cycles of the PCM. (Warm = transmission temp. > 50°C) If the power supply to the PCM is interrupted the PCM may lose the data in the ’Keep Alive Memory’. The data retention time for the PCM depends on the module temperature during the time that the power supply is interrupted (e.g. battery disconnected).
Engine Idle Up Strategy To ensure sufficient pump capacity the PCM controls the engine idle at different transmission oil temperatures.
The Shift Pressure Control System Variable Pressure Solenoid (VPS) Multiplexing System Friction element shifting pressures are controlled by the variable pressure solenoid No. 5. Line pressure is completely independent of shift pressure.
VPS pressure is supplied continuously to the converter clutch regulator valve and is multiplexed to the clutch and band regulator valves during timed 1. Shift Scoring gearshifts. The "Shift Scoring" parameter is used to record and monitor the position of the pedal at the start of a shift. The multiplexing is carried out by two normally open on/off solenoids. These on/off solenoids act via a The PCM does this using the APP signal. plunger to apply either VPS outlet pressure or Line 500 reference pressure to one end of the regulator 2. Launch Scoring valve. The other end of the regulator valve is fed with The “Launch Scoring” parameter is used to record band or clutch feed-back pressure. and monitor the pedal position each time the vehicle is accelerated from rest. The PCM does this using the Except when in Auto 1st , Manual 1st or RLO gear pedal position sensor and vehicle speed sensor (APP state, under steady state conditions the band and clutch regulator valve solenoids are switched off. This vs VSS). applies full Line 500 pressure to the plunger and because Line 500 pressure is always greater than S5 pressure, it squeezes the S5 oil from between the regulator valve and the plunger. The friction elements G73081 en
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DESCRIPTION AND OPERATION (Continued) are then fed oil pressure equal to Line 500 multiplied by the regulator valve amplification ratio. When a gearshift is not in progress the VPS current is set to 200 mA which gives a pressure of approximately 450 kPa. When a shift is initiated the required on/off solenoid is switched on cutting the supply of Line 500 oil to the plunger. At the same time the VPS pressure is reduced to the ramp start value and assumes control of the regulator valve by pushing the plunger away from the valve. The VPS then carries out the required pressure ramp and the timed shift is completed by switching off the on/off solenoid and returning the VPS to the standby pressure. This system enables either the band or clutch or both to be electrically selected for each gearshift. The multiplexing arrangement also increases transmission reliability since it requires both the VPS and one on/off solenoid to fail before a friction element burn-up can occur. The converter clutch regulator valve is permanently connected to the VPS but its regulated outlet pressure is only fed to the torque converter when the lock up solenoid LUS S7 is activated. The VPS has been fitted with nose filters to prevent the ingress of contaminants resulting in solenoid stiction and hence further increase the overall system reliability.
hence controls the shift pressures. It is also utilised to obtain Auto 1st, Garage 1st and 3rd Limp Home. S7 - Lock up solenoid LUS switches converter clutch on or off, solenoid on applies the clutch.
Variable Pressure Solenoid (VPS) Operation Solenoid S5 is a proportional or variable pressure solenoid that provides the signal pressure to the clutch and band regulator valves thereby controlling shift pressures. A variable pressure solenoid produces an oil pressure inversely proportional to the current applied. During a gearshift the PCM applies a progressively increasing or decreasing (ramped) current to the solenoid. Current applied will vary between a minimum of 0.2 amps and a maximum of 1.275 amps. Increasing current decreases output (S5) pressure. Decreasing current increases output (S5) pressure. Line 500 pressure, 480 kPa, is the reference pressure for the VPS. S5 output pressure has a maximum value of approximately 450 kPa. When the VPS is on standby (i.e. no gearshift is taking place), the VPS current is set at 0.2 amps giving maximum output pressure. This current may be lower when the lockup clutch is applied in high performance vehicles.
Solenoid Shifting Sequence Solenoid Valve Symbols (On/Off Solenoids) Tables 1 and 2 outline the usage of solenoid numbers S1, S2, S3, S4, S5 and S7 in each gear position and The solenoid symbol shown adjacent to each solenoid on the hydraulic system schematics indicates the during gear shifts. state of the oil flow through the solenoid valve with the In brief: power On or Off. S1 & S2 - determine static gear position by Both halves of the symbol are identical, only the operating the shift valves. spring end is labeled. S3 - Switches the clutch regulator valve off or on. In the example illustrated: It is also utilised to obtain Reverse, RLO, Manual POWER ON Line 500 port is closed. The S1 port 1st, Garage 1st and 2nd No Engine Braking. is open to exhaust at the solenoid valve. S4 - Switches the band regulator valve off or on. It POWER OFF The exhaust port is closed. The S1 is also utilised to obtain Auto 1st, Garage 1st and port is open to Line 500. 3rd Limp Home. S5 - Variable pressure solenoid VPS provides the signal pressure to the clutch, band regulator and
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DESCRIPTION AND OPERATION (Continued) On/Off Solenoid
Solenoid Logic States For Model 93/97LE GEAR STATE S1 PARK ON REVERSE ON² REVERSE LIMP HOME OFF RLO ON NEUTRAL ON MANUAL 1ST ON AUTO 1ST GARAGE 1ST 2ND (ENGINE BRAKING) 2ND LOCKED 2ND NO ENGINE BRAKING 3RD (ENGINE BRAKING)¹ 3RD LOCKED 3RD LIMP HOME 4TH (ENGINE BRAKING) 4TH LOCKED
OFF ON OFF OFF ON OFF OFF OFF ON ON
ELECTRICAL SHIFT SOLENOID STATES S2 S3 S4 S5 S7 MODE³ OFF OFF OFF X OFF NORMAL OFF OFF OFF X OFF NORMAL OFF OFF OFF X OFF LIMP HOME OFF ON OFF X OFF NORMAL OFF OFF OFF X OFF NORMAL ON ON OFF X OFF Sequential Sports Shift/M1 ON OFF ON 1000mA OFF NORMAL ON OFF ON 1000mA OFF GARAGE ON OFF OFF X OFF NORMAL ON OFF OFF STANDBY ON LIMP HOME ON OFF OFF X OFF LIMP HOME OFF OFF OFF X OFF NORMAL OFF OFF OFF STANDBY ON NORMAL OFF OFF ON 1000mA OFF LIMP HOME OFF OFF OFF X OFF NORMAL OFF OFF OFF STANDBY ON NORMAL
¹ Power down gear state. ² In Reverse S1 and S3 states are inverted each engagement into Reverse, solenoid status needs to be recorded into history so that it is not reset at key off. ³ Mode is broken down into four modes, normal which refers to the normal state which the driver selects using either the T-Bar or Column Shift Selector Lever. This covers all normal driving modes. Sequential Sports Shift (T-Bar) or M1 (Column Shift) modes are the specific modes where Manual 1st is selected. Garage mode is a transient mode used when shifting from N to D and the vehicle is stationary. Limp Home G73081 en
mode refers to the situation where a system or sub-system has been detected as being faulty and the transmission software has been put into this mode for protection.
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DESCRIPTION AND OPERATION (Continued)
Shift 1-2 1-3
1-4 2-3 3-4 3L-4L 4-3 KD 4-2 KD 4-1 KD 3-2 KD @20 kph @60 kph @100 kph 3-1 KD
Solenoid Operation During Gearshifts 93LE To Initiate Shift Typical S5 Current Ramp S1 OFF 700 mA to 550 mA S4 ON S1 OFF 500 mA to 350 mA S2 OFF S3 ON S4 ON S2 OFF 900 mA to 700 mA S3 ON S4 OFF S2 OFF 500 mA to 400 mA S3 ON S4 ON S1 ON 600 mA to 450 mA S4 ON S1 ON 600 mA to 450 mA S4 ON S4 ON 750 mA to 950 mA S4 OFF S3 ON 600 mA to 900 mA S3 ON S4 ON
400 mA to 900 mA
S2 ON S4 ON
500 600 700 700
S3 ON S4 ON
2-1 KD
S4 ON
CONV. CLUTCH ON OFF 3L-4
S7 ON
S1 ON S4 ON
mA mA mA mA
to 300 mA to 500 mA to 600 mA to 900 mA
700 mA to 900 mA
700 mA to 500 mA 700 mA to 900 mA 600 mA to 450 mA
To Complete Shift S4 OFF S3 OFF S4 OFF S3 OFF S4 OFF S3 OFF S4 OFF S4 OFF S4 OFF S1 OFF S1 OFF S2 ON S3 OFF S2 ON S3 OFF S4 OFF S4 OFF
S1 ON S2 ON S3 OFF S4 OFF S1 ON S4 OFF S7 OFF
S4 OFF S7 OFF
KD .... Power on Kickdown Shift L ...... Locked Shift 1-2 1-3
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Solenoid Operation During Gearshifts 97LE To Initiate Shift Typical S5 Current Ramp S1 OFF 650 mA to 400 mA S4 ON S1 OFF 800 mA to 500 mA S2 OFF S3 ON S4 ON
To Complete Shift S4 OFF S3 OFF S4 OFF
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DESCRIPTION AND OPERATION (Continued)
Shift 1-4 2-3 3-4 4-3 KD
Solenoid Operation During Gearshifts 97LE To Initiate Shift Typical S5 Current Ramp S2 OFF 750 mA to 550 mA S3 ON S4 OFF S2 OFF 700 mA to 500 mA S3 ON S4 ON S1 ON 600 mA to 400 mA S4 ON S4 ON 500 mA to 900 mA
4-2 KD
S3 ON
600 mA to 900 mA
4-1 KD
S3 ON S4 ON
650 mA to 900 mA
3-2 KD @20 kph @60 kph @100 kph 3-1 KD
S2 ON S4 ON
2-1 KD
S4 ON
CONV. CLUTCH ON OFF 3L-2 KD
S7 ON
4L-3 KD
S3 ON S4 ON
S2 S4 S7 S4 S7
ON ON ON ON ON
350 450 600 800
mA mA mA mA
to 250 mA to 350 mA to 500 mA to 900 mA
600 mA to 900 mA
600 mA to 400 mA 700 mA to 1000 mA 400 mA to 300 mA 500 mA to 900 mA
3L-1 KD
S3 ON S4 ON S7 ON
775 mA to 900 mA
4L-1 KD
S3 ON S4 ON S7 ON
650 mA to 900 mA
4L-2 KD
S3 ON S7 ON
450 mA to 900 mA
3L-4
S1 ON S4 ON S7 ON
550 mA to 350 mA
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To Complete Shift S3 OFF S4 OFF S3 OFF S4 OFF S4 OFF S1 OFF S4 OFF S1 OFF S2 ON S3 OFF S2 ON S3 OFF S4 OFF S4 OFF
S1 ON S2 ON S3 OFF S4 OFF S1 ON S4 OFF S7 OFF
S4 OFF S7 OFF S1 OFF S4 OFF S7 OFF S1 ON S2 ON S3 OFF S4 OFF S7 OFF S2 ON S3 OFF S4 OFF S7 OFF S1 OFF S2 ON S3 OFF S7 OFF S4 OFF S7 OFF
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DESCRIPTION AND OPERATION (Continued)
Shift 3L-4L
Solenoid Operation During Gearshifts 97LE To Initiate Shift Typical S5 Current Ramp S1 ON 500 mA to 300 mA S4 ON S7 ON
To Complete Shift S4 OFF S7 ON
KD .... Power on Kickdown Shift L ...... Locked
Power Flow and Hydraulic Systems Schematics Power Flow - Neutral and Park
No clutches or bands are engaged in Neutral or Park therefore there is no drive input to the planetary gear set. In Park the transmission is mechanically locked by engaging a case mounted pawl with teeth on the output shaft ring gear.
prevented from entering the Drive circuit by the Manual Valve. All Clutch and Band circuits are open to exhaust.
Control Solenoid 1 is switched ON, solenoid 2 is switched OFF. Line (pump) pressure is applied to the Primary Regulator Valve and to the Solenoid Supply Valve. The Converter, Oil Cooler and lubrication circuits are charged from the Primary Regulator Valve. The Line 500 circuit is charged from the Solenoid Supply Valve. The S5 circuit is charged by the Variable Pressure Solenoid - S5. Line pressure is G73081 en
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DESCRIPTION AND OPERATION (Continued) Hydraulic System - Neutral and Park
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DESCRIPTION AND OPERATION (Continued) Power Flow — Reverse
Drive is via the input shaft and the forward clutch preventing reverse pressure from applying the B2 cylinder to the hub of the C3 clutch. The C3 clutch is band. engaged and drives the reverse sun gear in a clock-wise direction. The B2 band is engaged and holds the planetary gear carrier stationary causing the long pinion to rotate anticlockwise about its axis on the pinion shaft. The long pinion drives the internal ring gear in the same direction. The internal ring being splined to the output shaft drives it in an anti-clockwise or reverse direction. Control Solenoid 2 is switched OFF. In any given reverse engagement S1 and S3 have opposite states (for example S1 ON, S3 OFF). Each subsequent reverse engagement changes the ON/OFF state of S1 and S3 (eg S1 OFF, S3 ON). Thus oil pressure from EITHER S1 OR S3 pilots the Reverse Lockout (RLO) valve into the B2 band applied position. Reverse (Line) pressure oil is routed from the Manual valve direct to the C3 clutch and through the RLO valve to both the inner and outer apply areas of the rear servo piston for B2 band application. All other clutch and band apply circuits are open to exhaust. To obtain the RLO state, solenoids 1 and 3 are switched ON to exhaust tracks S1 and S3. The RLO spring biases the RLO valve to the lockout position G73081 en
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DESCRIPTION AND OPERATION (Continued) Hydraulic System - Reverse
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DESCRIPTION AND OPERATION (Continued) Power Flow — Sequential Sport Shift 1 / Manual 1
Drive is via the input shaft to the forward clutch cylinder. The C2 clutch is engaged to drive the forward sun gear via the 3-4 OWC. The B2 band and the 1-2 OWC are engaged to hold the planetary gear carrier stationary. The forward sun gear drives the short pinion anti-clockwise. The short pinion drives the long pinion clockwise. The long pinion rotating about its axis drives the internal ring gear and the output shaft in a clockwise or forward direction. The C4 clutch provides engine braking by by-passing the 3-4 OWC on overrun. Control Solenoids 1, 2 and 3 are switched ON. The 1-2, 2-3, 3-4 shift valves are held in their first gear positions by Line 500 pressure. Drive (Line pressure) oil from the Manual valve applies the C2 clutch. Lo-1st (Line pressure) oil is routed through the 1-2 shift valve to the C4 clutch and to the inner apply area of the rear servo piston for B2 band application.
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DESCRIPTION AND OPERATION (Continued) Hydraulic System - Sequential Sports Shift 1 / Manual 1
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DESCRIPTION AND OPERATION (Continued) Power Flow — Auto 1
Drive is via the input shaft to the forward clutch cylinder. The C2 clutch is engaged to drive the forward sun gear via the 3-4 OWC. The forward sun gear drives the short pinion anti-clockwise. The short pinion drives the long pinion clockwise. The 1-2 OWC prevents the planetary gear carrier from rotating under reaction force and the long pinion rotates on its axis driving the internal ring gear and output shaft in a clockwise or forward direction. There is no engine braking on overrun.
deadheads 2nd oil and the Band Apply Feed (BAF) circuit is exhausted. Drive (Line pressure) is routed through the 3-4 shift valve to apply to C4 clutch.
Control Solenoids 1 and 3 are switched OFF. Solenoids 2 and 4 are switched ON. VPS is set to minimum pressure (approximately 0 kPa). Drive (Line pressure) oil from the Manual valve applies the C2 clutch. When solenoid S1 switches OFF, S1 oil pressure, derived from Line 500 moves the 3-4 shift valve to the left. At the same time S1 and S3 oil is directed to the 1-2 shift valve moving it to its second gear position. 2nd oil (Line pressure) from the 1-2 shift valve is directed to the Band Apply Regulator (BAR) valve and to the 2-3 shift valve. When solenoid S4 switches ON, the pressure behind the BAR piston is exhausted, S5 pressure is minimum allows the BAR spring to bias the BAR valve to the exhaust position. In this position the BAR valve
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DESCRIPTION AND OPERATION (Continued) Hydraulic System - Auto 1st
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DESCRIPTION AND OPERATION (Continued) Power Flow — D2 and Sequential Sport Shift 2/Manual 2
Drive is via the input shaft and forward clutch cylinder, only 2.32 times Line 500 pressure less 237 kPa (946 Clutch C2 is applied to drive the forward sun gear via kPa), to the Band Apply Feed (BAF) circuit. the 3-4 OWC. The forward sun gear drives the short Band Apply Feed oil is directed to: pinion anti-clockwise. The short pinion drives the long the outer apply area of the front servo piston pinion clockwise. The B1 band is applied holding the the 3-4 shift valve for use when the transmission reverse sun gear stationary therefore the long pinion is shifted to fourth gear ‘walks’ around the reverse sun gear taking the internal ring gear and output shaft with it in a clockwise or the 1-2 shift valve to provide an exhaust port forward direction. The C4 clutch is applied to by-pass when the transmission is shifted to first gear. the 3-4 OWC and provide engine braking on overrun. the 1-2 shift valve to provide an exhaust port when the transmission is shifted to first gear. Control Solenoids 1, 3 and 4 are switched OFF. Solenoid 2 is Drive (Line pressure) is routed through the 3-4 shift valve to apply to C4 clutch. switched ON. Drive (Line pressure) oil from the Manual valve applies the C2 clutch.
When solenoid S1 switches OFF, S1 oil pressure, derived from Line 500 moves the 3-4 shift valve to the left. At the same time S1 and S3 oils are directed to the 1-2 shift valve moving it to its second gear position. 2nd oil (Line pressure) from the 1-2 shift valve is directed to the Band Apply Regulator valve and to the 2-3 shift valve. The Band Apply Regulator valve supplies 2nd oil, regulated to a pressure 1.8 times Line 500 pressure less 191 kPa for the BAR spring (724 kPa) or for XR8
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DESCRIPTION AND OPERATION (Continued) Hydraulic System - D2 and Sequential Sports Shift / Manual 2
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DESCRIPTION AND OPERATION (Continued) Power Flow — D3 and Sequential Sport Shift 3/Manual 3
Drive is via the input shaft to the forward clutch cylinder. Clutch C2 is engaged to drive the forward sun gear via the 3-4 OWC. Clutch C1 is engaged to drive the planet carrier. Because the forward sun gear and the planet carrier are driven clockwise at the same speed there is no relative motion between the sun gear and the pinions. The ring gear and output shaft are driven in a clockwise or forward direction at input shaft speed. The C4 clutch is applied to by-pass the 3-4 OWC and provide engine braking on overrun.
the 1-2 shift valve to provide an exhaust port when the transmission is shifted to first gear. the 3-4 shift valve for use when the transmission is shifted to fourth gear. 2nd oil at the 2-3 shift valve is directed to the 3rd oil circuit. 3rd oil from the 2-3 shift valve is directed to the Clutch Apply Regulator valve and to the 4-3 sequence valve. Clutch Apply Feed oil is directed to: the C1 clutch Control the 4-3 sequence valve Solenoids S1, S2, S3 and S4 are switched OFF. With solenoids 1 and 2 switched OFF the 2-3 and 3-4 shift At the 4-3 sequence valve the CAF oil is directed, as Band 1 Release Feed (B1R-F) oil, through the 3-4 valves are held in third gear position by Line 500 shift valve to the spring end of the 4-3 sequence valve pressure. The 1-2 shift valve is held in third gear and to the release side of the front servo piston to position by S1-S2-S3 oil pressure. 2nd oil (Line hold Band 1 OFF. Drive oil (Line pressure) from the pressure) from the 1-2 shift valve is directed to the Band Apply Regulator valve and to the 2-3 shift valve. 3-4 shift valve applies the C4 clutch. The Band Apply Regulator valve supplies 2nd oil, regulated to a pressure 1.8 times Line 500 pressure less 191 kPa for the BAR spring (724 kPa) or for XR8 only 2.32 times Line 500 pressure less 237 kPa (946 kPa), to the Band Apply Feed (BAF) circuit. Band Apply Feed oil is directed to: the outer apply area of the Front Servo.
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DESCRIPTION AND OPERATION (Continued) Hydraulic System - D3 and Sequential Sports Shift 3 / Manaul 3
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DESCRIPTION AND OPERATION (Continued) Power Flow — D4 and Sequential Sports Shift 4/Manual 4
Drive is via the input shaft to the forward clutch cylinder. The C1 clutch is applied to drive the planet carrier clockwise. The B1 band is applied to hold the reverse sun gear stationary. As the planet carrier turns, the long pinion ‘walks’ around the stationary reverse sun gear and rotates around its axis driving the internal ring gear and output shaft in a clockwise or forward direction at a speed faster than the input shaft i.e. in overdrive ratio. The forward sun gear is also driven faster than the input shaft and overruns the 3-4 OWC. The C2 clutch is engaged to reduce the speed differential across the 3-4 OWC. Control Solenoid S1 is switched ON. Solenoid S2 is switched OFF. With solenoid S1 switched ON the 3-4 shift valve is held in fourth gear position by Line 500 pressure on the small end of the valve. With solenoid S2 switched OFF the 2-3 shift valve is held in fourth gear position by Line 500 pressure on the large end of the valve. The 1-2 shift valve is held in fourth gear position by S2 oil pressure. 2nd oil (Line pressure) from the 1-2 shift valve is directed to the Band Apply Regulator valve and to the 2-3 shift valve. The Band Apply Regulator valve supplies 2nd oil, regulated to a pressure 1.8 times Line 500 pressure G73081 en
less 191 kPa for the BAR spring (724 kPa) or for XR8 only 2.32 times Line 500 pressure less 237 kPa (946 kPa), to the Band Apply Feed (BAF) circuit. Band Apply Feed oil is directed to: the outer apply area of the front servo piston. the inner apply area of the front servo piston via the 3-4 shift valve. the 1-2 shift valve to provide an exhaust port when the transmission is shifted to first gear. 2nd oil at the 2-3 shift valve is directed to the 3rd oil circuit. 3rd oil from the 2-3 shift valve is directed to the Clutch Apply Regulator valve and to the 4-3 Sequence valve. The Clutch Apply regulator valve supplies oil, regulated to a pressure 2.25 times Line 500 pressure (1100 kPa) (93LE) 2.85 times Line 500 pressure (1375 kPa) (97LE or XR’s), to the Clutch Apply Feed (CAF) circuit. Clutch Apply Feed oil is directed to: the 4-3 Sequence valve the C1 clutch The C2 clutch is applied by Drive oil (Line pressure) from the Manual valve.
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DESCRIPTION AND OPERATION (Continued) Hyadraulic System - D4 and Sequential Sports Shift 4 / Manual 4
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DESCRIPTION AND OPERATION (Continued) Power Flow — D2, D3 and D4 Lockup Drive in this range is the same as for D2, D3 or D4 with the application of the converter Lockup clutch to provide positive no-slip converter drive. NOTE: D2 Lockup is only used as an overheat reduction strategy when in failure mode.
off and allowed to exhaust through the S7 solenoid, allowing the valve to move to the clutch applied position.
The Converter Clutch Regulator Valve (CCRV) supplies Line oil, regulated to a pressure 1.48 times S5 pressure plus 138 kPa (875 kPa), to the Regulated Apply Feed (BAF) circuit. This is directed by the CCCV to the apply side of the converter clutch. Control Control for this range is the same as for D2, D3 or D4 Converter clutch release oil is exhausted at the CCCV. Converter Feed oil is re-routed by the CCCV with the addition of the converter clutch circuit to the oil cooler and lubrication circuit. activated by solenoid S7, as illustrated. When solenoid S7 is switched ON, S7 feeds oil to the Converter Clutch Control Valve (CCCV) is switched
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DESCRIPTION AND OPERATION (Continued) Hydraulic System - D2, D3 and D4 Lockup
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DESCRIPTION AND OPERATION (Continued) Hydraulic Valves Manual Valve
When engine speed increases and the pump provides an excess of oil the PRV moves to uncover the converter feed port thereby pressurising the converter. As engine speed increases further the excess oil supplied by the pump is diverted back to the pump suction port as the PRV opens further against spring force. 1-2 Shift Valve (Manual 1st Shift Valve)
The manual valve is connected to the vehicle selector mechanism and controls the flow of oil to the forward and reverse circuits. The manual valve function is identical in all forward gear positions. Oil is prevented from entering the forward and reverse circuits when the manual valve is in the park or neutral position. Primary Regulator Valve
This is a two position valve that must be switched to the 2, 3 or 4 position in order to get any forward gear other than Manual 1st. It is used on every Manual 1st-2 and 2-Manual 1st gearshift hence its name. Drive oil from the manual valve is allowed to pass through to the 2nd circuit during a Manual 1st-2 gearshift. During a 2-Manual 1st shift the band apply feed oil is allowed to exhaust via this valve. It also routes oil to the C4 clutch and the rear band servo. The switching of this valve is achieved by supplying pressure from solenoid 1, 2 and/or 3, or exhausting pressure through solenoid 1, 2 and 3. 2-3 Shift Valve
This valve is used on 2-3 and 3-2 shifts. The switching of this valve is done directly by solenoid 2 which is located at the end of the 2-3 shift valve. The function of this valve is to regulate the When in the 1 and 2 position 2nd oil from the 1-2 shift transmission line pressure (pump outlet pressure). valve is prevented from entering the 3rd circuit. When This valve gives either low, or high, line pressure the valve is shifted to the 3 and 4 position the 3rd depending on whether solenoid #6 is switched ON, or circuit is fed from the 2nd circuit and the transmission OFF. When the #6 solenoid is switched ‘ON’ S6 will shift to 3rd gear. pressure is applied to the PRV moving it against spring pressure and opening the line pressure circuit to the pump suction port resulting in reduced line pressure. Low line pressure is used during light throttle applications and cruising. Heavy throttle application will cause solenoid #6 to switch ‘OFF’ allowing the PRV to close off increasing line pressure. This stepped line pressure control does not have a detrimental effect on shift quality because all shifting pressures are controlled by separate band and clutch regulator valves and the output of solenoid #5. The PRV also regulates the supply of oil to the torque converter via the converter feed port. The lands on the PRV are designed such that priority is given to maintaining line pressure at very low engine speeds. G73081 en
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DESCRIPTION AND OPERATION (Continued) 2-3 Shift Valve
3-4 Shift Valve This valve is used for 3-4 and 4-3 shifts. Switching of this valve is done directly by solenoid 1 which is located at the end of the valve. The function of the valve during a 3-4 shift is as follows: 3-4 Shift Valve
4-3 Sequence Valve
This valve switches during 3-4 and 4-3 gearshifts although it performs no function during the 3-4 shift. It’s sole purpose during the 4-3 shift is to delay the connection of the clutch apply feed circuit (CAF) to the B1R circuit until the B1R circuit has been fully pressurised by using the 3rd circuit. It prevents objectionable engine flare at the completion of the 4-3 gearshift. B1R Exhaust Valve
exhausts the front band release circuit (B1R) thereby allowing the application of the band. connects the inner apply area of the front servo (B1AI) to the band apply feed circuit (BAF) thus allowing greater apply forces to the front band. exhausts the overrun clutch circuit (O.C.) which will allow the C4 clutch to release. The exact opposite of the above functions will occur on a 4-3 downshift. This valve also switches during Manual 1st-2 and 2-Manual 1st gearshifts where it’s function is to apply the overrun clutch (C4) in 2nd gear but to release it in Manual 1st gear. Note that the C4 clutch is applied in Manual 1st by the 1-2 shift valve.
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This valve is located in the case directly adjacent to the front servo. Its function is to allow the servo release oil to be rapidly exhausted into the transmission case during application of the front band rather than forcing the oil back into the valve body and through the 3-4 shift valve. In addition the spring on one end prevents oil entering the release area of the servo until the circuit pressure reaches approximately 70 kPa. This valve also ensures that C1 pressure has reached 70 kPa on a 2-3 shift before B1 is allowed to begin releasing, thus preventing unwanted engine flare at the commencement of the gearshift.
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DESCRIPTION AND OPERATION (Continued) Converter Clutch Regulator Valve (CCRV)
the apply side of the converter. This oil does not return from the converter because the converter clutch piston will be sealed against the flat friction surface of the converter cover. To provide cooler flow the converter clutch control valve will now direct converter feed oil from the PRV directly to the cooler circuit. The spring on the plug end of this valve ensures that the valve will remain in the released condition during engine shutdown, thus limiting the amount of torque converter draindown that can occur over long periods of non use. Solenoid Supply Valve
This valve regulates the pressure of the oil which applies the converter clutch. Input oil to this valve is from the Line Pressure and the output pressure is variable according to the signal pressure from the solenoid 5 circuit (S5). Converter clutch apply and release feel is made smooth by electronically varying the S5 pressure. The spring on the S5 end of this valve allows the CCRV to boost its regulator apply feed pressure to a level above S5 pressure during 3rd locked to 4th unlocked gearshifts to prevent torque converter clutch slippage during these shifts. The load of this spring results in an additional 140 kPa output from this valve during gear changes. This A constant pressure is supplied to all the solenoids by valve arrangement is common to both 93LE and 97LE this valve. Line pressure is used as the feed oil to this regulator and the output is termed Line 500 due to its transmissions. approximate 500 kPa pressure value. Converter Clutch Control Valve Line Pressure Boost Valve S6 pressure applied to the end of the PRV opposes spring force and causes LOW line pressure for light throttle application and cruising. Heavy throttle application causes the normally open S6 solenoid to switch OFF closing Line 500 and opening S6 to exhaust. Removal of S6 pressure from the PRV results in HIGH line pressure. Clutch Apply Regulator Valve
The two positions of this valve cause the converter clutch to be either off or on. The switching of this valve is governed by the signal pressure from solenoid 7. With the valve in the off or released position, converter feed oil from the PRV is directed to the release side of the converter. After flowing through the converter, oil returns to the converter clutch control valve and is then directed to the cooler. When the valve is in the applied position, regulated oil from the converter clutch regulator valve is directed to G73081 en
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DESCRIPTION AND OPERATION (Continued) The clutch apply regulator (CAR) valve is a 2.25:1 (93LE) and 2.85:1 (97LE or XR’s) ratio valve. This valve provides a regulated pressure to the C1 clutch and controls the rate of change of state of the clutch to give the desired shift quality. 3rd oil fed to the valve is regulated to provide an output pressure (CAF) of 2.25 times the S5 signal pressure or 2.25 times the Line 500 (93LE) - 2.85 times the S5 signal pressure or 2.85 times the Line 500 (97LE or XR’s) pressure depending on the ON/OFF condition of the S3 solenoid. Band Apply Regulator Valve
The band apply regulator (BAR) valve is a 1.8:1 ratio valve (2.32:1 in XR8). This valve provides a regulated pressure to the front servo and controls the rate of change of state of the front band (B1) to give the desired shift quality. The BAR spring retained in the bore of the BAR valve enables the output pressure (BAF) to be regulated to zero to fully release the front band. This feature is used in Auto 1st, Garage 1st and 3rd limp home gear states. 2nd oil fed to the valve is regulated to provide a BAF pressure of 1.8 times the S5 signal pressure or the Line 500 pressure less 191 kPa (2.32 times S5 or Line pressure, less 237 kPa in XR8) depending on the ON/OFF condition of the solenoid S4.
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DIAGNOSIS AND TESTING
Automatic Transmission
thoroughly checked to determine the source of the fault.
Electronic Control System
Diagnostic Connector Location Diagnosis and Testing of the Automatic Transmission electronic control system is covered in Section 303-14 as part of the Powertrain Control Module Diagnosis and Testing. The Worldwide Diagnostic System (WDS) is connected to the vehicle using the Diagnostic Link Connector (DLC). The WDS retrieves Diagnostic Trouble Codes (DTC’s), initiate self-testing diagnostics, review Parameter Identification (PID) values or reset the Keep Alive Memory (KAM) or adaptive values. Component description, maintenance and diagnosis, (including DTCs and PIDs) for the following components is found in Section 303-14: Vehicle Speed Sensor VSS Transmission Fluid Temperature Sensor TFT Symptom Chart Transmission Range Sensor TR Default Transmission Operating Modes Shift Solenoid 1 SS1 The PCM relies on accurate information from its Shift Solenoid 2 SS2 inputs and complete control of its outputs to effectively Shift Solenoid 3 SS3 control the transmission. To ensure that it has both Shift Solenoid 4 SS4 valid inputs and functioning outputs, the PCM carries out both hardware and software fault detection Variable Pressure Solenoid 5 VPS routines. The PCM will respond to any faults detected Power Control Solenoid 6 PCS by adopting the operating modes which are detailed Lock Up Solenoid 7 LUS below. Solenoid 5 has a resistance range of 3.8 to 6.2 ohms The following symptoms of faults are the most depending on its temperature. All other solenoids obvious results of each fault under "normal" have a resistance range from 23 to 45 ohms conditions. There is always the possibility that a fault depending on their temperature. Should a circuit may not be detected. If undetected fault conditions register a reading outside the above limits the are present, the operation of the transmission is COMPLETE CIRCUIT including the solenoid and all difficult to predict. its associated wiring and connectors should be Default Transmission Operating Modes Fault Condition Default Operation Pedal Fault The default pedal position in the event of a pedal sensor fault is 9%. The transmission software will respond normally as if the pedal is held at 9%. Engine Speed Fault All shifts will be firm as an engine speed corresponding to peak engine torques is assumed. If a fault is undetected, the engine speed is likely to be interpreted as stalled resulting in soft shifting possibly with an end of shift bump.
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DIAGNOSIS AND TESTING (Continued) Fault Condition Vehicle Speed Sensor Fault
Default Operation The PRNDL display will flash, Performance and Sequential Sports Shift modes will be inhibited and the torque converter will be unlocked at all times. If the transmission is in 4th gear at high engine speed it will stay in 4th gear, otherwise it will shift to 3rd Limp Home gear state. The vehicle will be speed limited to approximately 140 km/hr. The reverse lockout feature will only operate above engine speeds of 3000 ERPM. In the event of a loss of speed signal the engine speed is used to estimate vehicle speed. NOTE: Speedo transducer faults are likely to cause the vehicle’s speedometer to become inoperative. Gear Lever Fault (Inhibitor/PRNDL The gear lever is assumed to be in the Drive position, Sequential switch) Sports Shift and performance modes will be inhibited. The torque converter will be unlocked at all times. Transmission Oil Temperature All shifts will be firm until the transmission has warmed up, as a Sensing FaultTransmission Oil high transmission oil temperature is assumed. If a fault is Temperature Sensing Fault undetected, the temperature is likely to be evaluated as being lower than actual resulting in softer shifts with "end bump" (very firm feel at the end of the shift). Sequential Sports All shifts will occur as if the mode is set to Adaptive in the Shift/Performance Mode Setting instance of the Performance mode switch a being faulty.v Fault All shifts will occur as if the mode is set to Performance in the instance of the Sequential Sports Shift mode switches being faulty. The mode indicator will not respond to changes in the mode switch setting. If a fault is undetected, the mode as indicated by the mode indicator is likely to not respond to the mode switch.
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DIAGNOSIS AND TESTING (Continued) Fault Condition Battery Voltage Sensing Fault
ON/OFF Solenoid Electrical Fault (Solenoid 1, 3, 4, 5 & 6)
ON/OFF Solenoid Electrical Fault (Solenoid 2)
ON/OFF Solenoid Electrical Fault (Solenoid 7)
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Default Operation If the battery voltage is too low then:If the battery voltage is too low then: Shifts into 1st gear prohibited. Transmission uses High Line. If the battery voltage is too high or faulty then:If the battery voltage is too high or faulty then: Standby S5 current is set to 0 mA for all gears except Auto 1st.v If a fault is detected in the electrical circuit of solenoid 1, 3, 4, 5 or 6 the Fault Detection Strategy puts the transmission into a Limp Home Mode where: If a fault is detected in the electrical circuit of solenoid 1, 3, 4, 5 or 6 the Fault Detection Strategy puts the transmission into a Limp Home Mode where: The PRNDL display will flash. The transmission will shift to 3rd Limp Home gear state The torque converter will be unlocked at all times. Performance and Sequential Sports Shift modes will be inhibited. No shift ramps will be available. Above approximately 90 km/hr the solenoid 6 is switched ON supplying Low Line Pressure to the transmission to soften high speed gear shift engagement. In the case of a single solenoid fault the vehicle will be speed limited to approximately 120 km/hr, if multiple faults are present then the vehicle is limited to approximately 45 km/hr. Engine torque is limited to protect the transmission from stall starts in 4th. The reverse lockout feature will not operate in the event of a solenoid 1 or 3 fault. If a fault is detected in the electrical circuit of solenoid 2 the Fault Detection Strategy puts the transmission into a Limp Home Mode where: The PRNDL display will flash. The transmission will shift to 3rd Limp Home gear state if below 90 km/hr or S3 fault is present, otherwise a shift to 4th gear will be attempted. The torque converter will be unlocked at all times. Performance and Sequential Sports Shift modes will be inhibited. No shift ramps will be available. Above approximately 90 km/hr the solenoid 6 is switched ON supplying Low Line Pressure to the transmission to soften high speed gear shift engagement. In the case of a single solenoid fault the vehicle will be speed limited to approximately 120 km/hr, if multiple faults are present then the vehicle is limited to approximately 45 km/hr. Engine torque is limited to protect the transmission from stall starts in 4th. The reverse lockout feature will be available. If Solenoid 7 is found faulty it is disabled resulting in transmission always unlocked. The transmission does not go into LOS.
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DIAGNOSIS AND TESTING (Continued) Fault Condition ON/OFF Solenoid Hydraulic Fault (Solenoid 1 & 3)
ON/OFF Solenoid Hydraulic Fault (Solenoid 2)
Software Fault
Power Supply Fault
Default Operation When Reverse is selected solenoid 1 is switched OFF while solenoid 3 is switched ON, once a speed signal has been recognised the solenoid switching state is inverted next time Reverse is selected. A hydraulic solenoid 1or 3 fault is detected when Reverse is selected and the engine exceeds the stall speed while the vehicle is stationary, that is the transmission is neutralised. The Fault Detection Strategy puts the transmission into Limp Home Mode as if it had a solenoid 1 or 3 electric circuit fault as in 9A. Whenever the transmission is in 3rd or 4th gear and is not in the process of a gear shift the engine speed is monitored to confirm that it is in a valid vehicle speed range for 3rd and 4th gear states. In the event that it is not, the Fault Detection Strategy puts the transmission into Limp Home Mode as if it had a solenoid 2 electric circuit fault as in 9B. The transmission adopts its Limited Operation Strategy of operation. i.e. 3rd gear, unlocked and high line pressure. The operation of the PCM under this condition is difficult to predict. Its operation may be erratic. If a fault is undetected, the operation of the PCM is likely to be erratic. The transmission adopts its Limited Operation Strategy of operation. i.e. 3rd gear, unlocked and high line pressure. If there is an intermittent power supply connection, the PCM will power-up in fourth gear and then shift to the appropriate gear to satisfy the conditions present. The power supply is not monitored for fault evaluation.
If a fault is undetected, the operation of the transmission is dependent of which solenoid is actually faulty. The following is a list of characteristics for different solenoid fault conditions. Solenoid Fault Transmission Response (when fault undetected) Solenoid Condition 1 Always OFF
Always ON
2
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Always OFF
Transmission Operation Auto 1st gear instead of Garage 1st 3rd gear instead of 4th. Manual 1st unavailable. Reverse Lockout feature not available. This results in delayed N-D engagement. Garage 1st gear instead of Auto 1st. 4th gear instead of 3rd. Loss of engine braking in 2nd gear. Loss of Reverse every second reverse engagement. This results in a 1 -> 2->4->4 shifts as the vehicle accelerates from rest. 3rd gear instead of Garage 1st, Auto 1st and 2nd. Manual 1st unavailable. This results in 3 -> 3 -> 3 -> 4 shifts as the vehicle accelerates from rest.
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DIAGNOSIS AND TESTING (Continued) Solenoid
Condition Always ON
3
Always OFF
Always ON
4
Always OFF
Always ON
5
Output Pressure High Output Pressure Low
6
Always OFF
Always ON 7
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Always OFF Always ON
Transmission Operation 2nd gear instead of 3rd. Garage 1st gear instead of 4th. This results in a 1 -> 2 -> 2 -> I (overrun) downshift as the vehicle accelerates from rest. Manual 1st gear unavailable. Reverse Lockout feature not available. The following shifts become poor:1 -> 3, 1 -> 4, 2 -> 1, 2 -> 3, 4 -> 2, 4 -> 1. Manual 1st gear instead of Garage 1st. Loss of Reverse every second reverse engagement.The following shifts become poor:3 -> 4, 4 -> 3, 3 -> 2. There may be slippage in the gears during torque converter locking. 2nd gear instead of Garage 1st and Auto 1st. This results in a 2 -> 2->3->4 shifts as the vehicle accelerates from rest. The following shifts become poor:2 -> 3, 3 -> 2, 3 -> 4, 4 -> 3. 2nd gear instead of Garage 1st and Auto 1st. This results in a 2 -> 2->3->4 shifts as the vehicle accelerates from rest. The following shifts become poor:2 -> 3, 3 -> 2, 3 -> 4, 4 -> 3. Garage 1st gear and Auto 1st not available. All shifts become poor. Torque converter slips during lockup. All shifts become poor. Line pressure always high. Torque Converter Blow off valve noise may be audible at low speeds and throttle. Line pressure always low thus resulting in risk of slippage in gears. Torque converter always unlocked. Torque converter always locked, engine stall at low speed.
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DIAGNOSIS AND TESTING (Continued) Connector Circuit Reference Automatic Transmission Connector Switch
Pin B34 VPWR B46 VPWR A43 LUS A2 PCS B41 PRNDL B41 PRNDL B41 PRNDL B41 PRNDL B41 PRNDL B41 PRNDL B41 PRNDL B41 PRNDL B41 PRNDL B41 PRNDL B41 PRNDL B41 PRNDL B41 PRNDL B41 PRNDL A17 MSC1 A39 VPS A37 TFT A37 TFT A32 SIGRTN A19 GSS1 A20 GSS2 A18 MCS2 B43 TRSA_2 B43 TRSA_2 B43 TRSA_2 B43 TRSA_2
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Condition A A B B A A A A A A A B B B B B B B B B A B C B B B A A A A
Measurable Value Voltage to GND B1 Voltage to GND B1 Resistance to GND B1 Resistance to pin B46 VPWR Voltage to pin A32, M1* Voltage to pin A32, M2* Voltage to pin A32, M3* Voltage to pin A32, D Voltage to pin A32, N Voltage to pin A32, R Voltage to pin A32, P Resistance to pin A32, M1* Resistance to pin A32, M2* Resistance to pin A32, M3* Resistance to pin A32, D Resistance to pin A32, N Resistance to pin A32, R Resistance to pin A32, P Resistance to pin B46 VPWR Resistance to pin B46 VPWR Voltage to pin A32 SGRTN Resistance to pin A32 SGRTN Resistance to GND B Resistance to pin B46 VPWR Resistance to pin B46 VPWR Resistance to pin B46 VPWR Voltage to pin B33, D Voltage to pin B33, S Voltage to pin B33, UP Voltage to pin B33, DOWN
Min 10V 10V 23 Ohm 23 Ohm 0.90V 1.40V 1.90V 2.40V 2.90V 3.40V 3.9V 1.0 kOhm 1.8 kOhm 3.0 kOhm 4.5 kOhm 6.8 kOhm 10.6 kOhm 18.6 kOhm 23.0 Ohm 3.1 Ohm 0.25V 57.0 Ohm 1 0.0V 23.0 Ohm 23.0 Ohm 23.0 Ohm
Max 14V 14V 45 Ohm 45 Ohm 1.10 V 1.60V 2.10V 2.60V 3.10V 3.60V 4.10V 1.4 kOhm 2.2 kOhm 3.4 kOhm 4.9 kOhm 7.2 kOhm 11.2 kOhm 19.0 kOhm 45.0 Ohm 5.0 Ohm 4.8V 15.5 kOhm 1.0V 45 Ohm 45 Ohm 45 Ohm 3.94V 2.88V 1.83V 0.83V
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DIAGNOSIS AND TESTING (Continued) *Reading only applicable to column shift. Conditions A PCM connected to vehicle wiring harness. Ignition turned on. Measurement at pin of vehicle wiring harness. B PCM disconnected from vehicle wiring harness. Measurement at pin of vehicle wiring harness. C PCM disconnected from vehicle wiring harness. Measurement at pin of PCM.
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GENERAL PROCEDURES
Hydraulic System Preliminary inspection
9. If leakage is found at the manual lever shaft, replace seals that are leaking. 10. Check the front and rear servo covers. 11. Fluid leakage from the converter housing may be caused by engine oil leaking past the rear main bearing or from oil gallery plugs. Be sure to determine the exact cause of the leak.
When diagnosing transmission problems, first refer to the diagnosis guide for detailed information of the items that could be causing the problem. The following preliminary checks should be made in the order listed. Converter Area Leakage 1. Check the fluid level. Check the fluid for a burnt clutch plate odour. 2. Check the manual linkage adjustment. 3. Check engine idle speed. 4. Check electrical connections. 5. Check that the transmission is not in failure mode. 6. Check front and rear band adjustment.
Fluid Level A fluid level that is too high will cause the fluid to become aerated. Aerated fluid will cause low line pressure, and the aerated fluid may be forced out the vent. Low fluid level can effect the operation of the transmission and may indicate fluid leaks that could cause transmission damage.
Fluid leakage checks 1. Check the speedometer transducer installation at the transmission (if fitted). 2. Leakage at the oil pan seal often can be stopped by tightening the attaching bolts to the proper torque. 3. If necessary, replace the seal. 4. Check the fluid plug. If the plug O-ring seal is leaking, replace the seal. 5. The transmission fluid is water cooled; check the fluid lines and fittings between the transmission and the cooler in the radiator tank for looseness, wear, or damage. If leakage cannot be stopped by tightening a fitting, replace the defective parts. 6. Check the engine coolant in the radiator. If transmission fluid is present in the coolant, the cooler in the radiator tank is probably leaking. 7. The cooler can be further checked for leaks by disconnecting the lines at the cooler fittings and applying 500 kPa maximum air pressure to the fittings. The radiator cap must be removed when making this check to relieve the pressure on the exterior side of the cooler. If the cooler is leaking and will not hold this pressure the radiator must be replaced. The cooler cannot be replaced separately. 8. Leakage in the extension housing area may be caused by a worn extension housing bush, seal, drive shaft yoke, the housing to case gasket or the speedo transducer (if fitted).
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Fluid Leakage Converter Area In diagnosing and correcting fluid leaks in the front pump and converter area, use the following procedures to facilitate locating the exact cause of the leakage. Leakage at the front of the transmission, as evidenced by fluid around the converter housing, may have several sources. By careful observation, it is possible, in many instances, to pinpoint the source of the leak before removing the transmission from the vehicle. The paths which the fluid takes to reach the bottom of the converter housing are as shown. 1. Fluid leaking from the front pump seal lip will tend to move along the drive hub and onto the back of the impeller housing. In the case of a total seal failure, fluid leakage past the lip of the seal will be deposited on the inside of the converter housing only, near the outside diameter of the housing.
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GENERAL PROCEDURES (Continued) 2. Fluid leakage from the outside diameter of the seal and front pump body will follow the same path as leaks from the front pump seal or may run down the face of the front pump. 3. Fluid that leaks by front pump to case bolts will be deposited on the inside of the converter housing only. Fluid will not be deposited on the back of the converter. 4. Leakage by the front pump to case and O-ring seal may cause fluid to be deposited on the inside lower part of the converter housing. Engine oil leaks are sometimes improperly diagnosed as front pump seal leaks. The following areas of possible leakage should also be checked to determine if engine oil leakage is causing the problem: Leakage at the rocker arm cover may allow oil to flow over the converter housing or seep down between the converter housing and cylinder block causing oil to be present in or at the bottom of the converter housing. Oil gallery plug leaks will allow oil to flow down the rear face of the block to the bottom of the converter housing. Leakage from the crank shaft seal will work back to the flywheel, and then into the converter housing. Fluid leakage from other areas, forward of the transmission could cause fluid to be present around the converter housing due to blow-back or road draft. The following procedure should be used to determine the cause of leakage before any repairs are made: 5. Remove the transmission plug and note the colour of the fluid. Original factory fill fluid is dyed red to aid in determining if leakage is from the engine or transmission. Since road draft may cause leaking rocker cover oil to be present on the transmission, this leakage, if present, should be eliminated before performing work on the transmission. 6. Remove the converter lower housing cover. Clean off any fluid from the top and bottom of the converter housing, front of the transmission case, and rear face of the engine and engine oil pan. Clean the converter area by washing with suitable non-flammable solvent, and blow dry with compressed air. 7. Wash out the converter housing and the front of the flywheel. Blow all washed areas dry with compressed air. 8. Start and run the engine until the transmission reaches its normal operating temperature. Observe the back of the block and top of the converter housing for evidence of fluid leakage. Raise the car on a hoist and run the engine at fast idle, then at engine idle, occasionally shifting to the drive and reverse ranges to increase pressures within the transmission. Observe the G73085 en
front of the flywheel, back of the block (in as far as possible), and inside the converter housing. Run the engine until fluid leakage is evident and the probable source of leakage can be determined.
Gear shift Cable check Correct cable adjustment is necessary to position the manual valve for proper fluid pressure direction to the different transmission components. Improper adjustment may cause subsequent transmission failure. Refer to Gear Shift Cable Adjustment for detailed adjustment procedures.
Initial Engagement check Initial engagement checks are made to determine if initial band and clutch engagements are smooth. Run the engine until its normal operating temperature is reached. With the engine at kerb idle speed, shift the selector lever from N to D and R. Observe the initial band and clutch engagements. Band and clutch engagements should be smooth in all positions. Rough initial engagements are caused by high engine idle speed or high line pressures.
Transmission operation checks - Test preparation When testing the transmission, the transmission and engine must be at normal operating temperature. 1. Check the transmission fluid level. 2. Check the gear shift cable adjustment. 3. Attach a tachometer to the engine. 4. Firmly apply the parking brake and start the engine.
Stall test, Engine speed Ensure that the park and service brakes are firmly applied during these tests and the A/C is off. The stall test is made in D and R at full throttle, speeds should agree with the specifications shown in the Converter Stall Speed table. While making this test, do not hold the throttle open for more than five seconds at a time. Then move the selector lever to Neutral and run engine at 1000 rpm for about 15 seconds to cool the converter before making the next test. If the engine speed recorded by the tachometer exceeds the maximum limits specified in the Converter Stall Speed table, release the accelerator immediately because clutch or band slippage is indicated. Type 6 Cyl 8 Cyl
Stall Speed 2000-2200 rpm 2000-2400 rpm
Stall speed too high A higher stall speed than that specified indicates that the converter is not receiving its required fluid supply or that slip is occurring. Excessive engine speed in ‘D’ 01/2003 2003.0 BA Falcon
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GENERAL PROCEDURES (Continued) indicates C2 clutch slippage or gear train one way clutch slippage. Excessive engine speed in ‘R’ indicates C3 clutch or B2 band slippage. Stall speed too low
2. Disconnect the battery for approximately one minute. 3. Reconnect the battery. 4. Place the T-bar in the "D" position. When the stall test speeds are low and the engine is 5. Turn the key to the "RUN" position (Key On properly tuned, converter stator clutch problems are Engine Off); indicated. A road test must be performed to determine 6. Leave the T-bar in "D" for at least ten (10) the exact cause of the trouble. If the stall test speeds seconds after key-on. are 300 to 400 rpm below the specified values, and 7. Move the T-bar to the "Park" position for at least the car cruises properly but has very poor ten (10) seconds. acceleration, the converter stator clutch is slipping. If 8. Move the T-bar to "Neutral" position. the stall test speeds are 300 to 400 rpm below the specified values, and the car drags at cruising speeds 9. Ten (10) seconds later, the PRNDL display will and acceleration is poor, the stator clutch could have fast flash "N" on the display to confirm that the been installed backwards. Remove the converter and "green" strategy has been activated. check the stator clutch by replacing with a converter 10. The operation is complete and it is safe to either known to be operating correctly and retesting. Below key through to start the vehicle, or key off. standard acceleration in top gear above 50 km/h To check whether "green" transmission strategy combined with a substantially reduced maximum is active speed, indicates that the stator one-way clutch has locked in the engaged condition. This condition will If this procedure is performed when the battery has also be indicated by the transmission overheating, not been disconnected, or on a key-on cycle other although the stall speed will remain as specified. than the first after battery is disconnected, it will not Renew the converter. reset the "green" transmission strategy. Instead it will NOTE: The torque converter is a sealed unit without a fast flash "N" to indicate if the "green" transmission strategy is still active, or "N" will remain steady if the drain plug. The unit must not be dismantled. If a converter is unsatisfactory in any way then it must be strategy has expired (i.e. 1500km/1600km has elapsed since vehicle or transmission was new). replaced.
Green Transmission Strategy (Retraining for new Automatic Transmission)
Line Pressure Boost Check
This test requires that the vehicle be driven on the road or on a dynamometer whilst monitoring PID EPCDC with the WDS tester. There should be a sharp Where a new automatic transmission has been rise in line pressure when solenoid No. 6 switches off installed, or any of the transmission bands or clutches as the vehicle is gently accelerated in Drive or have been replaced, the Powertrain Control Module Reverse. This should occur at approximately 8% (PCM) must be reset for "green" transmission (93LE)/ 10% (97LE) of throttle opening in Drive or 5% strategy. (93LE)/17% (97LE) of throttle opening in Reverse. This strategy ensures that the line pressure is Lack of pressure boost: This may be caused by a regulated to correspond with the lower friction sticking primary regulator valve, a sticking line coefficient of new clutch material. The strategy pressure boost valve, faulty No. 6 solenoid or faulty remains in effect for 1,500km for all six cylinder connections or wiring. variants including SFLPG and Turbo, and 1,600km for Road testing all V8 variants including XR8 and GT. Instructions to activate the "green" transmission NOTE: A road test, using the WDS tester, will strategy determine if the ECU, transmission and converter are This procedure is now independent of the WDS. It is a functioning correctly. The WDS tester incorporates: T-Bar sequence that will only work on the first key-on cycle after the battery has been disconnected NOTE: This reset procedure (Steps 5-9) must be complete within sixty (60) seconds from the first Key-On in Step 5. 1. Ensure the ignition is off.
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a Parameter Identification PID to monitor the state of each ON/OFF solenoid (1, 2, 3, 4, 6 and 7): SS1-4, EPC and TCC. a PID to monitor transmission gear state: GEAR. a PID to monitor the current ramp of the Variable Pressure Solenoid (S5): EPCD
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GENERAL PROCEDURES (Continued) Diagnosis Guide C1 Clutch Failure
C2 Clutch Failure C3 Clutch Failure C4 Clutch Failure B1 Band Failure
B2 Band Failure 1-2 OWC Slip 1-2 OWC Seized
3-4 OWC Slip
3-4 OWC Seized
Slip or no drive in 3rd or 4th gear Will drive in 1st instead of 3rd, and 2nd instead of 4th Normal drive in 1st, 2nd and reverse. Slip or no forward drive. Normal reverse. Slip or no reverse drive. Normal forward drive. No engine braking in Manual 1, D2 or D3. No 2nd or 4th gear. Will operation in 1st instead of 2nd, and 3rd instead of 4th No reverse drive. Manual 1 will not have engine braking. No drive in D1. Drive in Manual 1. D1 will have engine braking. Transmission will lock up in other forward gears with probable gear or friction element damage. Reverse will function normally. No drive in D1. Probable loss of drive in Manual 1 because of C4 clutch burn out. Transmission lock up in 4th gear causing probable damage of C1/C2 clutch or B1 band burn out.
Road Test 1. Check that the engine will only start in Neutral and Park.
2. Drive the vehicle normally. Do solenoids 1, 2, 3, 4 & 5 operate in the correct sequence? Gear Solenoid States Gear S1 S2 Auto 1 OFF ON 2 OFF ON 3 OFF OFF 4 ON OFF
3. 4. 5. 6.
Do solenoids 3 and 4 operate during gearshifts? Does solenoid 5 current ramp during gearshifts and return to 0.2 amps when shift is completed (except in Garage 1& Auto 1)? Is solenoid 6 ON at light throttle and OFF at heavy throttle? Does solenoid 7 indicate converter clutch lock-up in 3 and in Drive? Drive the vehicle at minimum throttle and check shift speeds in both adaptive and performance modes. Drive the vehicle at 40% throttle opening and check shift speeds in both adaptive and performance modes. Where safe, and legally permissible, drive the vehicle at wide open throttle and check shift speeds in both adaptive and performance modes. Where safe, and legally permissible, check the Sequential Sports Shift / Manual Downshift and Kickdown shift speeds. During the road test take note of the shift quality, abnormal noise and any evidence of slip or shudder for further investigation.
Air Pressure checks A ‘NO DRIVE’ condition can exist even with correct transmission fluid pressure, because of inoperative clutches or bands. Inoperative bands can be located through a series of checks by substituting air pressure for the fluid pressure to determine the location of the malfunction. To make the air pressure checks, drain the transmission fluid and then remove the oil pan and control valve body. The inoperative units can be located by introducing air pressure into the transmission passages leading to the bands. CAUTION: Do not apply air pressure to the C4 clutch passage as this may dislodge the piston ‘O’ ring.
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GENERAL PROCEDURES (Continued) Pressure Apply Ports
Servos
Transmission fluid level adjustment
Apply air pressure to the inner passage of each servo. The band will be seen to tighten around the drum if the servo is operating. Apply air pressure to the outer passage of each servo. Again the band will be seen to tighten around the drum if the servo is operating. While holding air pressure to the outer passage of the front servo apply air pressure to the release passage of the front servo. The air pressure in the release passage, aided by the return spring, should release the front band against the apply pressure.
WARNING: Do not touch a hot exhaust pipe with your hands or allow transmission fluid to contact the exhaust pipe. NOTE: The transmission is sealed from the factory, oil level and oil condition checks should only be required when fluid leakage from the transmission or reduced transmission performance has occurred.
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To determine the correct fluid level, proceed as follows: 1. Place the transmission selector in ‘PARK’ Engine switched OFF. 01/2003 2003.0 BA Falcon
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GENERAL PROCEDURES (Continued) 2. Raise the vehicle on a hoist or place on a service 4. Partially fill the transmission (if the vehicle is on a pit. hoist, it should be lowered). Ensure the park-brake is applied and the selector lever is in 3. The transmission sump should be warm to touch the ‘PARK’ position. Start the engine and allow to (this indicates that the transmission is at the idle, cycle the transmission selector through all correct temperature for checking oil level). positions while adding transmission fluid until gear If the vehicle is at operating temperature application is felt. allow the vehicle to cool down for two, but no Filler Plug Location greater than four hours (while hot, the ATF level is higher and removing the filler plug may result in oil being expelled from the filler hole, this will result in low ATF level). If the engine is cold - the vehicle should be driven between 3.5 and 4.5 kilometres at light throttle so engine does not exceed 2500RPM. 4. Clean all dirt from around the service plug prior to removing. Allow approx. 3 minutes for transmission oil drainback. Remove the filler plug and check the O-ring for damage (replace as necessary). 5. The correct fluid level is reached when the ATF is level with the bottom of the filler hole, if the level is low install the filler pump and add oil to the NOTE : Approx. 9 litres if converter is empty correct level. When the level is correct, refit and (dry transmission). Approx. 4 litres if converter tighten the filler plug to 30 - 35 Nm. is full (Service refill). An additional 0.5 litres Filling a drained/dry transmission and when gear application is felt as above.
convertor to determine the correct fluid level
1. Place the transmission selector in ‘PARK’ 5. Engine switched OFF. 2. Raise the vehicle on a hoist, or place on a pit (if the vehicle is placed on stands, it should be kept level). 6. 3. Clean all dirt from around the service fill plug prior to removing the plug. Remove the oil service fill plug, clean the plug and replace the O-ring as 7. necessary. Install the oil filler tube into the transmission filler hole. 8. 9.
10.
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CAUTION: Be careful not to spill oil during the filling procedure. Switch off the engine, remove the oil filler tube and refit the filler plug (raise the vehicle on the hoist if required). The plug is to be tightened to 30-35Nm. The vehicle should be driven on light throttle so theengine does not exceed 2500RPM for approx. 3.5 to 4.5 kilometres. While the engine is idling and with the brake applied, cycle the transmission selector through all gear positions. Stop the engine and raise the vehicle ensuring the vehicle is level. Allow the vehicle to sit for 3 minutes after the engine has been turned off. The transmission sump should be warm to touch. Remove the filler plug, the correct level is reached when the transmission fluid is aligned with the bottom of the filler hole. If the level is low, add a small quantity of transmission fluid and recheck. Refit the transmission filler plug and tighten to 30-35 Nm. Clean all transmission fluid from the transmission.
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GENERAL PROCEDURES (Continued)
Gear shift cable adjustment
Rear Band
For more information, refer to Section 307-05.
1. Measure distance ‘A’ from the Rear Servo Piston to the inner face of the Transmission Case using Band adjustment vernier calipers. 1. Apply air at 650/700 kPa to the Rear Servo Front band apply area (B2 outer). 1. Measure projection of Front Servo Push Rod from 2. Measure travel of the Piston, subtract 3.75mm Transmission Case. and divide the remainder by 2.5 to find Shim 1. Apply air at 650/700 kPa to the Front Servo size. apply area (B1 outer) 3. Release Air. 2. Measure travel of Push Rod and subtract 4. Fit Shim as per 2 below and re-check Piston 3mm to find Shim size. travel is 3.75mm ± 0.625mm. 3. Release Air. NOTE: A minimum of one Shim is required at 4. Fit Shim as per 2 below and re-check Push all times - minimum Shim size is 1mm. Rod travel is 3 mm ± 0.25mm. NOTE: A minimum of one Shim is required at 2. Fit the Shim(s) selected to the shank of the Anchor Strut as follows: all times - minimum Shim size is 1 mm. 1. Inspect Shims for damage, wear or corrosion 2. Fit the Shim(s) selected to the shank of the and replace as necessary. Anchor Strut as follows: 2. Shims are to be installed between the Case 1. Inspect Shims for damage, wear or corrosion abutment face and the Anchor Strut flange. and replace as necessary. 3. Shim(s) are to be fitted by hand and under no 2. Shims are to be installed between the Case circumstances to be hammered or forced. abutment face and the Anchor Strut flange. 4. Shim(s) are to be pressed on by hand until an 3. Shim(s) are to be fitted by hand and under no audible click is heard. The click indicates that circumstances to be hammered or forced. the Shim is clipped home correctly. 4. Shim(s) are to be pressed on by hand until an 3. The Shim thickness available are: audible click is heard. The click indicates that 1. 1 mm ± 0.05, 2.0mm ± 0.07 the Shim is clipped home correctly. 2. 1.2mm ± 0.05, 2.2mm ± 0.08 3. The Shim thickness available are listed below: 3. 1.5mm ± 0.06, 2.4mm ± 0.08 1. 1 mm ± 0.05, 2.0mm ± 0.07 4. 1.8mm ± 0.07, 2.7mm ± 0.09 2. 1.2mm ± 0.05, 2.2mm ± 0.08 NOTE: All hardware must be correctly 3. 1.5mm ± 0.06, 2.4mm ± 0.08 installed and torqued to specification. 4. 1.8mm ± 0.07, 2.7mm ± 0.09 Rear Band Adjustment Front Band Adjustment
Oil cooler flushing When a clutch or band failure or other internal trouble has occurred in the transmission, any metal particles or clutch plate or band material that may have been carried into the cooler should be removed from the system by flushing the cooler and lines before the G73098 en
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GENERAL PROCEDURES (Continued) transmission is put back into service. In no case should an automatic transmission having a clutch or band failure or other internal trouble resulting in fluid contamination, be put back into service without first flushing the transmission oil cooler. 1. After installing a new or rebuilt automatic transmission and converter assembly in the vehicle, do not connect the cooler lines to the transmission.
4. Connect the cooler lines to the transmission. I6 Auto transmission cooling lines
V8 Auto transmission cooling lines
2. Place a pan under the cooler lines. 3. Using an air pressure of 100 kPa and a cleaning gun charged with clean transmission fluid, flush the cooler and lines until the fluid from the return line runs clean.
5. Fill the transmission with the specified Automatic Transmission Fluid following the procedure detailed under FILLING A DRY TRANSMISSION AND CONVERTER in the ADJUSTMENTS SECTION. 6. Check the system for leaks.
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REMOVAL AND INSTALLATION
Inhibitor Switch Special Tool(s) Selector shift pin Remover/Installer
Removal 1. Raise the vehicle. 2. Disconnect the wiring connector. NOTE: Be careful not to lose the silicone seal contained within the two-pin connector. 3. Remove the external cross-shaft pin using pin remover tool 307-467. CAUTION: When using a pin punch to remove/install the external cross shaft pin, be sure to support the cross shaft to ensure that it is not damaged. 4. Remove the two screws securing the switch and remove the switch. Installation 1. Engage the switch with the transmission cross shaft and install the two screws.
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2. Install a new external cross-shaft pin using tool 307-467. CAUTION: When using a pin punch to remove/install the external cross shaft pin, be sure to support the cross shaft to ensure that it is not damaged. 3. Install the wiring connector. Check that the 2 pin plug has the red silicon gasket in place. 4. Lower the vehicle.
Radiator Oil Cooler When fluid leakage is found at the radiator oil cooler the radiator must be replaced. The oil cooler cannot be separated from the radiator for servicing.
Oil Cooler Tube WARNING: Tubing and fittings must be free of any kinks or restrictions i.e. flattened areas. When a fluid cooler steel tube must be replaced, the replacement tube must be fabricated from the same size steel tubing as the original line. Using the old tube as a guide, bend the new tube as required. Add the necessary fittings and install the tube. After the fittings have been tightened, add fluid as needed and check for leaks. (Replacement tubing must be new and clean, oxidised tubing is not acceptable).
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REMOVAL AND INSTALLATION (Continued)
Gear Shift — Column Shift 1. For steering column components, refer to Section 211-04. I6 Steering column components
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REMOVAL AND INSTALLATION (Continued) V8 Steering column components
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REMOVAL AND INSTALLATION (Continued)
Gear Shift — Floor Mounted Removal 1. Raise the vehicle and disconnect the transmission shift cable from the lower selector lever. I6 Floor mount shift components
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REMOVAL AND INSTALLATION (Continued) V8 Floor mount shift components
2. Disconnect the four nuts that attach the housing to the floorpan.
3. Lower the vehicle. 4. Remove the centre console (Refer to section 307-05). 5. Detach the back light bulb/wiring.
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6. Remove the whole floor shift housing by lifting vertically Installation 1. To install the floor shift housing to the floorpan reverse the above instructions in order 6, 5, 4. 2. Place the selector lever in the ‘P’ position. 3. Raise the vehicle. 4. Reconnect the four nuts that attach the housing to the floorpan. 5. Install the shift cable back onto the lower selector lever. 6. Tighten the lock nut to the required torque to 28 Nm. 7. Lower the vehicle and check transmission operation in each selector lever detent position. 8. Check that the mode light functions correctly. For further information, refer to Section 307-05.
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REMOVAL AND INSTALLATION (Continued)
Cross Shaft Seals
Mass Damper / Extension Housing
Special Tool(s)
93 LE (I6) Selector shift pin remover and installer
Manual selector shaft seal remover
Manual selector shaft seal installer
Removal 1. Raise the vehicle. 2. Detach the transmission lever and/or the inhibitor switch from the cross shaft. For 93LE only the external cross shaft pin must be removed using tool 307-467 prior to removing the inhibitor switch. 3. Carefully remove the seal/s from the case using special tool 307-365. Installation 1. Cover the shaft with plastic tape to prevent damage to the seal and using special tool 307-366 drive the new seal into the case until it is flush with the boss. Remove the tape. 2. Install the transmission lever and/or inhibitor switch. For 93LE only install the external cross shaft pin using tool 307-467 prior to installing the transmission lever. 3. Lower the vehicle.
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Item 1 2 3 4 5 6 7 8 9 10 11
Description Nut M8 I6 AutomaticTransmission Extension Housing Extension Housing adapter Support Bracket Bolt M10x25 Transmission Support Lock Nut M10 Bolt M10x50 Cross Member Bolt M8X46 Bolt M10x89
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Automatic Transmission
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REMOVAL AND INSTALLATION (Continued) 97 LE (V8)
Item 1 2 3 4 5 6 7 8 9 10 11
Description Nut M8 V8 AutomaticTransmission Extension Housing Extension Housing adapter Support Bracket Bolt M10x25 Transmission Support Lock Nut M10 Bolt M10x50 Cross Member Bolt M8X46 Bolt M10x89
6. If the extension housing is to be removed mark the driveshaft and pinion flange alignment and remove the driveshaft. NOTE: When disconnecting or removing the driveshaft it is essential that the position of the slip yoke relative to the output shaft and position of the companion flange hardware be identified as illustrated. Failure to return all parts to their original position may induce driveline vibration. 7. Separate the park brake cable at the cable joiner. 8. Remove the speedometer transducer (non-ABS vehicles only). 9. Loosen the extension housing bolts to drain the fluid. 10. Remove the extension housing bolts and withdraw the extension housing. Discard the gasket. Installation 1. Install a new gasket on the extension housing. 2. Install the extension housing. 3. Install the speedometer transducer (non-ABS vehicles only). 4. Position the mass damper and insulator assembly. 5. Install the insulator bolts then the mass damper bolts. 6. Install the cross member. 7. Remove the transmission jack. 8. Install the drive shaft aligning the mating marks. 9. Connect the park brake cable joiner. 10. Lower the vehicle. 11. Check the transmission fluid level. NOTE: All hardware must be correctly installed and torqued to specification.
Speedometer drive gear (Non-ABS vehicles only)
Removal 1. Remove the extension housing. 2. The speedometer drive gear is retained to the output shaft by a spring clip. Depress the tang of the clip and slide the gear from the shaft. Installation Removal 1. Position the retaining clip on the shaft with the 1. Raise the vehicle. flanged end towards the case. 2. Support the transmission with a jack. 2. Slide the gear over the clip. Ensure that the 3. Remove the transmission cross member. retaining leg of the clip prevents the gear from 4. Remove the insulator from the extension housing. moving rearwards. 5. Remove the bolt/s securing the mass damper to 3. Install the extension housing with a new gasket. the rear of the extension housing one bolt securing the mass damper bracket on the side of 4. Check the fluid level. the extension housing. Remove the damper.
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REMOVAL AND INSTALLATION (Continued)
Extension housing seal Removal 1. Raise the vehicle. 1. Mark the driveshaft and pinion flange alignment and remove the drive shaft. 2. Prise the seal from the housing. Installation 1. Using the seal replacing tool, drive the seal until the seal seats. 2. Lubricate the seal and the driveshaft yoke with MIC75B grease and install the driveshaft aligning the marks on the shaft and pinion flange. 3. Lower the vehicle.
2. Place a drain pan under the transmission. Remove the screws at the rear of the oil pan. Loosen the remaining screws and allow the fluid to drain.
CAUTION: The fluid will be very hot if the transmission has just been operated. 3. Remove the remaining screws and lower the pan carefully, it will still contain a quantity of fluid. Discard this fluid and the oil pan seal. 4. Unclip the oil filter assembly. Remove the filter. Installation 1. Thoroughly clean the oil pan, filter assembly and the seal face of the transmission. 2. Check the condition of the ‘O’ ring seal on the oil filter spigot and replace if necessary. Extension housing bush 3. Position the filter assembly on the valve body and install the retaining clip. Removal 4. Check the location of the oil pan magnet. 1. Remove the extension housing. 5. Place a new seal on the oil pan and install the 2. Prise the seal from the housing. pan. Torque to 4.5 Nm. 3. Using the bush removing tool press the bush from 6. Fill the transmission with approved fluid. the housing. 7. Lower the vehicle. Installation 1. Place a new gasket on the extension housing and 8. Check for leaks. install the housing. Valve Body Assembly 2. Align the lubrication hole in the bush with the rib along the upper inner surface of the housing. Removal 3. Using the bush replacing tool, drive the bush into 1. Raise the vehicle and remove the oil pan. the housing until it is flush with the inner edge of 2. Remove the filter assembly. the seal recess. Lubricate the bush. 3. Disconnect the solenoid wiring at the solenoids. 4. Drive the seal into the housing with the seal 4. Remove the manual valve lever to manual valve replacing tool. link. 5. Lubricate the seal and the driveshaft yoke with 5. Remove the screws securing the valve body MIC75B grease and install the driveshaft. assembly to the case and lower the valve body. Oil Pan and Filter Installation 1. Ensure that the locating pin is correctly Removal positioned. Offer the valve body assembly to the 1. Raise the vehicle. case. Ensure the z-link is connected to the manual valve and detent lever. Fit the long end of the link to the manual valve first. 2. Install the screws. Torque the screws in the specified sequence.
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REMOVAL AND INSTALLATION (Continued) Tightening Sequence Valve Body to Case
NOTE: All hardware must be correctly installed and torqued to specification. 3. Check the alignment of the detent roller in the manual lever detent quadrant. 4. Connect the solenoid wiring. 5. Lubricate the ‘O’ ring seal on the filter spigot and carefully install the filter assembly on the valve body. The spigot must not lean on one side while being fitted. Install the retaining clip. 6. Clean the oil pan and install a new seal on the pan. 7. Install the oil pan. Torque to 4.5 Nm. 8. Fill the transmission with approved transmission fluid. 9. Lower the vehicle. 10. Check for leaks.
Front Servo Removal 1. Raise the vehicle. 2. Remove oil pan, filter and valve body as previously described. 3. Remove the servo cover retaining circlip. 4. Remove the servo piston by pushing carefully on front servo pushrod. G73112 en
Installation 1. Check the condition of the piston, push rod and cover ‘O’ ring seals and replace if necessary. 2. Lubricate the ‘O’ rings with automatic transmission fluid and install the servo piston in the case. Ensure that Band struts are correctly seated and located in push rod and anchor strut and that shim is correctly retained. 3. Install the retaining circlip. 4. Adjust the band with correct shims. 5. Install valve body, filter and oil pan. 6. Lower the vehicle. 7. Check the fluid level, top up as necessary. 8. Check for leaks.
Rear Servo Removal 1. Raise the vehicle. Remove the oil pan, filter and valve body as previously described. 2. Remove the cover bolts and remove the assembly with the spring and rod. 3. Remove the gasket.
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REMOVAL AND INSTALLATION (Continued) Installation 6. Remove the cover plate from the front of the converter housing and remove the converter to 1. Lubricate the piston ‘O’ rings with A.T.F. and fit to flywheel bolts. Detach the inhibitor switch shield the piston. Assemble the piston to the cover. (93LE only). Position the spring over the piston spigot and the servo rod in the piston spigot. 7. Disconnect the inhibitor switch, speedometer transducer (where fitted) and solenoid wiring 2. Assemble gasket to cover and assemble in case. connectors from the side of the transmission. NOTE: Do not use petroleum jelly on gasket. Transmission - 93LE 3. Apply ‘Loctite 567’ sealant to the bolt threads. Install the bolts and tighten. 4. Check that the band struts are correctly located. Check band adjustment. 5. Install valve body, filter and oil pan as previously described. 6. Lower the vehicle. 7. Check the fluid level and top up as necessary. 8. Run the engine and check for leaks at the cover in Reverse and Manual 1.
Transmission Removal 1. Disconnect the battery. Item Description 2. Raise the vehicle. If work is to be carried out on 1 Transmission wiring loom connector the transmission or torque converter when 2 Inhibitor switch connector removed from the vehicle, drain the transmission fluid. Transmission Wiring and Shield - 97LE 3. Mark the driveshaft and pinion flange alignment and remove the driveshaft. Install the extension housing seal tool in the extension housing. NOTE: When disconnecting or removing the driveshaft it is essential that the position of the slip yoke relative to the output shaft and position of the companion flange hardware be identified as illustrated. Failure to return all parts to their original position may induce driveline vibration. For more information, refer to Section 205-01 4. Remove the catalytic converter assembly by disconnecting it from thre axhaust manifold, muffler inlet pipe and bracket. 5. Loosen the engine brace to cylinder block bolts. Remove the brace to converter housing bolts (97LE only).
Item 1 2
Description Transmission wiring loom connector Inhibitor switch connector
8. Remove the starter motor mounting bolts and position the starter motor to one side. 9. Disconnect the fluid cooler lines. Plug the lines. 10. Separate the park brake cable joiner. 11. Support the transmission with a transmission jack. Install the safety chain. 12. Remove the transmission crossmember. 13. Remove the mass damper and insulator from the extension housing. 14. Lower the transmission jack until it is just supporting the transmission. G73112 en
01/2003 2003.0 BA Falcon
307-01-63
Automatic Transmission
307-01-63
REMOVAL AND INSTALLATION (Continued) 15. Remove the transmission control lever from the transmission cross shaft. 16. Remove the converter housing to cylinder block bolts. 17. Hold the converter firmly against the transmission, move the transmission rearward and lower. Secure the converter to the transmission and remove the assembly from under the vehicle. Installing Transmission - 93LE
Item 1 2 3
Description Transmission case Lubricant ESA-MK-75B Bolt M12x55
G73113 en
01/2003 2003.0 BA Falcon
307-01-64
Automatic Transmission
307-01-64
REMOVAL AND INSTALLATION (Continued) Installing Transmission - 93LE
Item 1 2 3 4
Description Transmission case Bolt M10x50 Bolt M10x18 Cover flywheel
G73113 en
01/2003 2003.0 BA Falcon
307-01-65
Automatic Transmission
307-01-65
REMOVAL AND INSTALLATION (Continued) Installing Transmission - 97LE
Item 1 2 3
Description Transmission case Bolt M12x55 Wiring retainer
Installation 1. With the converter properly installed on the transmission, place it on the jack and install the safety chain. 2. Raise the transmission into position. 3. Install the transmission to engine attaching bolts. 4. Install the converter to flywheel bolts. Install the converter housing cover and engine to body earth cable. 5. Install the starter motor. 6. Loosely connect the transmission cooler pipes. 7. Install the mass damper and rear mount on the extension housing. 8. Detach the safety chain, raise the transmission and install the transmission cross member. 9. Remove the jack. 10. Tighten the cooler line unions. 11. Install the control lever on the transmission cross shaft. 12. Check the gear shift cable adjustment (refer section 307-05). G73113 en
13. Connect the inhibitor switch, speedometer transducer (if fitted) and solenoid wiring. Ensure that the inhibitor switch 2 pin plug and breather tube are sealed. Attach the inhibitor switch shield. 14. Install the drive shaft. Match the alignment marks and secure the flange bolts. NOTE: When disconnecting or removing the driveshaft it is essential that the position of the slip yoke relative to the output shaft and position of the companion flange hardware be identified as illustrated. Failure to return all parts to their original position may induce driveline vibration. 15. 16. 17. 18. 19.
Install the catalytic converter assembly. Connect the park brake cable. Lower the vehicle. Connect the battery. Check the fluid level and top up with approved fluid as required (see Transmission Fluid Level Check). 20. Check the operation of the transmission controls. 21. Carry out the ’Throttle Learn’ procedure.
01/2003 2003.0 BA Falcon
307-01-66
Automatic Transmission
307-01-66
REMOVAL AND INSTALLATION (Continued) 22. If a new transmission has been installed the PCM must be configured using an WDS tester and the Service Card: Enter SERVICE BAY FUNCTIONS Select PCM Select TRANSMISSION CONFIGURE (1) This procedure ensures that the line pressure is regulated to correspond with a green/new transmission.
G73113 en
01/2003 2003.0 BA Falcon
307-01-67
Automatic Transmission
307-01-67
DISASSEMBLY
Transmission Special Tool(s) Transmission bench cradle
12. Remove the input shaft, forward clutch cylinder, and the overdrive shaft as an assembly, withdrawing them through the front of the case. 13. Remove the C3 clutch cylinder and sun gears. 14. Remove the front band struts. Remove the front band. 15. Remove the two centre support retaining bolts using a T50 Torx bit. 16. Remove the centre support retaining circlip.
Pump housing aligner
It is assumed that the transmission fluid has been drained when the transmission was removed from the vehicle and that the ‘special tools’ quoted are available. The transmission is dismantled in a modular fashion, and the details of disassembly for each module is given under the appropriate subject. 1. Remove the converter and the converter housing. 2. Mount the transmission on the bench cradle No. 17. Remove the centre support, 1-2 one way clutch, 307-003. planetary gearset and output shaft as an 3. Remove the oil pan and the oil pan seal. assembly. 4. Detach each end of the filter retaining clip from the valve body and remove the filter. CAUTION: On no account hammer the output shaft to remove the centre support as 5. Detach the wires from each solenoid and lay the this will cause permanent damage to the wiring to one side. thrust bearing surfaces. 6. Remove the valve body securing screws and 18. Remove the parking rod cam plate. (T40 Torx bit). remove the valve body from the case. 7. Remove the front servo cover circlip. Remove the 19. Remove the rear band struts and remove the band. cover and piston. NOTE: Plastic Servo block is retained by piston Transmission Case return spring only. 8. Remove the extension housing and the speedometer drive gear (if fitted). 9. Remove the pump bolts using a multihex 8mm spanner. 10. Remove the ‘O’ ring from the input shaft. 11. Using puller No. 307-003, remove the pump.
Special Tool(s) Manual selector shaft seal remover
Cross pin remover installer
G73115 en
01/2003 2003.0 BA Falcon
307-01-68
Automatic Transmission
307-01-68
DISASSEMBLY (Continued) Disassembly 1. Remove the external cross shaft pin using tool 307-467 (93LE only). Remove the inhibitor switch from the case. Remove the cross shaft seals with special tool 307-365. 2. Remove the circlips from the cross-shaft. Pull the shaft to release the drivepin from the selector quadrant. 3. Using tool 307-467 press the cross shaft pin from the cross-shaft and withdraw the shaft from the case. Retrieve the spring and pin. Removing and Installing the Cross Shaft Pin
4. Remove the manual valve lever and the park rod. 5. Depress the tangs on the wiring loom plug and detach it from the connector in the case. Detach the No. 7 solenoid wire from the front of the case. 6. Remove the wiring connector retainer and withdraw the connector from the case. Remove the loom assembly. 7. Remove the parking pawl pivot and the pawl and spring from the case. 8. Remove the rear servo lever and shaft. 9. Remove the rear servo cover and piston assembly. 10. Remove the front servo release exhaust valve. 11. Remove both band adjustment shims. 12. Inspect the output shaft bushing in the case and replace if necessary. 13. Inspect cooler line fittings and replace as necessary. 14. Inspect the case for damage. 15. Do not remove the park rod lever unless absolutely necessary. NOTE: To Remove: Tap the outer end of the shaft until it moves to break the grip in the case. Using a wide shallow tapered drift as a wedge, drive the pin out from the inside of the case and remove the lever and spring.
G73115 en
01/2003 2003.0 BA Falcon
307-01-69
Automatic Transmission
307-01-69
DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES
Forward Clutch Cylinder Special Tool(s) Clutch compression kit.
Disassembly
1. Place the assembly in a horizontal position. 11. Mount the clutch cylinder on tool 307-369 with C2/C4 end uppermost and compress the piston 2. Remove the thrust bearing and adjustment shims return spring. Remove the spring retaining circlip. from the input shaft. Release the tool and remove the circlip, keeper 3. Remove the circlip from the front of the clutch and spring. cylinder and remove the input shaft. CAUTION: When removing the spring 4. Remove the overdrive shaft and the C1 clutch hub compressor, make sure that the spring keeper assembly from the clutch cylinder. has not been trapped in the circlip groove and 5. Remove the C1 clutch plates from the cylinder. that all spring pressure has been released 6. Remove the circlip retaining the C3 clutch hub in before removing the tool. the rear of the clutch cylinder and remove the hub. 7. Remove the C2/C4 clutch hub assembly and remove the thrust bearing from the C4 hub. 8. Remove the C2 clutch plates. 9. Invert the clutch cylinder and remove the C4 clutch sleeve, clutch plates and the two wave washers. The 3-4 one way clutch is located between the C2 and C4 clutch hubs and the hubs may be separated by rotating one hub clockwise and withdrawing it from the other. 10. Remove the thrust block from the C4 clutch cylinder hub.
G73116 en
01/2003 2003.0 BA Falcon
307-01-70
Automatic Transmission
307-01-70
DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES (Continued) Compressing the Clutch Return Spring
C3 Clutch Cylinder Special Tool(s) Clutch compression kit.
Disassembly 1. Remove the forward sun gear and thrust bearing from the C3 clutch cylinder.
2. Remove the nylon thrust bearing, bearing support, needle thrust bearing and thrust block from the clutch cylinder hub. 12. Invert the clutch cylinder on the compressor tool and remove the C1 clutch piston return spring in a 3. Mount the clutch assembly on tool 307-369 and compress the piston return spring. Remove the similar manner. circlip and release the spring. 13. To remove the clutch pistons from the clutch cylinder, apply air pressure to the apply ports in CAUTION: Make sure that the spring the bore of the cylinder. keeper has not been caught in the circlip groove. Ensure all spring pressure has been released before removing tool.
4. Remove the tool, circlip, keeper and spring. Remove the reverse sun gear ‘O’ ring. 5. Remove the clutch plate retaining circlip and remove the clutch plates. G73116 en
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307-01-71
Automatic Transmission
307-01-71
DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES (Continued) 6. To remove the clutch piston from the clutch cylinder, apply air pressure to the port between the iron sealing rings on the bearing journals of the cylinder. 7. Remove the reverse sun gear from the cylinder.
Planet Carrier & Centre Support Disassembly
3. Remove the 4 Torx head screws from the cover plate (Torx bit No. 30). 4. Lift the cover plate from the cover. Remove the ball check valves and spring from the pump cover. 5. The retaining pins for the 3 valves are loose in the cover, remove the pins. This may be done by pushing the sealing plugs in slightly and allowing the pins to fall out or by withdrawing the pins with a magnet. Remove the 3 sealing plugs. 6. Remove the 3 valves. 7. Remove the ‘O’ ring seal from the periphery of the pump cover. 8. Remove the pump gears from the pump body. 9. Remove the ‘O’ ring seal from the pump body. 10. Remove the lip seal from the front of the pump body. NOTE: Do not remove the seal unless replacement is required.
Valve Body Disassembly 1. Separate the planet carrier and centre support 1. Remove the detent spring and retainer plate using from the output shaft. Remove the thrust bearings a T40 Torx bit. from the output shaft and the planet carrier. 2. Slide the manual valve out of the lower valve 2. Separate the centre support from the planet body. carrier by rotating it anti-clockwise. 3. Take note of the angular relationship of the 3. Lift the one way clutch from the planet carrier. solenoid terminals to the valve body. Remove the 4. Remove the circlip retaining the one way clutch solenoid and valve assembly as follows: outer race in the planet carrier and remove the No. 1 solenoid. race. No. 2 solenoid. 5. Remove the one way clutch retainer and o-ring No. 3 solenoid. from the planet carrier. No. 4 solenoid. Pump No. 5 solenoid. No. 6 solenoid. Disassembly NOTE: The following valves are housed in the pump 4. Place the valve body assembly on the bench with the upper body uppermost. Remove the 24 cover: clamping screws with a No. 30 Torx bit. Separate No. 7 solenoid. the upper and lower valve bodies by lifting the upper body and the separator plate together. Turn Converter clutch control valve. the upper body over the place on the bench with Converter clutch regulator valve. the separator plate uppermost. Primary regulator valve. 5. Lift the separator plate and gaskets from the 1. Remove the wiring loom retainer plate and upper valve body, remove the 3 nylon (white) and remove the No. 7 solenoid with a T30 Torx bit. 3 PIA (olive) check balls exposed in the valve body. Remove the keeper plate from the reverse 2. Remove the 5 washer head bolts from the cover lockout valve, spring and plug will drop out when plate using a multipoint 8 mm socket. Separate the upper valve body is tipped on its end. the pump assembly from the pump cover assembly. 6. Remove the 1 filter and the one large nylon check NOTE: The pump assembly should be supported ball from the lower valve body. as the bolts are removed. If the pump assembly 7. Remove the keeper plates and pins from the 1-2, does not come away freely from the pump cover 2-3, 3- 4, bar and car valves. The plates are loose do not strike the converter support tube to free the in the valve body and will drop out when the valve pump assembly. body is turned over. Pins can be removed with a magnet. G73120 en
01/2003 2003.0 BA Falcon
307-01-72
Automatic Transmission
307-01-72
DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES (Continued) 8. Remove the 1-2, 2-3 and 3-4 shift valves. 9. Depress the 4-3 sequence valve plug and remove the keeper plate. Remove the plug, valve and spring. 10. Depress the damper valve. Remove the keeper pin and remove the valve and spring. 11. Drive out the roll pin and remove the spring and ball check valve adjacent to the BAR valve. NOTE: AII hardware must be correctly installed and torqued to specification.
G73120 en
01/2003 2003.0 BA Falcon
307-01-73
Automatic Transmission
307-01-73
ASSEMBLY 4. Install the rear servo lever and pivot pin. The lever must pivot freely on its pin.
Transmission Special Tool(s) Manual selector shaft shift seal remover
Selector shaft pin remover and installer
Transmission bench cradle
5. Assemble the park rod lever complete with return spring and pivot pin. Apply a small amount of sealer to the outer end of the pivot pin. No sealant allowed between pin and lever. The lever must pivot freely on its pin and the spring must return the park rod lever.
1. Turn the transmission case upside down on the bench and mount it to the transmission cradle 307-003. 2. Install all fittings, plugs and the breather. Apply sealant where applicable. Ensure that the breather is clear. Check that the tube fitting in the rear of the case is filled and clear of obstruction. 3. Assemble the BIR valve and spring and secure with the circlip. Ensure the circlip is completely seated in its groove.
6. Install the parking pawl with its spring and install the pivot pin. The pawl must pivot freely on its pin.
7. Connect the park rod to lever. Ensure the spring and cam collar is firmly installed on the rod. Check that the cam collar slides freely on the rod.
G73121 en
01/2003 2003.0 BA Falcon
307-01-74
Automatic Transmission
307-01-74
ASSEMBLY (Continued) 8. Start the cross shaft into the case from the cable side of the case, inhibitor switch end first, and install the antirattle spring on the shaft. Position the manual valve detent lever, aligning it with the cross-shaft bore in the case. Push the shaft through the detent lever until it starts in the detent lever side of the case. Install the detent lever drive pin in the shaft using tool 307-467 with the adaptor over the pin. Press the pin into the shaft until the tool bottoms. Remove the tool. Fit the spring retaining circlip. Manual Valve Detent Lever
Manual Valve Detent Lever
G73121 en
01/2003 2003.0 BA Falcon
307-01-75
Automatic Transmission
307-01-75
ASSEMBLY (Continued) 9. Install new cross shaft seals using tool 307-366. 10. Install the inhibitor switch on the case. NOTE: All hardware must be correctly installed and torqued to specification. 11. Thoroughly check the internal wiring loom for condition and continuity. Install a new external cross shaft pin using tool 307-467. Press the pin into the shaft until the tool bottoms. 12. Thoroughly check the internal wiring loom, position the loom and locate the S7 solenoid terminal in the pump mounting flange at the front of the case. The S7 solenoid wire is routed under the park rod and cross shaft in the case. 10 Pin connector and installation
13. Install the ten pin connector in the case engaging the tangs into the notches in the case. It is important that both tangs fully engage. This can be checked visually on the outside of the case.
G73121 en
01/2003 2003.0 BA Falcon
307-01-76
Automatic Transmission
307-01-76
ASSEMBLY (Continued)
Output Shaft & Gear Assembly 93LE (Non-ABS shown)
Assembly 1. Check that the output shaft bush is not worn or damaged. Replace if necessary. 2. Check for damage to parking pawl teeth on ring gear. Replace if necessary. 3. Check that the sealing ring grooves have not been damaged. 4. Lubricate the sealing ring with automatic transmission fluid. 5. Assemble the sealing rings to the output shaft with the scarf cut uppermost. 6. If previously dismantled, assemble the ring gear to the output shaft and secure with circlip. Ensure that the circlip is firmly seated in its groove. 7. Fit the thrust bearing assembly No. 10 on the output shaft using petroleum jelly. 8. Install the output shaft assembly in the case carefully to prevent damage to the sealing rings. Lubricate the case bush with petroleum jelly. 9. Install the speedo drive gear (non-ABS models only).
G73124 en
01/2003 2003.0 BA Falcon
307-01-77
Automatic Transmission
307-01-77
ASSEMBLY (Continued) Thrust Bearing Location
G73124 en
01/2003 2003.0 BA Falcon
307-01-78
Automatic Transmission
307-01-78
ASSEMBLY (Continued)
Rear Band
Planet Carrier and Centre Support
Assembly 1. Check the band for any cracks or damage along the lining and metal backing. 2. Soak a new band in automatic transmission fluid for a minimum of five minutes prior to assembly. 3. Install reaction anchor strut into maincase without shims. 4. Install the rear band carefully into the transmission case and ensure that it is properly fitted in the case. 5. Position the apply strut on the rear band. 6. Engage the apply strut in the servo lever. 7. Band adjustment is to be left backed off to allow easy installation of the planet carrier assembly into transmission. 8. Install the cam plate and tighten screws to specification. NOTE: AII hardware must be correctly installed and torqued to specification.
Assembly Planet Carrier Assembly and Centre Support (93LE Shown)
1. Check the carrier and planet assembly for any damage or irregularity and ensure that all pinions rotate freely and that pinion and float is within 0.1 to 0.5 mm. 2. Install the o-ring into the planet carrier o-ring groove. Rear Servo 3. Install the one way clutch retainer to the planet carrier with the inner edge pointing downwards. Assembly Inspect the one way clutch race and the sprag assembly for wear or damage. Replace if necessary. 4. Install the outer race in the drum. Press the race to the bottom of the drum and install the retaining circlip, as illustrated. Ensure the circlip is firmly seated in its groove. 5. Install the one way clutch into the outer race with the lip edge uppermost, as illustrated. Lubricate the sprags with automatic transmission fluid. 6. Check that the plugs are fitted to the centre support and assemble the centre support into the one way clutch, as illustrated. Ensure that the support will rotate in an anti-clockwise direction only. 1. Check the servo piston ‘O’ ring and gasket for any damage. 7. Lubricate the needle thrust bearing No. 9 with petroleum jelly and fit it to the rear face of the 2. Lubricate the servo piston ‘O’ rings with automatic planet carrier. transmission fluid and fit the ‘O’ rings to the piston grooves. 8. Install the planet assembly and the centre support into the case and align the centre support 3. Assemble the piston to the cover. Ensure that ‘O’ mounting bolt holes. Install the centre support ring compression is adequate but not excessive. bolts finger tight. Install the circlip retainer 4. Align the spring on the piston spigot. Position the ensuring that circlip is completely seated in the rear servo rod in the spigot. groove of the case. 5. Assemble the gasket to the cover and fit the 9. Remove the centre support bolts and apply assembly to the case. Loctite 222 or equivalent to the threads. Install the NOTE: Do not use petroleum jelly on gasket. bolts and torque to specifications. 6. Apply Loctite 567 sealant to the bolts. Install the 10. Adjust the rear band to specifications. bolts and tighten to specification. Fit the wiring loom clip to hold the wiring vertical. G73123 en
01/2003 2003.0 BA Falcon
307-01-79
Automatic Transmission
307-01-79
ASSEMBLY (Continued)
Extension Housing
Front Band
Assembly
Assembly
Extension Housing
1. Check the condition of the extension housing bush, replace if necessary. 2. Install a new seal to the extension housing. 3. Position a new gasket to the extension housing. NOTE: Do not use petroleum jelly to hold gasket in position. 4. Install the extension housing and torque the bolts to specification.
Front Servo Assembly 1. Lubricate the cover ‘O’ ring with automatic transmission fluid and assemble to the cover. 2. Lubricate the piston ‘O’ rings with automatic transmission fluid and assemble to the piston. 3. Fit the piston push rod assembly into the front servo cover ensuring that the ‘O’ ring compression is adequate but not excessive. 4. Install the front servo assembly into the case. Ensure that the cover ‘O’ ring compression is adequate but not excessive. 5. Compress the servo cover and fit the servo cover retaining circlip and ensure that it is completely seated in its groove.
G73130 en
1. Install the reaction anchor strut to the case. 2. Check the band for any cracks or damage along its lining and metal backing. 3. If fitting a new band, soak the band in automatic transmission fluid for a minimum of 5 minutes prior to assembly. 4. Install the front band into the transmission case and ensure that it is properly seated in place. 5. Position the reaction strut in its retaining clip and engage it with the band and anchor strut. Position the apply strut in its retaining clip and engage it with the band and the servo piston rod. 6. Band adjustment is to be backed off to aid installation of the clutch cylinder.
C2/C4 Clutch Special Tool(s) Clutch compression kit
Clutch measuring kit 307-370
01/2003 2003.0 BA Falcon
307-01-80
Automatic Transmission
307-01-80
ASSEMBLY (Continued) Assembly
1. 2.
3. 4.
5. 6.
7.
8. 9.
10.
11.
12. Install the spring and spring retainer on the piston. Using Tool 307-369 compress the spring until the retaining circlip can be installed. Ensure that the circlip is firmly seated in its groove and remove the tool. The wire diameter of this spring is 5.26 mm. 13. Install the C2 wave washer in the cylinder with the crest of one wave covering one of the bleed orifices in the C2 piston. 14. Measure and record the thickness of the flange of the C2 sleeve. 15. Install the C4 clutch plates and wave washer into the C2 actuating sleeve, with the rounded edge of the steel plates down, in the following sequence: Steel plate Check the C2 piston bleed orifices for obstruction. Friction disc Check the feed orifices in the cylinder bore. Steel plate Lubricate the ‘O’ rings with automatic Friction disc transmission fluid. Fit the small ‘O’ ring on the Steel plate inner groove and the large ‘O’ ring on the outer groove of the piston. ‘O’ rings must not be twisted. Friction disc Check the C4 piston bleed orifices for obstruction. Steel plate (selective) Check the feed orifices in the cylinder bore. Wave washer Lubricate the ‘O’ rings with automatic NOTE: Hold the cylinder horizontal and install the transmission fluid and fit the small ‘O’ rings to the sleeve and clutch plate assembly into the cylinder with inner groove and the large ‘O’ rings to the outer the crest of one wave of the washer in line with one of groove of the piston. the holes in the outside of the cylinder until the sleeve Position the clutch cylinder with the C2/C4 cavity contacts the C2 wave washer. facing upwards. 16. Check the C4 clutch pack clearance using special Fit the C4 piston into the C2 piston with the bleed tool 307-370 as illustrated. Use selective plates to orifices in alignment. Ensure that the C4 piston achieve the correct specification. If new friction outer ‘O’ ring compression is adequate but not plates are being fitted, remove the clutch pack excessive. and soak the friction plates in ATF for a minimum Install the C2/C4 piston assembly into the cylinder of 5 minutes prior to reassembly. Clutch pack with the piston bleed orifices aligned with the clearance must be taken before the elements are holes on the outside of the cylinder until the OD of soaked in ATF. Reassemble the sleeve and clutch the C2 piston enters the inner diameter of the pack into the cylinder. cylinder. Ensure the C2 piston outer ‘O’ ring compression is adequate not excessive. Assemble the piston return spring to the piston and fit the spring retainer over the spring. The wire diameter of this spring is 4.3 mm. Using special tool 307-369 compress the spring sufficiently to enable the installation of the retaining circlip. Ensure that the circlip is firmly seated in its groove and remove the tool. Check the C1 piston check valves for correct function and the cylinder feed orifices for obstructions. Lubricate the ‘O’ rings with petroleum jelly and fit to their respective grooves. The ‘O’ rings must not be twisted in the grooves. Position the cylinder with the C1 cavity upwards. Install the piston into the cylinder until the OD of the piston enters the inner diameter of the cylinder.
G73130 en
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307-01-81
Automatic Transmission
307-01-81
ASSEMBLY (Continued) C4 Clutch Pack Clearance
G73130 en
01/2003 2003.0 BA Falcon
307-01-82
Automatic Transmission
307-01-82
ASSEMBLY (Continued) C2 Clutch Pack Clearance
17. Fit the thrust plate over the inner hub. 18. Install the C2 clutch plates in the cylinder in the following sequence. Friction disc Steel plate Friction disc Steel plate Friction disc Steel plate (selective) Friction disc Steel plate (selective) Friction disc 19. Check the clutch pack clearance using the weight only from tool 307-370 as illustrated. Use selective plate to achieve the correct specification. If new friction plates are being fitted, remove the clutch pack and soak the friction plates in ATF for a minimum of 5 minutes prior to reassembly. Clutch pack clearance must be taken before the elements are soaked in ATF. 20. Lubricate and fit the 3-4 OWC. Lubricate and fit the C2 OWC and end caps to the C2 hub. 21. Align the tangs and fit the nylon thrust washer onto the C4 hub as illustrated.
G73130 en
22. Align and fit the C4 hub to the C2 clutch and OWC assembly. Check the rotation of the C2 hub. While holding the C4 hub, the C2 hub should rotate in the clockwise direction and lockup in the anti-clockwise direction when viewed from the C2 hub.
23. Apply petroleum jelly to thrust bearing No. 5 and fit it to the C4 hub. 24. Remove the C2 clutch plates from the clutch cylinder. 25. Engage the C2/C4 clutch hub assembly in the C4 clutch plates. 26. Install the C2 clutch plates. 27. Install the C3 hub and secure it with the circlip. Ensure that the circlip is firmly seated in its groove.
01/2003 2003.0 BA Falcon
307-01-83
Automatic Transmission
307-01-83
ASSEMBLY (Continued)
C3 Clutch, Reverse Sun Gear & Forward Sun Gear Assembly Special Tool(s) Clutch Compression Kit
Clutch Measuring Kit
Assembly C3 Clutch and Reverse Sun Gear
5. Align the C3 piston in the cylinder until the OD of the piston enters the inside diameter of the cylinder. Ensure that the piston ‘O’ ring compression is adequate but not excessive. Assemble the spring and spring retainer on the piston. Using tool 307-369 compress the spring sufficiently to enable the installation of the retaining circlip. Ensure that the circlip is firmly seated in the groove and remove the tool. Fit the C3 wave plate to the C3 piston face with one crest of the wave plate directly over one of the piston orifices. Assemble the clutch plates and discs into the cylinder in the following sequence: 1. Steel plate outer. 2. Friction disc inner. 3. Steel plate outer. 4. Friction disc inner. 5. Steel plate outer. 6. Friction disc inner. 7. Steel plate outer. 8. Friction disc inner. Align and fit the pressure plate with the counterbore facing away from the clutch plates. Install the circlip. 6. Check the clutch clearance using special tool 307-370 in the following manner: Forward sun gear and C3 clutch assembly
1. Check the orifices in the cylinder are clear. Check the C3 cylinder bush outside diameter against the centre support inside diameter. Coat the sealing rings with automatic transmission fluid and fit into the C3 cylinder grooves. 2. Check the reverse sun gear splines, grooves and thrust face for condition. Coat the ‘O’ ring with automatic transmission fluid and fit it to the groove and the reverse sun gear. 3. Install the reverse sun gear in the C3 cylinder. Ensure that the ‘O’ ring compression is adequate but not excessive. 4. Coat the C3 piston ‘O’ rings with automatic transmission fluid and fit the small ‘O’ ring to the inner ring and the large ‘O’ ring to the outer ring of the C3 piston. ‘O’ rings must not be twisted in grooves. Check that the bleed orifices of the piston are clear.
G73131 en
1. (weight only) Place the weight on the pressure plate and measure the distance from the end of the cylinder to the top of the pressure plate. Record this figure. 2. Remove the weight. 3. Lift the pressure plate up against the circlip and measure the distance from the end of the cylinder to the top of the pressure plate. Record this figure. 4. Subtract the second reading from the first reading to obtain the clutch pack clearance. 5. If new friction plates are being fitted, remove the clutch pack and soak the friction elements 01/2003 2003.0 BA Falcon
307-01-84
Automatic Transmission
307-01-84
ASSEMBLY (Continued)
6. 7.
8. 9. 10.
11.
12.
in automatic transmission fluid for a minimum of five minutes prior to reassembly. Clutch pack clearance must be taken before the elements are soaked in automatic transmission fluid. Lubricate the needle thrust bearing assembly No. 7 with petroleum jelly and fit the bearing over the forward sun gear, thrust washer face to gear. Align and fit the C3 clutch assembly over the forward sun gear. Fit the thrust plate securely over the reverse sun gear. Lubricate the needle thrust bearing No. 6 with petroleum jelly and fit it to the thrust plate. Ensure the lugs on the OD of the bearing fit in the thrust plate counterbore. Align and fit the plastic thrust washer to the thrust plate with petroleum jelly as illustrated. Install the assembly over the foward sun gear shaft against the No. 6 thrust bearing. Place assembly to one side.
C3 Clutch Assembly Clearance
G73131 en
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307-01-85
Automatic Transmission
307-01-85
ASSEMBLY (Continued)
C1 Clutch Overdrive Shaft & Input Shaft
C1 Clutch Assembly Clearance
Special Tool(s) Clutch Measuring Kit
Assembly 1. Check the overdrive shaft grooves for any defect. 2. Coat the sealing rings, large and small, with petroleum jelly and fit them to the overdrive shaft. The sealing rings may be held in place with a small amount of petroleum jelly. 3. Assemble the clutch plate and disc into the cylinder in the following sequence: 1. Steel plate outer. 2. Friction disc inner. 3. Steel plate outer. 4. Friction disc inner. 5. Steel plate outer. 6. Friction disc inner. 7. Steel plate outer (selective). 8. Friction disc inner. 9. Steel plate outer (selective). 10. Friction disc inner. 4. Check the clutch pack clearance using special tool 307-370. Use selective plates to achieve the correct specification. If new friction plates are being fitted, remove the clutch pack and soak the friction elements in automatic transmission fluid for a minimum of five minutes prior to assembly. Clutch pack clearance must be taken before elements are soaked in automatic transmission fluid.
G73133 en
5. Check the fit of the C1 clutch hub on the overdrive shaft. If it is loose, the hub and shaft assembly must be replaced. 6. Coat the small nylon thrust spacer with petroleum jelly and install it into the cylinder hub. 7. Carefully fit the overdrive shaft into the C1 cylinder so as not to damage the sealing ring. 8. Fit the small bronze C1 hub thrust washer in place with petroleum jelly. 9. Check the input shaft for any defect. Fit the input shaft into the cylinder and secure it with the circlip. Ensure the circlip is completely seated in the groove 10. Coat the front and rear sealing rings and the outer ‘O’ ring with petroleum jelly and fit the input shaft. 11. Assemble the C1/C2/C4 clutch assembly to the C3 clutch and sun gear assembly. 12. Install thrust bearing No. 8 onto the overdrive shaft with spigot into the forward sun gear. 13. Install this assembly in the transmission case.
01/2003 2003.0 BA Falcon
307-01-86
Automatic Transmission
307-01-86
ASSEMBLY (Continued)
Clutch C1, C4, C2 Clutch
C1, C4, C2, C3 Clutch
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Automatic Transmission
307-01-87
ASSEMBLY (Continued)
Pump Cover & Converter Support Special Tool(s) Pump Aligner
Assembly Pump Cover
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307-01-88
Automatic Transmission
307-01-88
ASSEMBLY (Continued) Pump, Cover and Converter Support
1. Check the pump body for any damage, scoring or similar in the pump gear recess. Check the pump bush for wear or damage. 2. Thoroughly clean the pump body gear recess, pump body flange and the pump gears. Install the gears in the pump body and check the pump end clearance using a depth micrometer or similar. The end clearance should be 0.020 - 0.040 mm. 3. Remove the gears from the pump body and install the seal flush with the front face of the pump body if this was removed previously.
G73134 en
4. Lubricate the pump bush and the drive and driven gears with automatic transmission fluid. Install the pump driven gear and the pump drive gear to the pump body. 5. Lubricate the pump body ‘O’ ring with automatic transmission fluid and fit to the pump body. Put the pump body to one side. 6. Ensure that the pump cover cavities, ports, holes etc. are clean and free of any obstruction. 7. Lubricate all loose parts with automatic transmission fluid prior to assembly.
01/2003 2003.0 BA Falcon
307-01-89
Automatic Transmission
307-01-89
ASSEMBLY (Continued) 8. Assemble the Primary Regulator valve to the pump cover. Ensure that the regulator valve slides freely and that the regulator valve plug ‘O’ ring compression is adequate but not excessive. Install the retaining pin. Primary Regulator Valve
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307-01-90
Automatic Transmission
307-01-90
ASSEMBLY (Continued) 9. Install the converter clutch regulator valve and plug. The compression of the plug ‘O’ ring must be adequate but not excessive. Install the retaining pin.
10. Install the converter clutch control valve, spring and plug. Plug ‘O’ ring compression must be adequate but not excessive. Install the retaining pin.
Converter Clutch Regulator Valve
Converter Clutch Control Valve
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Automatic Transmission
307-01-91
ASSEMBLY (Continued) Valve Retaining Plugs
Converter Relief Valve
11. Install the converter feed check ball and spring.
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Automatic Transmission
307-01-92
ASSEMBLY (Continued) Check Ball Location
12. Install the gasket on the pump cover with petroleum jelly. 13. Install the cover plate and the solenoid wiring retainer to the pump cover. Ensure that the periphery of the cover plate is flush with the periphery of the pump cover. Tighten screws to specification. 14. Fit No. 7 solenoid and secure it with the retainer and screw. Check that wiring or connector does not rub on the input shaft or the C1/C2 clutch cylinder.
G73134 en
15. Assemble the pump to the pump cover using alignment tool 307-363. Tighten all bolts finger tight ensuring that the pump is flush against the pump cover. Check that the alignment tool can still be rotated. Tighten the bolts and the screw to 14 Nm in the order shown. Check that the alignment tool can still be rotated. Tighten bolts to 27 Nm in the order shown. Check that the alignment tool can be rotated.
01/2003 2003.0 BA Falcon
307-01-93
Automatic Transmission
307-01-93
ASSEMBLY (Continued) Pump bolt tightening sequence
16. Install the pump to transmission case gasket on the case with petroleum jelly. Install the pump and cover assembly over the input shaft being careful not to damage the sealing rings. Tighten the pump cover to case bolts to specification. Tightening sequence pump to case
17. Check the transmission end float. Set to 0.5-0.65mm. Attach a dial indicator to the front of the transmission case with the stylus resting on the end of the input shaft. Apply a force of approximately 250 newtons or 25kgs to the input shaft. Zero the dial indicator. Place a small lever behind the forward clutch cylinder and lever the cylinder forward. The measurement recorded on the dial indicator is the transmission end float or clearance between the No. 4 bearing and the converter support tube. If unshimmed end float is greater than specification, shims are to be placed between the No. 4 bearing and the input shaft bearing surface. If end float is less than 0.5 or greater than 0.65mm then the transmission has been assembled incorrectly or the parts are out of specification. 18. Adjust the front band to specifications.
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Automatic Transmission
307-01-94
ASSEMBLY (Continued) Gear Train End Float Check
Valve Bodies
7. Install the 1-2 shift valve, plug and retaining plate.
1-2 Shift Valve Assembly 1. Wash the upper and lower valve bodies thoroughly with cleansing solvent and blow dry. 2. Check the valve body cavities, ports and holes for impurities or obstructions. 3. Install the detent lever locating pin. 4. Thoroughly wash all loose components. 5. Check that all valves slide freely in their location. 6. Install the S5 damper spring, piston and retaining pin. S5 Solenoid and Damper
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Automatic Transmission
307-01-95
ASSEMBLY (Continued) 8. Install the 3-4 shift valve and retaining plate. S1 Solenoid and 3-4 Shift Valve
9. Install the 2-3 shift valve and retaining pin. S2 Solenoid and 2-3 Shift Valve
11. Install the bar valve, springs, plunger and retainer pin. Band Apply Regulator Valve and S4 Solenoid
12. Install the car valve, springs, plunger and retainer pin. Clutch Apply Regulator Valve and S3 Solenoid
10. Install the 4-3 sequence valve, spring, plug and retaining plate. 4-3 Sequence Valve
13. Install the solenoid supply valve, spring and retainer plate. CAUTION: This aluminium valve is easily damaged. Solenoid Supply Valve and S6 Solenoid
14. Install S6 plunger, spring and retaining pin.
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Automatic Transmission
307-01-96
ASSEMBLY (Continued) 15. Position the third feed ball (large nylon) in the valve body and install the S5 and S6 solenoid filters. 16. Check the separator plate for burrs etc. 17. Check the upper and lower valve body gaskets. 18. Install the lower valve body gasket on the lower valve body. Lower valve body
19. Install the Reverse Lockout valve, spring, plug and retaining plate. Position the 6 PIA (olive) ball checks in the upper valve body. CAUTION: On separating the valve body all 6 ball checks need to be replaced with new PIA (olive) balls, using worn or incorrect ball material may lead to reduced transmission durability or erratic gear shifts. 20. Fit the upper valve body gasket. Install the separator plate over the upper valve body. 21. Holding the separator plate to the upper valve body to prevent the check ball from falling out, install the upper valve body on the lower valve body. Upper valve body with checkball locations
22. Install all screws finger tight then tighten the screws to specification in the prescribed sequence.
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Automatic Transmission
307-01-97
ASSEMBLY (Continued) Tightening Sequence Upper to Lower Valve Body
23. Install the No. 4 solenoid. Ensure the solenoid is firmly secured by the retainer and that the screw is tightened to specification. 24. Install the No. 3 solenoid. Ensure the solenoid is firmly secured by the retainer and that the screw is tightened to specification. 25. Install the S6 solenoid assembly. 26. Install the 2-3 shift valve solenoid S2. 27. Install the 3-4 shift valve solenoid S1. 28. Install the S5 solenoid. Ensure that the solenoid is pushed firmly into the valve body by the clamping plate. 29. Install manual feed ball and spring (on lower face adjacent to the BAR valve) and secure with the retaining pin. 30. Install the manual shift valve. 31. Install the detent spring assembly (spring, shims, support plate and screw). Ensure the screw is tightened to specification. Check the spring for wear or damage. 32. Align the valve body assembly on the transmission case and install the manual valve lever to manual valve link. Fit the long end of the link to the manual valve first. Install the securing bolts and tighten to specification in the specified sequence.
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Automatic Transmission
307-01-98
ASSEMBLY (Continued) Tightening Sequence Valve Body to Case
33. Check the alignment of the detent roller and the manual lever quadrant. 34. Connect the solenoid wiring. S1 - Red S2 - Blue S3 - Yellow S4 - Orange S5 - Green S6 - Violet 35. Check that the cross-shaft torque is within specification. To do this, rotate the cross shaft to the "P" position. Rotate the output shaft until the parking mechanism locks. Measure the torque required to rotate the cross-shaft from P-R (with the output shaft unloaded). This torque must be 2.5-3.5 Nm. Add or remove shims from under the detent spring as necessary to ensure correct torque. NOTE: All hardware must be correctly installed and torqued to specification.
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307-01-99
Automatic Transmission
307-01-99
ASSEMBLY (Continued)
Oil Filter and Pan Assembly Assembly Oil Filter Installation
1. Lubricate the oil filter sealing ring with automatic transmission fluid. 2. Carefully assemble the oil filter to the valve body. The spigot must not lean on one side while being fitted.
5. Assemble the gasket on the pan lip. The gasket must be free of any distortion when installed.
3. Secure the oil filter assembly with the retainer. Engage the long leg of the retainer first. 4. Check that magnet is located in the dimple in the corner of the oil pan.
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Automatic Transmission
307-01-100
ASSEMBLY (Continued) 6. Fit the oil pan assembly to the transmission case and tighten the securing bolts to specification. Do not over torque. Oil Pan Tightening Sequence
Torque Converter & Housing Assembly 1. Fit the "O" ring seal to the input shaft. 2. Locate the torque converter housing on the transmission main case. Install and tighten the securing bolts. 3. Fit the torque converter by pushing it fully back and turning the converter until it engages the pump drive dogs. 4. The converter is correctly installed when the torque converter pilot hub is 4mm for 93LE and 0.5mm for 97LE in from the front face of the torque converter housing. NOTE: All hardware must be correctly installed and torqued to specification.
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307-05-1
Automatic Transmission External Controls
307-05-1
SECTION : 307-05 Automatic Transmission External Controls VEHICLE APPLICATION : 2003.0 BA Falcon CONTENTS
PAGE
DESCRIPTION AND OPERATION Automatic Transmission External Controls ...........................................................................307-05-2 Sequential Sport Shift Selector ............................................................................................307-05-2 DIAGNOSIS AND TESTING Automatic Transmission External Controls ...........................................................................307-05-3 Connector Circuit Reference ................................................................................................307-05-3 GENERAL PROCEDURES Selector Cable Adjustment ...................................................................................................307-05-4 REMOVAL AND INSTALLATION Handle Assembly ..................................................................................................................307-05-5 Torsion Spring .......................................................................................................................307-05-5 Housing Sub Assembly .........................................................................................................307-05-5 Gear Indicator Globe .............................................................................................................307-05-6 Cap .......................................................................................................................................307-05-7 Loom PCB (Printed Circuit Board) .........................................................................................307-05-8 Guide Lever ..........................................................................................................................307-05-9 Gearshift Assembly .............................................................................................................307-05-10 Bucket (Metal Pressing) ......................................................................................................307-05-12 Base and Lever Assembly ..................................................................................................307-05-12 Spring Leaf Detent ..............................................................................................................307-05-13 Selector Lever Cable ..........................................................................................................307-05-15
01/2003 2003.0 BA Falcon
307-05-2
Automatic Transmission External Controls
307-05-2
DESCRIPTION AND OPERATION The Selector can be shifted from Drive(D) to Neutral (N) without depressing the Button on the Handle. The Button must be depressed to shift from (N) to (R) and from (R) to (P) as well as (P) to (R). Sequential Sport Shift Selector The Button does not need to be depressed when The Sequential Sport Shift (SSS) Selector system is a shifting from (R) to (D) or when using Sequential cable operated mechanical and Electronic Selector Sport Shift. system. Mechanically it works similarly to previous Remove center console gear shift surround and model T/Bars when moving from the Park to Drive center console wing trims (refer Section 501-12). position.
Automatic Transmission External Controls
However when the lever is in ‘D’ position it can be moved into Performance/Sport position by pushing the lever to the left. It now Electronically controls the Transmission.
NOTE: This is the Recommended ‘Towing’ position for the Selector as well the Sequential Sport or Performance position for Manual operation of the Sequential Sports Shift. The transmission will shift ‘Automatically’ when the selector is in D or ‘Performance/Sport’ until the selector lever is moved either forward or rearward to the +/- position. The Sequential Sport Shifter is now in Manual Mode and sequential Manual shifting is now required. If the Selector is pulled rearward (+) the ‘SSS’ will be activated and the Transmission will upshift to a higher gear, if the selector is pushed forward (-) the transmission will shift down to a lower gear provided the vehicle speed is within the safe operating speed for the transmission. G77031 en
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307-05-3
Automatic Transmission External Controls
307-05-3
DIAGNOSIS AND TESTING
Automatic Transmission External Controls Connector Circuit Reference Loom PCB
Pin Number(s) 2&3 1&3
G77032 en
Circuit Designation/Description Normal Condition/Measurement 5V Power Supply through 5V 4.7kOhm resistor Voltage Measure Position ‘D’ — 3.96V Position ‘DPEPF’ — 2.88V Position ‘+’ — 1.83V Position ‘–’ — 0.78V
01/2003 2003.0 BA Falcon
307-05-4
Automatic Transmission External Controls
307-05-4
GENERAL PROCEDURES
Selector Cable Adjustment 1. Move Selector to "P" position. 2. Raise the vehicle and ensure the transmission operating lever is also in "P" (this is the most Rearward position). 3. Connect the Cable to the Transmission Cable Mount by pushing rearwards until the side tabs of the cable click into the lock position.
NOTE: The Cable Push Rod is snapped onto the Pin. Finally the adjuster clip is pushed closed on the Cable auto adjuster.
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Automatic Transmission External Controls
307-05-5
REMOVAL AND INSTALLATION
Handle Assembly
Torsion Spring Removal 1. Remove Centre Console and other associated components. For additional information, refer to Section 501-12. NOTE: Do not remove Gearshift assembly from the vehicle. 2. Move Handle to "P" position. 3. Open the spring legs with pliers and disengage from the nest.
Removal and Installation NOTE: Do not remove console and other associated components from the vehicle. 1. Move Handle to "D" position. 2. Remove screw. 3. Remove Handle.
4. Remove torsion spring. Fit new spring. Installation 1. To install, reverse the removal procedure.
Housing Sub Assembly Removal 1. Remove Centre Console and other associated components. For additional information, refer to Section 501-12. NOTE: Do not remove Gearshift assembly from the vehicle. Item 1 2
Description Selector handle Screw
4. Insert new Handle then secure with screw. G77034 en
2. Disconnect main loom from Plug then Plug from base (squeeze clips). 3. Repeat process for the top LH corner of the shifter. 01/2003 2003.0 BA Falcon
307-05-6
Automatic Transmission External Controls
307-05-6
REMOVAL AND INSTALLATION (Continued) 4. Lift corner labeled "A" first using narrow nose pliers placing them between the Housing assembly and base.
3. Move Cover slide hole to "D" position. 4. Slide Housing assembly onto Lever through Cover slide hole. 5. Place Housing assembly into Bezel recesses then push down until locked into the Base. 6. Clip Plug into Base. 7. Connect main loom.
Gear Indicator Globe Removal 1. Remove Centre Console and other associated components. For additional information, refer to Section 501-12. NOTE: Do not remove Gearshift assembly from the vehicle. 5. Squeeze flexible legs with pliers and lift until disengaging the base.
6. Lift Housing assembly until disconnected from lever. 7. Turn Globe holder with pliers until holder can be pulled out of lower Housing. 8. Remove Housing assembly. Installation 1. Insert Globe holder inside lower housing then rotate approx 45 deg. 2. Move orange indicator into the "D" position. G77034 en
2. Remove the handle assembly. For additional information, refer to Handle Assembly in this section. 3. Remove the housing assembly. For additional information, refer to Housing Sub Assembly in this section.
Item 1 2 3
Description Selector handle Screw Housing assembly 01/2003 2003.0 BA Falcon
307-05-7
Automatic Transmission External Controls
307-05-7
REMOVAL AND INSTALLATION (Continued) 4. Pull out Globe from globe holder.
3. Remove the housing assembly. For additional information, refer to Housing Sub Assembly in this section.
5. Push new Globe into Globe holder. Installation 1. To install, reverse the removal procedure. For additional information, refer to Housing Sub Assembly.
Cap Removal 1. Remove Centre Console and other associated components. For additional information, refer to Section 501-12. NOTE: Do not remove Gearshift assembly from the vehicle. 2. Remove the handle assembly. For additional information, refer to Handle Assembly in this section. Item 1 2 3
Description Selector handle Screw Housing assembly
4. Move Lever into Tip position.
5. Remove damaged Cap by lifting the face above the clip, and slide out.
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Automatic Transmission External Controls
307-05-8
REMOVAL AND INSTALLATION (Continued) 6. Fit new Cap, pushing onto arm until clipped.
2. Remove the handle assembly. For additional information, refer to Handle Assembly Replacement in this section. 3. Remove the housing assembly. For additional information, refer to Housing Sub Assembly in this section.
Installation 1. To install, reverse the removal procedure.
Loom PCB (Printed Circuit Board) Removal 1. Remove Centre Console and other associated components. For additional information, refer to Section 501-12. NOTE: Do not remove Gearshift assembly from the vehicle.
G77038 en
Item 1 2 3
Description Selector handle Screw Housing assembly
01/2003 2003.0 BA Falcon
307-05-9
Automatic Transmission External Controls
307-05-9
REMOVAL AND INSTALLATION (Continued) 4. Cut off tab with sharp blade.
Guide Lever Removal 1. Remove Centre Console and other associated components. For additional information, refer to Section 501-12. NOTE: Do not remove Gearshift assembly from the vehicle. 2. Remove the handle assembly. For additional information, refer to Handle Assembly Replacement in this section. 3. Remove the housing assembly. For additional information, refer to Housing Sub Assembly Replacement in this section.
5. Remove faulty Loom PCB. 6. Place new Loom PCB. 7. Secure new Loom PCB with screw provided in the kit.
Installation 1. To install, reverse the removal procedure.
G77039 en
Item 1 2 3
Description Selector handle Screw Housing assembly
01/2003 2003.0 BA Falcon
307-05-10
Automatic Transmission External Controls
307-05-10
REMOVAL AND INSTALLATION (Continued) 4. Move Lever into Tip position.
7. Open two clips and push out Guide lever.
5. Press and lift to unclip in the order shown below.
Installation 1. To install, reverse the removal procedure.
Gearshift Assembly Removal 1. Raise the vehicle and disconnect the transmission shift cable from the lower selector lever. I6
V8
6. Move Handle to "D" position.
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Automatic Transmission External Controls
307-05-11
REMOVAL AND INSTALLATION (Continued) 2. Disconnect the four nuts that attach the housing to the floorpan.
3. Lower the vehicle. 4. Remove the centre console and other associated components. For addition information, refer to section 501-12. 5. Detach the back light bulb/wiring and selector cable.
3. Remove the centre console and other associated components. For addition information, refer to section 501-12. 4. Place the selector lever in the ’P’ position. 5. Raise the vehicle. 6. Reconnect the four nuts that attach the housing to the floorpan.
7. Hold the transmission shift rod and engage Park on the transmission by pushing the shift rod as far forward as possible. 8. Install the shift rod on the lower selector lever. I6
6. Remove the whole floor shift housing by lifting vertically. Installation 1. Install the whole floor shift housing by lifting vertically. 2. Attach the back light bulb/wiring and selector cable.
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V8
01/2003 2003.0 BA Falcon
307-05-12
Automatic Transmission External Controls
307-05-12
REMOVAL AND INSTALLATION (Continued) 9. Tighten the lock nut to the required torque to 28 Nm. 10. Lower the vehicle and check transmission operation in each selector lever detent position. 11. Check that the mode light functions correctly.
Bucket (Metal Pressing) Removal 1. Remove Centre Console and other associated components. For additional information, refer to Section 501-12. 2. Remove shifter assembly from vehicle. For additional information, refer to Gearshift assembly in this section.
4. Remove metal Bucket Remove two washers. Remove Gasket (new gasket to be used when assembling to original condition). Remove metal Bucket (pressing). Replace with new. Installation 1. To install, reverse the removal procedure.
3. View before and after replacement of damaged Bucket.
Item 1 2 3
Description Star washer Gasket Metal bucket
Base and Lever Assembly Removal and Installation 1. Remove Centre Console and other associated components. For additional information, refer to Section 501-12.
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Automatic Transmission External Controls
307-05-13
REMOVAL AND INSTALLATION (Continued) 2. Remove shifter assembly from vehicle. For 6. Disassemble and rebuild the bottom part of the additional information, refer to Gearshift assembly assembly. Refer to Bucket Replacement in this in this section. section.
3. View before and after replacement.
4. Disassemble and rebuild the top part of the assembly. Refer to Housing Sub Assembly Replacement in this section. 5. Replace faulty sub assembly.
Item 1 2 3 4 5 6 7
Description Selector handle Screw Housing assembly Lever assembly Metal bucket Gasket Star washer
Spring Leaf Detent Removal and Installation 1. Remove Centre Console and other associated components. For additional information, refer to Section 501-12.
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Automatic Transmission External Controls
307-05-14
REMOVAL AND INSTALLATION (Continued) 2. Remove shifter assembly from vehicle. For additional information, refer to Gearshift assembly in this section.
Reverse disassembly process when rebuilding to original condition.
3. View before and after replacement of damaged spring.
4. Remove damaged spring. Remove two washers. Remove gasket (new gasket to be used when assembling to original condition). Remove metal pressing. Undo and remove screw. Remove damaged spring. Place new spring on the Base and secure with the screw.
G77044 en
Item 1 2 3 4 5
Description Star Washer Gasket Metal Bucket Screw Spring Leaf Detent
01/2003 2003.0 BA Falcon
307-05-15
Automatic Transmission External Controls
307-05-15
REMOVAL AND INSTALLATION (Continued)
Selector Lever Cable Removal 1. Release locking tab from the Transmission Cable Mount. 2. Disconnect the cable from the housing. 3. Use a screwdriver to release the cable push rod from the cable arm. Installation 1. To reassemble simply push the cable end fitting back into the pin. I6 Selector Cable
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307-05-16
Automatic Transmission External Controls
307-05-16
REMOVAL AND INSTALLATION (Continued) V8 Selector Cable
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308-01-1
Clutch
308-01-1
SECTION : 308-01 Clutch VEHICLE APPLICATION : 2003.0 BA Falcon CONTENTS
PAGE
SPECIFICATIONS Specifications .........................................................................................................................308-01-2 DESCRIPTION AND OPERATION Clutch .....................................................................................................................................308-01-3 Introduction ..........................................................................................................................308-01-3 Clutch Function ....................................................................................................................308-01-3 DIAGNOSIS AND TESTING Clutch .....................................................................................................................................308-01-6 Symptom Chart ....................................................................................................................308-01-6 GENERAL PROCEDURES Pressure Plate Inspection ......................................................................................................308-01-8 Clutch Disc Inspection ...........................................................................................................308-01-8 Clutch Pressure Plate Adjustment (XR6 Turbo Variant) ........................................................308-01-8 REMOVAL AND INSTALLATION Disc and Pressure Plate ........................................................................................................308-01-9 Flywheel — I6 (all variants including XR6 Turbo) ................................................................308-01-10 Flywheel — All V8 Vehicles (incl XR8 & GT) .......................................................................308-01-11 Pilot Bearing — All Vehicles ................................................................................................308-01-11 DISASSEMBLY AND ASSEMBLY Flywheel Auto Flex-Plate (XR6 Turbo only) .........................................................................308-01-13 Ring Gear — All Vehicles except XR6 Turbo ......................................................................308-01-13 Ring Gear — XR6 Turbo only ..............................................................................................308-01-14
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308-01-2
Clutch
308-01-2
SPECIFICATIONS Torque Specifications Description CSC to clutch housing CSC to pipe fitting nut CSC Bleed screw Clutch pressure plate to flywheel
Nm 9.5 14 8
I6 20 V8 48 Flex plate to flywheel disc (Turbo only) 60 Flywheel to crankshaft I6 75 V8 80 Dowel insertion depth in flywheel (Proud of friction face) I6 8mm XR6 Turbo 10.5mm V8 11.5mm NOTE: The V8 flywheel is designed so that the dowel will bottom out at the correct insertion depth.
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Clutch
308-01-3
DESCRIPTION AND OPERATION
Clutch Introduction Three clutch variants are used across the manual BA Falcon range. All manual I-6 vehicles, except XR6T are fitted with a one-piece flywheel and 254mm clutch. Manual XR6T vehicles are fitted with a two-piece flywheel and a heavy-duty 267mm clutch. All manual V8 vehicles are fitted with a one-piece flywheel, 292mm pressure plate and 280mm clutch disc to provide a high torque capacity.
Clutch Function The primary function of the clutch system is to connect and disconnect engine power to the transmission upon driver command.
Clutch System Components — STD I6
Item 1 2 3
Description Flywheel Transmission input shaft pilot bearing Clutch disc
G86727 en
Item 4 5
Description Clutch pressure plate Clutch slave cylinder/clutch release hub and bearing
01/2003 2003.0 BA Falcon
308-01-4
Clutch
308-01-4
DESCRIPTION AND OPERATION (Continued) Clutch System Components —XR6 Turbo
Item 1 2 3 4 5
Description Flywheel (2 piece assembly) Transmission input shaft pilot bearing Clutch disc Clutch pressure plate Clutch slave cylinder/clutch release hub and bearing
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308-01-5
Clutch
308-01-5
DESCRIPTION AND OPERATION (Continued) Clutch System Components — V8 Standard (3 valve) & XR8 (4 Valve)
Item 1 2 3 4 5
Description Flywheel Transmission input shaft pilot bearing Clutch disc Clutch pressure plate Clutch slave cylinder/clutch release hub and bearing
A pilot bearing supports the end of the input shaft. The bearing does not require lubrication unless the clutch system is serviced. The clutch does not require pressure plate re-setting after disasembly or disc renewal. NOTE: The clutch pressure plate should always be adjusted before installation.
For Standard I6, XR6 & all V8: The clutch is a single plate, dry friction clutch disc with a self-adjusting, diaphragm-style spring clutch pressure plate. The clutch operating mechanism consists of a clutch slave cylinder with an integral release bearing. A pilot bearing supports the end of the input shaft. The bearing does not require lubrication unless the clutch system is serviced. The clutch does not require pressure plate re-setting after disasembly or disc renewal. For XR6 Turbo: The clutch is a single plate, dry friction clutch disc with diaphragm-style spring clutch plate. The clutch operating mechanism consists of a clutch slave cylinder with an integral release bearing. G86727 en
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308-01-6
Clutch
308-01-6
DIAGNOSIS AND TESTING
Clutch Symptom Chart Condition Clutch does not disengage correctly
Clutch pedal hang-up or excessive clutch pedal effort
Source
Action
Worn clutch disc.
Replace worn or defective parts
Failed pressure plate.
Replace pressure plate
Self Adjusting Clutch (SAC) over adjusted.
Remove SAC and reset
Air in hydraulic system
Bleed hydraulic system
Damaged Concentric Slave Cylinder (CSC).
Repair or replace CSC. Refer to Section 308-02.
CSC damaged.
Repair or replace CSC. Refer to Section 308-02.
Master cylinder damaged.
Replace clutch master cylinder
CSC bearing failure
Replace CSC. Refer to Section 308-02.
Clutch disc damaged
Replace clutch disc
Binding at pedal support bracket
Lubricate with engine oil or replace support bracket bushing
CSC damaged
Replace CSC. Refer to Section 308-02.
Binding within pressure plate
Lubricate pressure plate pins
Worn or contaminated clutch lining Grease or oil on clutch facings from: Release bearing Engine CSC Pilot bearing Transmission
Replace defective part. (If grease or oil is causing the clutch to slip, replace the disc, remove the grease or oil from the pressure plate and flywheel and reuse if it is not burned or scored.) Repair source of leakage.
Weak or failed pressure plate
Replace pressure plate
Loose pressure plate to flywheel bolts
Torque bolts to spec
Loose engine mount bolts
Torque bolts to spec
Damaged CSC
Replace CSC. Refer to Section 308-02.
Failed master cylinder
Replace clutch master cylinder
Intermittent squawk
Flywheel housing misalignment
Replace flywheel housing
Clutch noisy when disengaged (Engine running)
Pilot bearing worn
Replace pilot bearing
CSC bearing worn
Replace CSC. Refer to Section 308-02.
Failed pressure plate
Replace pressure plate
Grease on linings of clutch disc
Replace clutch disc and degrease pressure plate and flywheel
Flywheel housing out of alignment
Align to specifications
SAC over adjusted
Remove SAC and reset
Damaged clutch disc
Fit clutch disc correctly, if damaged replace
Noisy clutch operation when engine running
Noisy clutch operation with engine off
Clutch slips or chatters
Clutch spin or drag
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308-01-7
Clutch
308-01-7
DIAGNOSIS AND TESTING (Continued) Condition
Source
Action
Binding of the disc on the input shaft splines
Check splines for burrs, rusting and damage. Clean up splines and lubricate with the specified lubricant
Air in hydraulic system
Bleed hydraulic system
Low fluid level in hydraulic clutch system
Bleed clutch system and fill clutch fluid reservoir
CSC damaged
Replace CSC. Refer to Section 308-02.
Clutch master cylinder damaged
Replace master cylinder
NOTE: CSC - Concentric Slave Sylinder SAC - Self Adjusting Clutch (not XR6 Turbo)
G86728 en
01/2003 2003.0 BA Falcon
308-01-8
Clutch
308-01-8
GENERAL PROCEDURES
Pressure Plate Inspection 1. Inspect the friction surface of the pressure plate for burn marks, scoring or ridges, and warpage. Generally, pressure plate resurfacing is not recommended. However, minor burn marks, scores or ridges may be removed. 2. During the resurfacing process, the flatness of the pressure plate must be maintained. If the pressure plate is badly heat checked, or deeply scored, replace it. 3. Clean the pressure plate and flywheel to be sure the surfaces are free from any oil film. Do not use cleaners with petroleum base, and do not immerse the pressure plate in solvent. 4. Prior to fitment, insure the self adjusting clutch pressure plate is reset as outlined in this section.
2. Adjust the clutch pressure plate. 1. Rotate the adjusting ring counter clokwise until the tension springs are compressed. In compressed form the springs should not be greater than 14 mm. 2. Hold adjusting ring while releasing the pressure on the clutch diaphragm fingers.
Clutch Disc Inspection 1. Inspect the clutch disc facings for oil or grease. Eliminate the source of any oil or grease before replacing the disc. Excessive grease will contaminate the disc facings. Too much lubricant in the transmission vent will force the transmission lubricant past the input shaft seal and into the disc facings. 2. Inspect the clutch disc for worn or loose facings. Check the disc for distortion and for loose rivets at the hub. Check for broken springs and springs that can be moved radially. Springs that can be moved laterally are acceptable. 3. Replace the disc assembly if any of these defects are present. Be especially careful when installing a new disc to avoid dropping it or contaminating it with oil or grease. Check that the disc will slide on the input shaft prior to installation.
Clutch Pressure Plate Adjustment (XR6 Turbo Variant) NOTE: The clutch pressure plate should always be adjusted before installation. 1. Compress the clutch diaphragm fingers. 1. Position the clutch pressure plate in a press. 2. Use a suitable adapter and press the clutch diaphragm fingers until the adjusting ring moves freely. WARNING: Do not over-travel as damage will occur and clamp load will be reduced.
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01/2003 2003.0 BA Falcon
308-01-9
Clutch
308-01-9
REMOVAL AND INSTALLATION Vehicle Item variant XR6T Screw M8x1.25x16 HEX FLG HD All V8 Bolt M10x1.5x28.5 HEX FLG HD PILOT
Disc and Pressure Plate
Specification
QTY
Grade 8.8 S36D 6 The following illustrations show the removal and Surface finish installation procedure for the standard I6 pressure plate and clutch disc, alone. However the accompanying removal and installation instructions N808969-S100 6 are pertinent to standard I6, XR6T and V8 clutch systems, which are alike. As such the following instructions should be followed when assembling and/or disassembling any of these clutch systems. Removal NOTE: All V8 and I6 clutch systems, except XR6T 1. Remove the transmission. For additional clutch, utilise a self-adjusting pressure plate. In such information, refer to Section 308-03. systems the friction surface of the pressure plate ratchets progressively forward as the clutch disc 2. Remove the bolts, clutch pressure plate and the becomes worn. As such the ratcheting mechanism in clutch disc. the self-adjusting pressure plates must be reset CAUTION: If the clutch disc and pressure before reassembling the clutch system with a new plate are to be reinstalled, bolts must be clutch disc in place. The procedure for resetting these removed evenly or permanent damage to the pressure plates are in clutch pressure plate diaphragm spring will occur resulting in adjustment covered earlier in this section. complete clutch release. Special Tool(s) If the parts are to be reused, index-mark the clutch pressure plate to the flywheel. Also Aligner, Clutch Disc inspect the pressure plate and clutch disc as All I6: Tool 308-257 (E9276) or outlined in this section. Transmission Input Shaft (23T) All V8: Generic Tool or Input Shaft (10T)
Installation 1. Lubricate the transmission input shaft pilot bearing with grease. Materials Item High-Temperature 4x4 Front Axle and Wheel Bearing Grease Threadlock and Sealer
Specification ESA-M1C198-A Locktite 243
Hardware - Pressure Plate-to Flywheel Vehicle Item Specification variant All I6 Bolt E602550-S36D (except M8x1.25x25.5 XR6T) HEX HD
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QTY 6
01/2003 2003.0 BA Falcon
308-01-10
Clutch
308-01-10
REMOVAL AND INSTALLATION (Continued) 2. Using the special tool, position the clutch disc on the flywheel.
5. Install the transmission. 1. For additional information, refer to Section 308-03.
Flywheel — I6 (all variants including XR6 Turbo) Materials Item Threadlock and Sealer E0AZ-19554-AA
3. Using the special tool, align the clutch disc and fit the clutch pressure plate. Install the bolts and tighten in a star pattern sequence. NOTE: If reusing the clutch pressure plate and flywheel, align the marks made during removal. 4. Remove tool.
Specification Loctite 243 or equivelant Loctite
Hardware - Flywheel-to-crankshaft Vehicle Item Specification variant All I6 Bolt V800322 (except M10x1.25x25 XR6T) HEX HD XR6T Screw V800524 M8x1.25x19 HEX FLG HD All V8 Bolt N808139-S100 M10x1x26.5 HEX HD
QTY 6 6 8
Removal 1. Remove the transmission. For additional information, refer to Section 308-03. 2. Remove the clutch disc and pressure plate. For additional information, refer to Disc and Pressure Plate in this section. 3. Remove four of the six bolts. Leaving two opposing bolts in place, loosely. CAUTION: Two bolts should be loosened but left in to prevent the flywheel from falling.
4. Separate the flywheel from the crankshaft. 5. Remove the bolts remaining in the crankshaft. 6. Remove the flywheel.
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01/2003 2003.0 BA Falcon
308-01-11
Clutch
308-01-11
REMOVAL AND INSTALLATION (Continued) Installation 1. Position the flywheel onto the crankshaft and install the flywheel-to-crankshaft bolts. Apply threadlock and sealer to bolt threads. NOTE: Both the standard I6 & XR6 Turbo flywheel and crankshaft are designed with a single offset bolthole to ensure correct angular alignment between crankshaft and flywheel. These holes must be aligned before installing the six flywheel-to-crankshaft bolts.
4. Separate the flywheel from the crankshaft. 5. Remove the bolts remaining in the crankshaft. 6. Remove the flywheel. Installation 1. Position the flywheel onto the crankshaft and install the flywheel-to-crankshaft bolts. Apply the threadlock and sealer to bolt threads.
2. Install the disc and pressure plate. For additional information, refer to Disc and Pressure Plate in 2. Install the disc and pressure plate. For additional this section. information, refer to Disc and Pressure Plate in 3. Install the transmission. For additional information, this section. refer to Section 308-03. 3. Install the transmission. For additional information, refer to Section 308-03.
Flywheel — All V8 Vehicles (incl XR8 & GT) Removal 1. Remove the transmission. For additional information, refer to Section 308-03. 2. Remove the clutch disc and pressure plate. For additional information, refer to Disc and Pressure Plate in this section. 3. Remove six of the eight bolts. Leaving two opposing bolts in place, loosely. CAUTION: Two bolts should be loosened but left in to prevent the flywheel from falling.
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Pilot Bearing — All Vehicles Special Tool(s)
Installer, Pilot Bearing 308-105 (T85T-7137-A)
Removal 1. Using a standard bearing puller, remove the transmission input shaft pilot bearing.
01/2003 2003.0 BA Falcon
308-01-12
Clutch
308-01-12
REMOVAL AND INSTALLATION (Continued) 2. Inspect the transmission input shaft pilot bearing for: misalignment and looseness in the flywheel. needle rollers for scoring, worn or broken needle rollers, inadequate grease or discoloration. seal leakage.
Installation NOTE: The transmission input shaft pilot bearing should only be installed with the seal facing the transmission. The transmission input shaft pilot bearing is pregreased and does not require additional lubrication. A new transmission input shaft pilot bearing must be installed whenever it is removed. 1. Using a soft-face hammer and the special tool, install the transmission input shaft pilot bearing.
G86738 en
01/2003 2003.0 BA Falcon
308-01-13
Clutch
308-01-13
DISASSEMBLY AND ASSEMBLY
Flywheel Auto Flex-Plate (XR6 Turbo only) Vehicle Item variant XR6T Bolt M10x1.25x17 HEX HD
Specification V810171S26D
QTY
Ring Gear — All Vehicles except XR6 Turbo Disassembly
4
Disassembly 1. Remove the flywheel assembly. For additional information, refer to Flywheel section. 2. Index mark the flywheel disc together with the auto-flex plate. 3. Undo the four screws attaching the flywheel disc to the auto flex-plate and separate the two components. Assembly 1. Using a brass drift and hammer, drive the flywheel ring gear off the flywheel. 1. Position the flywheel disc on the auto flex plate and align the markings on the disc and flex plate. CAUTION: Do not heat the flywheel ring NOTE: Both the XR6 Turbo flywheel and gear to remove. crankshaft are designed with a single offset bolthole to ensure correct angular alignment CAUTION: Tap the flywheel ring gear between the crankshaft and flywheel. These holes evenly to prevent binding. must be aligned before installing the six flywheel-to-crankshaft bolts. Assembly WARNING: This procedure should be performed only by a correctly equipped and experienced acetylene torch operator. To avoid personal injury, use tongs or wear welding gloves and safety goggles when handling the heated flywheel ring gear. 1. Evenly heat the flywheel ring gear. CAUTION: Do not heat the flywheel ring gear beyond 278°C (500°F). Use heat indicating crayons to prevent over heating. CAUTION: Keep the torch moving to prevent hot spots. 2. Install the flywheel disc-to-flex plate bolts.
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01/2003 2003.0 BA Falcon
308-01-14
Clutch
308-01-14
DISASSEMBLY AND ASSEMBLY (Continued) 2. Install the flywheel ring gear using a brass drift. NOTE: The bevel on the flywheel ring gear must face the rear of the flywheel.
Ring Gear — XR6 Turbo only WARNING: The ring gear should not be removed from the auto flex plate on XR6T flywheel assembly. Replace as assembly is required.
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01/2003 2003.0 BA Falcon
308-02-1
Clutch Controls
308-02-1
SECTION : 308-02 Clutch Controls VEHICLE APPLICATION : 2003.0 BA Falcon CONTENTS
PAGE
SPECIFICATIONS Specifications ........................................................................................................................308-02-2 DESCRIPTION AND OPERATION Clutch Controls .....................................................................................................................308-02-3 Acronyms and Abbreviations ...............................................................................................308-02-3 DIAGNOSIS AND TESTING Clutch Controls .....................................................................................................................308-02-4 Inspection and Verification - Clutch .....................................................................................308-02-4 Function Test .......................................................................................................................308-02-4 Symptom Chart ....................................................................................................................308-02-4 Pinpoint Tests ......................................................................................................................308-02-6 GENERAL PROCEDURES Clutch Bleeding .....................................................................................................................308-02-8 REMOVAL AND INSTALLATION Clutch Pedal ..........................................................................................................................308-02-9 Clutch Master Cylinder ..........................................................................................................308-02-9 Slave Cylinder .....................................................................................................................308-02-10 Clutch Hydraulic Fluid Tubes ..............................................................................................308-02-10 Clutch Reservoir ..................................................................................................................308-02-11
01/2003 2003.0 BA Falcon
308-02-2
Clutch Controls
308-02-2
SPECIFICATIONS General Specifications Description Clutch System Clutch control System adjustment Clutch pedal type Fluid Brake Fluid (Ford)
Specification Hydraulic Automatic Suspended Mobil ESZ - M6C55A
Torque Specifications Description Clutch Pivot Bolt Master Cylinder retaining bolts Adjuster Motor Retaining Bolts (adjustable pedal) Pedal Box Housing Brake Booster Retaining Nuts Clutch Pivot Bolt (M8) Clutch Assembly Bolt (M6) Reservoir Bracket Bolts
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Nm 20 14 5 ± 0.5 22.5 ± 3.4 22.5 ± 3.4 16 ± 2 6 ± 0.5 2-4
01/2003 2003.0 BA Falcon
308-02-3
Clutch Controls
308-02-3
DESCRIPTION AND OPERATION
Clutch Controls Component Location
Item 1 2 3 4 5
Description Clutch pedal deactivation switch Clutch reservoir Brake and clutch pedal support bracket Clutch master cylinder Clutch slave cylinder/clutch release hub and bearing The clutch control system actuates the clutch system. When the clutch pedal is depressed it pushes the clutch master cylinder plunger which transmits hydraulic pressure to the clutch slave cylinder. The clutch slave cylinder engages and compresses the clutch pressure plate diaphragm spring, releasing the pressure on the clutch disc which in turn disengages the transmission from the engine. The hydraulic clutch system adjusts automatically to compensate for clutch disc wear. The clutch pedal starter interlock switch is attached to the clutch pedal. Depressing the clutch pedal manually closes the switch and allows engine cranking. The clutch pedal deactivation switch deactivates the speed control system when the pedal is depressed.
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Acronyms and Abbreviations APM PCM BEM Step Over MSC PPS
Accelerator Pedal Module Power Train Module Body Electronic Module Height Difference Between Brake and Accelerator Pedal Memory Seat Controller Pedal Position Sensor
01/2003 2003.0 BA Falcon
308-02-4
Clutch Controls
308-02-4
DIAGNOSIS AND TESTING Function Test
Clutch Controls
Condition
Inspection and Verification - Clutch The transmission and the clutch transfer the engine torque to the wheels. When diagnosing the transmission. Both the transmission and the clutch should be considered when diagnosing concerns. Verify the customer concern by operating the system. Visually inspect for obvious signs of mechanical damage. If an obvious cause for an observed or reported concern is found, correct the cause ( if possible) before proceeding to the next step. If the concern is not evident, verify the symptom and refer to the Symptom Chart Check these items before entering Diagnostics. Topic Brake Fluid Reservoir
PEDAL FEEL
Possible Function Source Test Pedal Slow or Manual does not Application return Test of the Clutch Pedal to confirm Binding / Manual Raspy pedal Test Worn Pedal Visual Pad Inspection Clutch Pedal "Sinks" sinks to the Floor
Specification Ensure that the Reservoir is Filled to the Max Point. Use Ford Approved Brake Fluid Mobil ESZ M6C55A .
CRUISE Not CONTROL Functioning CLUTCH Adjustment SWITCH
CAUTION: Do not allow brake fluid to contact vehicle paint work. Ensure That Your Local State Speed Limits are Not Exceeded
HARD TO ENGAGE GEARS
Vehicle Test Drive to Confirm Fault Battery Voltage Must be Greater Than 12 Volts Obstructions Check for Any Obstructions at the Brake Pedal Area, Such as Floor Mats and Wiring Harnesses Visual Inspection Chart Electrical Oil leaks Visibly damaged or worm parts Loose or missing nuts or bolts
HARD TO ENGAGE GEARS (ctd)
Visual Inspection Visual Inspection Switch Visual Disconnected Inspection Master Visual Cylinder Inspection Leakage Slave Visual Cylinder Inspection Leakage
Clutch Plate Worn
Pressure plate Issue
Air in System
Pin Point Test B
C
Refer to Clutch Diagnosis in Section 206-06 A
A
Refer to Clutch Diagnosis in section 308-01 Refer to Clutch Diagnosis in section 308-01 Refer to Clutch Diagnosis in section 308-01 Refer to Clutch Diagnosis in section 308-01
Symptom Chart Symptom Chart - (MSC) Memory Seat Controller Condition Excessive effort needed to depress clutch pedal or has a rough or raspy or sticky feel
G56331 en
Source Clutch pedal binds at pivot
Action INSTALL a new clutch pedal
01/2003 2003.0 BA Falcon
308-02-5
Clutch Controls
308-02-5
DIAGNOSIS AND TESTING (Continued) Condition
Source
Action
Clutch Master Cylinder
CHECK Clutch Master Cylinder and REFER to the Clutch Master Cylinder Section.
Return clutch pedal spring damaged or bad positioned
CHECK the clutch pedal and INSTALL a new clutch pedal if necessary.
Worn or damaged clutch pedal
INSTALL a new clutch pedal.
Foreign object caught in clutch pedal
CHECK the clutch pedal.
Weak or broken clutch pedal return spring
CHECK the clutch pedal and INSTALL a new clutch pedal if necessary.
Foreign object caught in clutch pedal
CHECK the clutch pedal.
Unconnected cruise switch
CHECK the connection between the cruise switch and the cruise control.
Faulty clutch pedal switch flag
INSTALL a new clutch pedal.
Bad position of the cruise switch
CHECK the cruise switch. REPLACE or CHANGE cruise witch.
Connection between the low pressure line and master cylinder
CHECK any leak, CHANGE low pressure line if necessary.
Connection between the high pressure line and master cylinder
CHECK any leak, CHANGE high pressure line if necessary.
Fluid level
CHECK the fluid level and REFILL if necessary.
Master cylinder
CHECK the master cylinder, CHANGE it if necessary.
Discomfort on the clutch pedal
Clutch pedal pad worm or loose
CHECK clutch pedal pad and CHANGE it if necessary.
Padal feel
Clutch Pedal Not Returning Once Released "Raspy" Feel Pedal Binding at Pivot Pedal Pad Worn Obstruction at / Under Pedal
Go to PinPoint Test A
Gears "CRUNCH" when changing gears Gears hard to select
Clutch Master Cylinder Leaking / Faulty
Go to Section 308-01.
Clutch Slave Cylinder Leaking / Faulty
Go to Section 308-01.
Insufficient Master / Slave Cylinder Rod Travel
Go to PinPoint Test A
Worn / Damaged Clutch Plate
Go to Section 308-01.
Damaged / Worn Clutch Pressure Plate
Go to Section 308-01.
Manual Transmission Issue. Gears / Synchromesh Rings or Lack of Lubrication
Go to Section 308-03.
Air in System
Refer to Clutch Diagnosis in Section 308-01.
Cruise Control Switch Faulty / Plug Disconnected
Go to PinPoint Test A
Stop Lamp Switch Faulty / Plug Disconnected
Go to PinPoint Test C in Section 206-06.
Brake pedal does not return freely
No response from the cruise control when the clutch pedal is pressed
Nothing happening when the clutch pedal is pressed
Cruise control not turning off when clutch activated
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01/2003 2003.0 BA Falcon
308-02-6
Clutch Controls
308-02-6
DIAGNOSIS AND TESTING (Continued) Pinpoint Tests PINPOINT TEST A : CRUISE CONTROL CLUTCH PEDAL CUT OFF SWITCH Test Step A1
Result / Action to Take
STOP LAMP CIRCUIT FUSE Check the 15 Amp Fuse # 7 .
Yes
Replace Fuse and recheck. NOTE: If Fuse blows again, this could indicate an electrical system fault.
Was Fuse blown?
No
Go to A2
A2
CLUTCH PEDAL SWITCH CONTINUITY Remove the clutch pedal switch. Refer to Section 308-01. Carry out a continuity test. With the switch plunger Out = Continuity. Push the switch plunger Inwards = Open circuit. Push the switch pin Inwards = continuity.
Yes
Go to A3
No
Replace the clutch pedal switch. Refer to Section 308-01.
Is the clutch pedal switch electrical function Okay?
A3
SWITCH EARTH CIRCUIT CONTINUITY Disconnect the electrical connector C-111 at the clutch pedal switch and the PCM connector. Check the Blue/Yellow wire (92) from the switch connector C-111 to the PCM terminal B05 RBS.
Yes
PCM issue. Refer to Section 303-14.
No
Check and repair wiring or terminal fault.
Was there continuity?
PINPOINT TEST B : PEDAL NOT RETURNING ONCE RELEASED Test Step B1
Result / Action to Take
HYDRAULIC SYSTEM Check the fluid reservoir for clutch fluid. Was the reservoir empty?
Yes
Fill the reservoir with fluid. Refer to the specifications. Go to B2 to ensure that the master cylinder is not leaking.
No
Go to B2
B2
HYDRAULIC HOSES Carry out a visual inspection of the clutch hydraulic hoses and hose clamps to see evidence of a leakage point. Was a leak evident at the hoses, joints or clamps?
Yes
Rectify cause of fluid leakage or replace the offending hose.
No
Go to B3
B3
MASTER CYLINDER Yes
Carry out a visual inspection of the master cylinder push rod plunger to cylinder area for signs of fluid leakage between push rod plunger and the entry point to the master cylinder.
Replace the clutch master cylinder. Refer to Section 308-02.
Was a leak evident?
No
Go to B4
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01/2003 2003.0 BA Falcon
308-02-7
Clutch Controls
308-02-7
DIAGNOSIS AND TESTING (Continued) Test Step B4
Result / Action to Take
RETURN SPRING Carry out visual inspection of the Return spring at the pedal pivot for damage. Was the return spring damaged or broken?
Yes
Replace the complete Pedal box assembly. Refer to Section 308-02.
No
Go to B5
B5
OBSTRUCTION Check for an obstruction that could causing the pedal not to return such as floor carpet, wiring harness jammed at the upper pivot area, etc. Was an obstruction found?
Yes
Rectify cause of obstruction.
No
There appears to be no issue with clutch pedal return.
PINPOINT TEST C : CRUISE CONTROL CLUTCH PEDAL CUT OFF SWITCH Test Step C1
Result / Action to Take
PIVOT POINT BINDING OR "RASPY" Remove the 2 x Torx head bolts used to retain the clutch master cylinder to the pedal box. Gently turn the flexible inlet hose to the master cylinder so that the it is parallelWith the master cylinder body. This hose repositioning is carried out to enable the hose to pass through the master cylinder to mounting opening. Gently withdraw the master cylinder (including flexible hose) through the opening. Allow to hang loose.
Yes
Replace the clutch pedal / mount assembly. Refer to Section 206-06.
No
Clutch pivot pin okay. Refit the clutch master cylinder. Go to the clutch diagnosis section for slave cylinder and pressure plate diagnostics.
Manually push on the clutch pedal to evaluate if any binding at the pivot pin or "raspy" effect is felt. Did you notice any binding or "raspy" feel?
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01/2003 2003.0 BA Falcon
308-02-8
Clutch Controls
308-02-8
GENERAL PROCEDURES
Clutch Bleeding 1. Reconnect all lines and hoses and ensure routing is correct. ie. Ensure there are no kinks or siphons present in the soft lines (especially the reservoir line). This is extremely important as the system will be difficult or impossible to bleed if siphons exist. 2. Fill the clutch reservoir to Full mark and keep filled above 1/4 full at all times during bleed procedure. 3. Pump the clutch pedal at a moderate pace through its full travel ensuring the pedal returns fully up against it’s stop. Note that the pedal may need to be pulled back manually by hand to fully return. Rapid pedal returns can be of assistance if the clutch appears difficult to bleed. 4. Continue to pump the clutch pedal in bursts of 10 pumps with a rest for 5 seconds (with pedal fully returned) in between. 5. After 30 seconds to a minute some pedal feel should exist, continue the pumping/resting cycle until the pedal has come up fully (up to approx 5 minutes). Some rapid pumping at the end of this time may improve the bleed slightly but is not necessarily required. 6. If there is some initial sponginess or play in the first part of pedal travel at this stage continue with a CSC bleed. This is normally only required if the CSC has been drained or replaced. Elevate the vehicle to gain access to the underside of the transmission and bleed the CSC manually by depressing the pedal fully and holding it down whilst an assistant opens and then closes the bleed port on the side of the clutch housing (similar process to manually bleeding the brakes). Repeat until pumped fluid is not aerated (usually 2-4 strokes). Note that approx 3 full strokes will almost empty the reservoir. Ensure that fluid remains in the reservoir at all times or the procedure may need to be started again. 7. The Clutch system should now be fully bled. Ensure that the reservoir is filled to Full mark and test drive the vehicle to ensure that the clutch is disengaging properly and not dragging. Note that the system is self-bleeding and some slight improvement will occur in pedal feel and take-up point after the vehicle has sat for a few hours or overnight after the above bleed procedure. This is normal as any emulsified air will coalesce and bleed out automatically during this time.
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01/2003 2003.0 BA Falcon
308-02-9
Clutch Controls
308-02-9
REMOVAL AND INSTALLATION
Clutch Pedal
3. Remove the push on decoupler from the clutch pedal pin.
Removal 1. Remove two M6 nuts and bolts, Clutch assembly can now be removed. NOTE: Ensure that inserts in pedal box remain in place.
4. Pull the clutch master cylinder forward until the line clip is accessible. Remove the clip and disconnect the line.
2. Clutch Master Cylinder is now free of bracket but still retained on pedal by push-on fix. Installation 1. To install, reverse the removal procedure.
Clutch Master Cylinder Removal and Installation WARNING: Clutch fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately.
5. Disconnect the clutch master cylinder rod from the clutch pedal arm. Remove the clutch master cylinder from the vehicle.
CAUTION: Clutch fluid is harmful to painted or plastic surfaces. If the clutch fluid is spilled onto a painted or plastic surface, wash it immediately with water. 1. Partially drain the clutch reservoir. Drain to just below the clutch reservoir nipple. 2. Remove the hose at the clutch reservoir.
6. Remove the reservoir line from the clutch master cylinder.
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01/2003 2003.0 BA Falcon
308-02-10
Clutch Controls
308-02-10
REMOVAL AND INSTALLATION (Continued) 7. To install, reverse the removal procedure. Install new hose clamps on the reservoir line. Refill the brake master cylinder with the specified fluid. Bleed the clutch hydraulic system. For additional information, refer to procedure in this chapter.
Slave Cylinder Removal and Installation 1. Remove the transmission. For additional information, refer to Section 308-03. NOTE: Inspect the clutch housing for traces of fluid. If brake fluid is visible, install a new clutch slave cylinder. 2. Remove the clutch slave cylinder. 1. Remove the bolts. 2. Remove the clutch slave cylinder.
3. Inspect the clutch slave cylinder for the following: 1. Worn or damaged boot. 2. Leaking fluid. 3. Contract and return smoothly.
5. To install, reverse the removal procedure. 1. Position the clutch slave cylinder to the transmission and install the bolts. 2. Bleed the clutch hydraulic system. For additional information, refer to procedure in this chapter.
Clutch Hydraulic Fluid Tubes Removal and Installation WARNING: Clutch fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. CAUTION: Clutch fluid is harmful to painted or plastic surfaces. If the brake fluid is spilled onto a painted or plastic surface, wash it immediately with water. 1. Partially drain the clutch reservoir. Drain to just below the clutch reservoir nipple. 2. Remove the hose at the clutch reservoir. 3. Disconnect the hydraulic line from the clip on the instrument panel. 1. Using a 3/32-inch punch and hammer, drive out the roll pin and discard it. 2. Disconnect the hydraulic line. 4. Disconnect the hydraulic line from the clutch master cylinder. 5. Disconnect the lower end of the hydraulic line from the clutch slave cylinder. 6. Disconnect the hydraulic line from the clip on the transmission. NOTE: Make sure the O-ring is in the outlet port or on the tube connector.
CAUTION: The clutch release hub and bearing is prelubricated and should not be 7. To install, reverse the removal procedure. cleaned with solvent. The clutch release hub and 8. Bleed the clutch hydraulic system. For additional bearing are replaced as an assembly. Do not information, refer to procedure in this chapter. disassemble for inspection or replacement. 4. Inspect the clutch release bearing as follows: 1. Rotate the outer race while applying pressure. If the bearing rotation is rough, install a new clutch slave cylinder. 2. Inspect for wear or damage. If wear pattern is continuous (not segmented) and the wear appears to be deep in bearing face, install a new clutch slave cylinder.
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01/2003 2003.0 BA Falcon
308-02-11
Clutch Controls
308-02-11
REMOVAL AND INSTALLATION (Continued)
Clutch Reservoir Removal and Installation 1. Remove the two M6 nuts securing the reservoir to the reservoir bracket.
2. Remove the cap, drain the reservoir of all fluid and replace cap. 3. Undo clamp on reservoir line and remove reservoir.
4. To install, reverse removal procedure.
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01/2003 2003.0 BA Falcon
308-03a-1
Manual Transmission — I6
308-03a-1
SECTION : 308-03a Manual Transmission — I6 VEHICLE APPLICATION : 2003.0 BA Falcon CONTENTS
PAGE
SPECIFICATIONS Specifications ......................................................................................................................308-03a-3 DESCRIPTION AND OPERATION Manual Transmission ..........................................................................................................308-03a-4 Manual Transmission .........................................................................................................308-03a-4 DIAGNOSIS AND TESTING Manual Transmission ..........................................................................................................308-03a-8 Inspection and Verification .................................................................................................308-03a-8 Symptom Chart ..................................................................................................................308-03a-8 GENERAL PROCEDURES Transmission Cleaning .....................................................................................................308-03a-10 Transmission Inspection ...................................................................................................308-03a-10 Aluminium Transmission Case Service ............................................................................308-03a-10 Taper Roller Bearings Inspection .....................................................................................308-03a-11 Fluid Level Check .............................................................................................................308-03a-11 Drain and Refill Transmission ...........................................................................................308-03a-11 REMOVAL AND INSTALLATION Rear Extension Housing Oil Seal ......................................................................................308-03a-12 Shift Lever and Boot Assembly .........................................................................................308-03a-13 Speedometer Transducer and Drive Gear ........................................................................308-03a-14 Concentric Slave Cylinder (CSC) .....................................................................................308-03a-14 Transmission Damper .......................................................................................................308-03a-14 Reversing Light Switch .....................................................................................................308-03a-15 Transmission Cross - Member ..........................................................................................308-03a-15 REMOVAL Special Service Tools .......................................................................................................308-03a-17 Transmission .....................................................................................................................308-03a-17 INSTALLATION Transmission .....................................................................................................................308-03a-18 DISASSEMBLY Transmission .....................................................................................................................308-03a-19 DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES General .............................................................................................................................308-03a-26 Input Shaft Bearing ...........................................................................................................308-03a-26 Input shaft — to — output shaft bearing cup ....................................................................308-03a-27 Output Shaft ......................................................................................................................308-03a-28 Countershaft Bearing — Front ..........................................................................................308-03a-35 01/2003 2003.0 BA Falcon
308-03a-2
Manual Transmission — I6
308-03a-2
(Continued) Synchronizers ...................................................................................................................308-03a-36 Shift Cover ........................................................................................................................308-03a-37 Bearing Retainer Seal — Front .........................................................................................308-03a-40 ASSEMBLY Transmission .....................................................................................................................308-03a-41
01/2003 2003.0 BA Falcon
308-03a-3
Manual Transmission — I6
308-03a-3
SPECIFICATIONS General Specifications Gear Ratios XR6 T First 2.95:1 Second 1.94:1 Third 1.34:1 Fourth 1.00:1 Fifth 0.73:1 Reverse 2.76:1 Specified Clearances Component Preload output shaft 1st Gear 2nd Gear 3rd Gear 5th Gear Cluster shaft
I6 & XR6 3.35:1 1.92:1 1.29:1 1.00:1 0.72:1 3.15:1
Description CSC to Pipe Fitting CSC Bleed Screw Case to Flywheel Housing (retainer M8 bolts) Case to Flywheel Housing (M12)
Nm 14 8 21 75
Specification (mm) 0.01-0.1 0.18-0.33 0.23-0.66 0.23-0.58 0.13-0.86 0.013-0.102
Lubricant I6 & XR6
Capacity Specification
Oil Additive Shift Turret Colour Black Gold
XR6 T 2.2 litre ESR-M2C-163A CASTROL (DEXRON II) SYNTRANS B (Ford R1-36) 2.05 litre LubrizoI 7906 N/A (150 ml) Type Standard throw Short throw
Tightening Torques Description Lower Boot Retainer Shift Lever Bolts Reversing Light Switch Insulator to Extension Housing Insulator to Crossmember Crossmember to Body Muffler Inlet Pipe Flange Filler Plug Extension Housing to Case Reverse Spring Anchor Bolt Flywheel Housing to Engine Shift Lever Pivot Pin to Case Shift Cover Shift Turret to Ext. Housing CSC to Flywheel Housing G34500 en
Vehicle All I6 except XR6 T XR6 T Nm 2 37 37 50 50 50 35 35 50 35 65 45 10 27 9 01/2003 2003.0 BA Falcon
308-03a-4
Manual Transmission — I6
308-03a-4
DESCRIPTION AND OPERATION
Manual Transmission Manual Transmission Three variants of the BTR T5 (M57) transmission are used on the 6-cylinder BA Falcon range. The ABS & non ABS standard I6 transmission models use a carry over gearset (except for input shaft) and a standard throw shifter turret is used. On the ABS model, the speedo gear/tranducer ass’y is no longer required and the signal is via the ABS sensors. The XR6 Turbo model features a heavy-duty gearset, a short throw shifter turret and a high performance transmission lubricant. On all BA 6-cylinder models the flywheel/clutch housing incorporates the input bearing retainer into the housing casting. A Concentric Slave Cylinder (CSC) is mounted and bolted to the flywheel housing supports. On the shifter turret, the gear shift lever bolt mounting arrangement has been revised for all models. The M57 is a 5-speed manual transmission with 5th speed as an overdrive gear. The 1st through 4th gears and reverse gear are meshed within the case. The 5th speed gear and synchronizer are located on the back of the case in the extension housing where the reverse brake is installed. The floor mounted shift lever operates a shift rail which extends from the extension housing turret to the shift cover. The 1st/2nd and 3rd/4th shift forks are mounted in the cover. The 5th speed synchronizer and reverse sliding gear are shifted through an intermediate lever mounted on a pivot pin.
G34501 en
01/2003 2003.0 BA Falcon
308-03a-5
Manual Transmission — I6
308-03a-5
DESCRIPTION AND OPERATION (Continued)
Item 1 2 3
Description Plug, Fill/Drain Screw Control Lever & Housing Assy.
G34501 en
Item 5 6 7
Description Boot Vent Cap Vent & O-Ring Assy. 01/2003 2003.0 BA Falcon
308-03a-6
Manual Transmission — I6
308-03a-6
DESCRIPTION AND OPERATION (Continued) Item 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55
Description Harness, Plastic Bolt Gear – Driving Bushing – Extension Housing Connector Lead Transducer Assembly (for non ABS vehicles only) O-Ring Retaining Clip Bolt Extension, Bushing & Plate Assy. Plate, Detent Guide Plug, Cup Lever, Bonded Offset Isolator cup Ball Spring Seal, Oil Funnel, Oiling Bolt Bolt, Alignment Pin, Selector Arm Shaft, Shifter Fork, Shift, 3-4 Fork, Shift, 1-2 Insert Arm Assy., Selector Plate, Interlock Plate, Selector O-Ring Plug Cover, Case Ring, Retaining Pin, Pivot Switch, Back-Up Bolt, Spring Anchor Lever, Shift, 5-R Ring, Snap Spacer, Rev. Cone Cone, Reverse Ring, Blocking Synchronizer Assy., 5th Spring, Synchronizer Sleeve, Synchronizer Insert Hub, Synchronize Pin, Roll
G34501 en
Item 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 101
Description Fork, Shift, 5th Insert Rail Assy., Shift Gear, 5th Speed Drive Ring, Snap Gear, Speedo (Non ABS vehicles only) Clip, Speedo Gear (Non ABS vehicles only) Bolt Flywheel Housing (contains input shaft bearing retainer) Seal, Oil Shim Bearing Assy., Input Shaft Shaft, Input Cup Taper Roller Bearing Circlip Gear, 5th Driving Bearing Assy., Main Shaft Rear Gear, 1st Speed Sleeve Assy., Bearing Bearing Sleeve Ring Assy., Blocking Synchronizer Assy., 3rd-4th Spring, Synchronizer Sleeve, Synchronizer Insert Hub, Synchronizer Gear, 3rd Speed Bearing Spacer Ring, Snap Washer, Thrust Gear, 2nd Speed Bearing, 2nd Speed Spacer Shaft Assy., Output Ring, Spiral Retaining Washer, Thrust Cone, Inner Race, Outer Cone Ring, 1-2 Blocking Spring Gear, Reverse Sliding Insert 01/2003 2003.0 BA Falcon
308-03a-7
Manual Transmission — I6
308-03a-7
DESCRIPTION AND OPERATION (Continued) Item 102 103 104 105 106 107 108 109 110 111 112 113 114 115 116 117 118 119 120
Description Ball Shaft and Hub Assy. Spring Fork, Pin & Roller Assy., Reverse Bolt Retainer, Rear Shim Pin, Roll Shaft, Reverse Idler Gear, Reverse Idler O-Ring Bearing Assy., Countershaft Rear Bearing Assy., Countershaft Front Gear, Countershaft Case Assy., Transmission Bush Concentric Slave Cylinder & lines Screw Hose Clip
Reverse Brake The reverse brake is applied through the 5th synchro sleeve. This stops the rotation of the cluster gear before the reverse idler is engaged eliminating gear clash when the vehicle is stationary and reverse gear is selected. The spacer slides onto the cluster spline and rotates with it. A snap ring holds the reverse brake components in position. The tab on the reverse cone locates into a recess in extension housing adjacent to the lubrication funnel. A shift interlock system, located in the cover prevents engagement of more than one gear. The shift detent is located in the extension housing turret and consists of a detent plate, offset lever and spring loaded ball. All gears except reverse are synchronized and helical cut for smooth, crisp shifts and quiet operation. Reverse is provided through a reverse idler gear which slides along a shaft to engage spur gears on the countershaft and output shaft. The case is aluminium and all fasteners are metric.
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01/2003 2003.0 BA Falcon
308-03a-8
Manual Transmission — I6
308-03a-8
DIAGNOSIS AND TESTING
Manual Transmission Inspection and Verification NOTE: Gear rollover noise, inherent in manual transmissions, (caused by the constant mesh gears turning at engine idle speed while the clutch is engaged and the transmission is in NEUTRAL), and clutch release bearing noise are sometimes mistaken for mainshaft bearing noise. Noise caused by a worn or damaged clutch release bearing will be loudest when the clutch is held disengaged.
Gear rollover noise will disappear when the clutch is disengaged or when the transmission is engaged in gear. In the event that a transmission bearing is damaged, the noise is more pronounced while engaged in gear under load or coast conditions than in NEUTRAL. When concerns of this nature are encountered, it will be necessary to road test the vehicle to determine if bearing noise exists. Under no circumstances should any transmission rework be attempted to eliminate gear rollover noise, or clutch release bearing noise.
Symptom Chart Condition Transmission Noisy in Gear
Transmission Leaks
Transmission difficult to shift
G34502 en
Source
Action
Lubricant level low or wrong type.
Remove transmission. If noise is howling during start-up, check pilot bushing. Check for loose flywheel and housing alignment. Service or replace as required. Refer to Section 308-01.
Transmission to flywheel housing and flywheel housing to engine block bolts loose.
Fill to bottom of filler plug hold with proper lubricant.
Pilot bushing worn or damaged.
Tighten bolts to 61-88 N-m (45-65 lb-ft).
Improper transmission pilot engagement into flywheel housing.
Replace housing or input shaft bearing retainer as required. Refer to Section 308-01.
Worn or damaged internal components.
Disassemble transmission. Inspect Input, output and countershaft bearings, gear and gear teeth for wear and damage. Service or replace as required.
Excessive amount of lubricant in transmission–wrong type.
Check level and type. Fill to bottom of filler plug hole.
Other component(s) leaking.
Identify leaking fluid at engine, power steering and/or transmission.
False report.
Remove all traces of lubricant on exposed transmission surfaces. Check vent for free breathing. Operate transmission and Inspect for new leakage. Service as required.
Worn or damaged Internal components.
Remove transmission. Inspect for leaks at the input shaft bearing retainer seal and gasket, shift rail expansion plug top cover gasket. Inspect case for sand holes. Service or replace as required.
Inadequate thread sealant on threads.
Apply sealant to bolt threads.
Improper clutch release.
Refer to Section 308-01 for clutch servicing procedures.
Internal shift mechanism binding.
Remove transmission and free up shift mechanism.
Synchronizer sleeve to hub fit.
Remove and check for burrs or fit.
01/2003 2003.0 BA Falcon
308-03a-9
Manual Transmission — I6
308-03a-9
DIAGNOSIS AND TESTING (Continued) Condition
Gears Clash When Shifting from One Forward Gear to Another
Transmission Jumps Out of Gear
Transmission Will Not Shift Into One Gear – All Other Gears OK
Transmission is Locked in One Gear. It Cannot be Shifted Out of that Gear
Transmission Will Not Shift Into Reverse (All Others OK)
G34502 en
Source
Action
Binding condition between input shaft and crankshaft pilot bearing.
Check alignment and service as required. Refer to Section 308-01.
Improper fluid.
Drain and refill with specified fluid (refer Specifications section).
Engine idle speed too high.
Adjust engine idle speed.
Improper clutch release.
Ensure complete clutch release. Refer to Section 308-01 for clutch servicing procedures.
Binding condition between transmission input shaft and crankshaft pilot bushing.
Remove transmission and replace pilot bushing. Refer to Section 308-01.
Worn or damaged shifter forks, synchronizer assembly, or gear clutch teeth.
Service or replace as required.
Stiff or improperly installed boot.
Verify Jump-out with boot removed. Replace boot if necessary.
Interference between shift handle and console.
Adjust console to eliminate interference.
Transmission to engine mounting loose.
Tighten bolts to specification.
Flywheel housing to engine crankshaft out of alignment.
Replace parts as required. Refer to Section 308-01.
Improper engagement between transmission pilot and flywheel housing.
Replace parts as required. Refer to Section 308-01.
Input shaft pilot bearing worn.
Replace pilot bearing. Refer to Section 308-01.
Worn or damaged internal components.
Check input and output shafts for excessive end play, shift forks for loose mounting on shift rails, worn pads, shift rail detent system for wear or damage, synchronizer sliding sleeve and gear clutch teeth for wear or damage. Service or replace as required.
Floor shift, interference between shift handle and console or floor cut out.
Adjust console or cut out floorpan to eliminate interference.
Restricted travel of internal shifter components.
Remove transmission. Inspect shift rail and fork system, synchronizer system and gear clutch teeth for restricted travel. Service and replace as required.
Internal shifter components worn or damaged.
Remove transmission. Inspect the problem gear or gearshift rails and fork and synchronizer for wear or damage. Service or replace as required.
Selector arm finger broken.
Remove transmission. Replace selector arm assembly.
Bent shifter forks at pads and selector slot.
Service or replace as required.
Worn or damaged internal components.
Remove transmission. Check for damaged reverse geartrain, misaligned reverse relay lever, shift rail and fork system
01/2003 2003.0 BA Falcon
308-03a-10
Manual Transmission/Transaxle — I6
308-03a-10
GENERAL PROCEDURES 12. Inspect the synchronizer blocking rings for widened index slots, rounded clutch teeth, and 1. Wash all parts except ball bearings, O-rings and smooth internal surfaces (must have machined seals in a suitable cleaning solvent. Brush or grooves). With the synchronizer blocking ring on scrape all foreign matter from the parts. Be careful the cone, the distance between the face of the not to damage any parts with the scraper. synchronizer blocking ring and the clutch teeth on the gear must not be less than 0.5mm (0.020 CAUTION: Do not clean, wash or soak inch). transmission seals in cleaning solvents. Dry 13. Replace speedometer drive gear (where fitted) if all parts with compressed air. teeth are stripped or damaged. Make certain to 2. Rotate ball bearings in a cleaning solvent until all install correct size replacement gear. lubricant is removed. Hold bearing assembly to 14. Replace the output shaft if there is any evidence prevent it from rotating and dry it with compressed of wear or if any of the splines are damaged. air. 3. Lubricate bearings with Multi-Purpose Grease and 15. Inspect bushing and seal in the extension housing, and replace if worn or damaged. The wrap them in a clean, lint-free cloth or paper until bushing and/or seal should be replaced after the ready for use. extension housing has been installed on the 4. Clean the magnet in the bottom of the case with transmission. kerosene or mineral spirits. 16. Replace the seal in the input shaft bearing retainer. Transmission Inspection 17. Replace seals on the cam and shafts. 1. Inspect transmission case for cracks, worn or damaged bearing bores, damaged threads, or any other damage that could affect operation of the transmission. 2. Inspect the front face of the case for small nicks or burrs that could cause misalignment of the transmission with the flywheel housing. Remove all small nicks or burrs with a fine file. 3. Replace any cover that is bent or distorted. Make sure that the vent hole in the cover is open. 4. Check the condition of the shift levers, forks, shift rails, and the lever and shafts. 5. Inspect the bearings. Refer to Bearing Inspection. 6. Replace roller bearings that are broken, worn or rough, and check their respective races. Aluminium Transmission Case Service 7. Replace the countershaft (cluster) gear if the teeth NOTE: If an aluminum transmission case thread is are chipped, broken or worn. Replace the damaged, service kits may be purchased from local countershaft if it is bent, scored or worn. jobbers. To service a damaged thread, the following 8. Replace the reverse idler gear or sliding gear if procedures should be carefully followed. the teeth are chipped, worn or broken. Replace the idler gear shaft if bent, worn or scored. 1. Drill out the damaged threads, using the same drill size as the thread OD. For example, use a 9. Replace the input shaft and gear if the splines are 16mm drill for a M16x1.5 thread. damaged or if the teeth are chipped, worn or broken. If the roller bearing surface in the bore of 2. Select the proper special tap and tap the drilled the gear is worn or rough, or if the cone surface is hole. The tap is marked for the size of the thread damaged, replace the gear and the gear rollers. being serviced. Thus, the special tap marked M16x1.5 will not cut the same thread as a 10. Replace all other gears that are chipped, broken standard M16x1.5 tap. It does cut a thread large or worn. enough to accommodate the insert, and after the 11. Check the synchronizer sleeves for free insert is installed the original thread size movement on their hubs. Make sure that the (M16x1.5) is restored. alignment marks (if present) are properly indexed.
Transmission Cleaning
G34503 en
01/2003 2003.0 BA Falcon
308-03a-11
Manual Transmission/Transaxle — I6
308-03a-11
GENERAL PROCEDURES (Continued) 3. Select the proper coil inserting tool. These tools are marked with the thread size being serviced. Place the insert on the tool and adjust the sleeve to the length of the insert being used. Press the insert against the face of the tapped hole. Turn the tool clockwise and wind the insert into the hole until the insert is one-half turn below the face. 4. Working through the insert, bend the insert tang straight up and down until it breaks off at the notch. 5. Improperly installed inserts can be removed with the extractor tool. Place the extractor tool in the insert so that the blade rests against the top coil one-fourth to one-half turn away from the end of the coil. Tap the tool sharply with a hammer so that the blade cuts into the insert. Exert downward pressure on the tool and turn it counterclockwise until the insert is removed. These tools are marked with the thread size being serviced. Place the insert on the tool and adjust the sleeve to the length of the insert being used. Press the insert against the face of the tapped hole. Turn the tool clockwise and wind the insert into the hole until the insert is onehalf turn below the face.
3. Clean the plug, inspect the gasket condition and replace where necessary. 4. Install the plug.
Drain and Refill Transmission 1. Clean the area around the drain and filler plugs. 2. Remove the drain and filler plugs. 3. Clean the drain and filler plugs. (Apply pipe sealant with Teflon to the plug threads.) 4. Install the drain plug. 5. With the vehicle on a level surface fill the transmission to the bottom of the filler plug hole with the specified transmission oil. 6. Install the filler plug.
Taper Roller Bearings Inspection NOTE: It is recommended to replace all bearings during a major overhaul of the gearbox. The cost of removing and disassembling transmissions is too high to run the risk of bearing damage after they have been put back together. 1. If it is desired to reuse bearings, the cone assembly must not be removed from the component. The bearings should be inspected for the following damage: Discolouration of surfaces by heat. Excessive pitting and bruising caused by foreign material. Etching or corrosion. Spalls from fatigue of metal. Scoring of roller ends due to inadequate lubrication. Damaged bearing cage. Gauges or nicks on bearing surfaces. NOTE: The bearing should be replaced as a unit. Do not replace cup or cone assembly only.
Fluid Level Check 1. Clean around the filler plug and remove the plug. 2. If lubricant does not flow from the filler hole, fill the case with the specified lubricant until it is level with the bottom of the filler hole with vehicle in a level position.
G34510 en
01/2003 2003.0 BA Falcon
308-03a-12
Manual Transmission — I6
308-03a-12
REMOVAL AND INSTALLATION
Rear Extension Housing Oil Seal Special Tool(s) Impact slide hammer 100-001
Seal remover 307-365
Removal 1. Remove driveshaft. Refer to Section 205-01. WARNING: Failure to match marks when re-assembling the driveshaft may induce driveline vibration. NOTE: Before dis-assembly, mark the matching points on slip yoke and transmission output shaft. Mark the mating points on bolt, yoke flange, companion flange, nut and balance nut (if fitted). Re-assemble with matching points matched ± 1 spline, and all mating hardware in original hole. NOTE: Do not hang the driveshaft from the transmission extension housing as this may damage the extension housing oil seal and/or bush. 2. Remove oil seal from extension housing with impact slide hammer and seal remover.
Extension housing seal replacer 308-260 (E9321)
Installation 1. Lubricate extension housing oil seal bore by wiping with approved lubricant. 2. Using seal replacer, push oil seal into extension housing flush of housing rear face. 3. Lubricate oil seal lips with approved fluid.
G34511 en
4. Remove any contaminants from the driveshaft slip yoke’s working surface before re-installingit into the transmission extension housing. NOTE: During installation of the driveshaft into transmission, plunge the slip yoke the minimum distance into the extension housing to avoid slip yoke radius damaging oil seal.
01/2003 2003.0 BA Falcon
308-03a-13
Manual Transmission — I6
308-03a-13
REMOVAL AND INSTALLATION (Continued) 3. Working through the console aperture remove the one bolt and one nut securing the shift lever to the transmission and remove the lever.
WARNING: Failure to match marks when re-assembling the driveshaft may induce driveline vibration. NOTE: Before dis-assembly, mark the matching points on slip yoke and transmission output shaft. Mark the mating points on bolt, yoke flange, companion flange, nut and balance nut (if fitted). Re-assemble with matching points matched ± 1 spline, and all mating hardware in original hole.
Shift Lever and Boot Assembly Removal 1. Unscrew the gearshift knob from the gear lever. 2. Gently prise the boot retaining panel from the console and lift the boot and retainer from the lever. For more information refer to Manual Transmission Ecternal Control 308-06. Item 1 2 3 4 5 6 7 8 9 10
Description Lever Knob Lever Locator Bolt Nut Transmission Stalk Sleeve Plate Bolt Locator (with bolt stud) Nut Shift Lever Boot Assembly
Installation 1. Position the shift lever on the left hand side of the transmission lever, install and torque the bolts to specification. 2. Push yellow foam block down firmly over lever join to its home position. Make sure the "L" printed on foam block faces passenger side. 3. Locate the boot and retainer over the shift lever and press the retainer lugs into the console.
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01/2003 2003.0 BA Falcon
308-03a-14
Manual Transmission — I6
308-03a-14
REMOVAL AND INSTALLATION (Continued) 4. Apply loctite to threads. Screw the knob onto the shift lever until it starts to tighten, continue tightening until the graphics on the knob are correctly aligned.
2. Detach the fluid hose from the mounting clips and extricate it from the flywheel housing.
Speedometer Transducer and Drive Gear Removal NOTE: Only vehicles not fitted with ABS utilise a transmission driven speedometer transducer, hence the following removal/installation procedures are pertinent only to such vehicles. 1. Raise the vehicle. 2. Disconnect the wiring plug. 3. Remove the transducer. 4. Pry off the retaining clip and remove the gear. 5. Remove the ’O’ ring seal. Installation 1. Install the ’O’ ring. 2. Install the gear and the retaining clip. 3. Lubricate the seal and gear with transmission oil. 4. Install the transducer into the housing and connect the wiring. 5. Lower the vehicle.
Concentric Slave Cylinder (CSC) Removal NOTE: Before the CSC can be removed the transmission must be removed from the vehicle and the clutch bled according to the procedure setout in Section 308-01.
3. Using a T30 Torx® driver remove the two CSC mounting bolts that attach the CSC to the flywheel housing. Installation 1. Place the CSC in the position shown and install the two CSC mounting bolts. Torque to specification. 2. Route the CSC hydraulic hose in the orientation shown and tighten the CSC-to-hydraulic hose fitting. Torque to specification. NOTE: Ensure the hydraulic hose is mounted in the clips located on and in the flywheel housing.
Transmission Damper
Removal 1. Undo the nuts on the three transmission damper mounting bolts. 2. Remove the transmission damper mounting bolts. 1. Undo and disconnect the CSC fluid hose from the 3. Detach the damper and mounting bracket from CSC using a suitable 10-mm spanner. the transmission extension housing. Installation 1. Position the transmission damper and bracket such that the holes in the bracket line up with the holes in the extension housing. 2. Insert the three transmission damper mounting bolts through the aligned holes in the damper bracket and extension housing. 3. Thread the damper mounting nuts onto the bolts. Torque to specification. NOTE: The damper mounting nuts are of the Nyloc® variety and should be replaced each time the transmission damper is removed. Item 1 2 3
Description Hose Clip CSC-to-Hose fitting Bleed Screw
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01/2003 2003.0 BA Falcon
308-03a-15
Manual Transmission — I6
308-03a-15
REMOVAL AND INSTALLATION (Continued)
Reversing Light Switch Removal 1. Disconnect the wiring plug and remove the switch from the left hand side of the case with a 22 mm socket.
5. Detach the transmission-to-isolator mounting plate from the transmission, remove the nuts from the two mounting bolts numbered (3).
Installation 1. Clean the threads of the switch and apply pipe sealant with Teflon to the threads. 2. Install the switch and torque to specification.
Transmission Cross - Member Removal 1. Raise the vehicle on a hoist and support the transmission on a trolley jack. 2. Remove the four cross-member to chassis mounting bolts. 3. Unscrew the isolator-to-cross member mounting nut (numbered (6)) from the bolt numbered (2) in the figure below, together with the two bolts numbered (5). 4. Remove and disassemble the cross member-to-isolator assembly.
Item 1 2 3 4 5 6 7 8 9 10
Description Isolator-to-Cross Member Bracket Bolt - (M10x89) Wafer HD Bolt - (M8x46)x2 Wafer HD Insulator Element Nut - (M10x1.25) Bolt - (M10x1.5x25)x2 Screw - (M10x50)x4 (Trilobial) Transmission Cross Member Transmission-to-Isolator Mounting Plate Nut - (M8x1.25)
Installation 1. Position the transmission-to-isolator mounting plate in the orientation shown and attach it to the transmission by installing the two mounting bolts numbered (3) and mating nuts (numbered (10)). Torque nuts to specification. NOTE: Ensure that the isolator to cross-member bolt (numbered (2)) is installed in the mounting plate before affixing it to the transmission.
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01/2003 2003.0 BA Falcon
308-03a-16
Manual Transmission — I6
308-03a-16
REMOVAL AND INSTALLATION (Continued) 2. Assemble the cross member isolator assembly and attach it to the transmission isolator mounting plate. 3. Install the two screws numbered (5) and attach the nut numbered (6). Torque all screws and nuts to specification. 4. Using a transmission jack, ensure that the transmission cross member is aligned with the mounting points on the underside of the chassis. 5. Install the two cross-member-to-chassis mounting screws (numbered (7)). Torque screws to specification.
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01/2003 2003.0 BA Falcon
308-03a-17
Manual Transmission — I6
308-03a-17
REMOVAL
Special Service Tools Tool Number T40 E1673U15A T50 E9319 E9320 E9318 E7518B
E9322 E1673P or E1673MT E7511A E9321 T30
Transmission
Description Torx Bit (Countershaft) Puller Adaptor (Use with E1673P or E1673MT) Torx Bit (Pivot Pin) Snap Ring Expander/Installer Input Shaft Seal Installer Kit Countershaft Bearing Cup Remover/Installer Bearing Installation Tool (Countershaft) Attachment for E7511-A Handle Dial Indicator Mounting Rod Puller (Use with E1673U15A) Countershaft Bearing Installer (Handle) Extension Housing Torx Bit (CSC)
WARNING: Failure to match marks when re assembling the driveshaft may induce driveline vibration. NOTE: Before disassembly, mark the matching points on the slip yoke and transmission output shaft. Mark the mating points on the CV flange, companion flange, nut and balance nut (if fitted). Re-assemble with matching points matched ± 1 spline, and all mating hardware in original hole. 8. Bleed the concentric slave cylinder (CSC) according to the procedure set out in section 308-01. Disconnect the CSC hydraulic clutch line from the firewall.
9. 10. 11. 12. 13. 14.
WARNING: Failure to support CSC connector during tightening or loosening of bleed screw may result in damage to CSC. Remove the starter motor bolts and remove the motor. Support the engine and transmission assembly with a transmission jack. Remove the bolts securing the transmission cross-member to the body. Lower the transmission jack until the rear of the engine rests against the bulkhead. Disconnect the reversing light switch and, where necessary, the speedometer transducer. The engine must be tilted down at the transmission and before removing the flywheel housing-to-engine bolts. Raise the vehicle’s bonnet before tilting the engine or else the bonnet may be damaged. The engine can be tilted by either: 1. jacking up the front end or 2. using a harness to pull down the rear of the motor. Remove the flywheel housing-to-engine bolts.
Removal 1. Unclip the console cover to access the gear shifter prior to removing the gearshift boot, insulating foam and lever. 2. From inside the vehicle, remove the gearshift boot, insulating foam and lever. 3. Raise the vehicle on a hoist. 15. 4. The exhaust should be removed from the outlet WARNING: Do not seperate transmission manifold and unbolted from the vehicle. from vehicle engine by removing the 4 5. Detach the exhaust from the hanger bracket on transmission case bolts. the transmission damper. 6. After removing the exhaust, drain the clutch reservoir of all fluid into a container. This is to stop any change of the fluid dripping on to the exhaust when it is re-installed into the vehicle. 7. Mark the driveshaft so that it may be installed in the same relative position. Disconnect the shaft at the centre bearing mount, by detaching the centre bearing bracket from the centre bearing carrier (cross member) and detach the rear CV joint from the diff pinion companion flange, by undoing the bolts. Slide the driveshaft backwards, until the slip yoke slides off the output shaft. Install a dust cover or extension housing seal replacer into the extension housing to prevent lubricant leakage. G34518 en
01/2003 2003.0 BA Falcon
308-03a-18
Manual Transmission — I6
308-03a-18
REMOVAL (Continued) 16. Move the transmission rearward until the input shaft clears the pressure plate housing, then lower the jack and remove the transmission. NOTE: Removal of transmission from vehicle is easier if the front of the engine is jacked up carefully to tilt the transmission down at the rear.
Item 1 2 3
Description Bolt (M8) x2 Bolt (M10x50) x4 Screw (M10x50) x4 (Trilobial)
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01/2003 2003.0 BA Falcon
308-03a-19
Manual Transmission — I6
308-03a-19
INSTALLATION
Transmission Installation 1. Place the transmission on a transmission jack. NOTE: The CSC, CSC hydraulic line, transmission damper and transmission cross member must be attached to the transmission before installation can proceed.
13.
14. 2. The engine must be tilted down before the transmission can be moved into position. Raise the vehicle’s bonnet before tilting the engine. The engine can be tilted by either: 15. 1. jacking up the front end or 16. 2. using a harness to pull down the rear of the motor. 3. Using a jack, raise the transmission and move it forward until the flywheel housing locates on the engine guide pins, ensuring that the spline on the input shaft slides through the hub on the clutch disc and the end of the shaft locates in the spigot (pilot) bearing in the crankshaft. NOTE: Installation of transmission into the vehicle is easier if the front of the engine is jacked up carefully to tilt the transmission down at the rear.
the markings on the CV joint and companion flange mate up. Finally, bolt the centre-bearing bracket to the centre-bearing cross member. Torque all bolts to specification. Ensure any shims are re-used in original location. Attach the exhaust to the mounting bracket on the transmission damper, via the rubber isolator. Connect the exhaust to the outlet manifold. The exhaust should not be fitted prior to the CSC being reconnected and bled otherwise brake fluid will drip down onto the catalyst converter. Lower the vehicle. From inside the vehicle, install the gearshift lever, insulator foam and boot.
4. Install the flywheel housing to engine bolts. Torque all bolts to specification. 5. Connect the wiring to the reversing light switch and, where necessary, the speedometer transducer. 6. Install the starter motor and mounting bolts. Torque to specification. 7. Raise the transmission using the jack until the transmission cross member rests against the chassis. 8. Install the bolts securing the transmission cross member to the chassis. Torque to specification. 9. Remove the transmission jack. 10. Attach the CSC hydraulic clutch line to the firewall and charge the clutch system with fluid according to the procedure set out in Section 308-01. 11. Remove any contaminants from the driveshaft slip yoke’s working surface before re-installing it into the transmission extension housing. NOTE: During installation of the driveshaft into transmission, plunge the slip yoke the minimum distance into the extension housing to avoid slip yoke radius damaging oil seal. 12. Install the driveshaft. Ensure that the markings on the transmission output shaft and slip yoke line up, before sliding the slip yoke over the output shaft and that the centre bearing bracket mates up with the centre bearing cross member. Once the driveshaft is connected to the transmission, bolt the rear CV joint to the differential pinion companion flange, ensuring that G34529 en
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DISASSEMBLY
Transmission Disassembly 1. Mount the transmission (with flywheel housing attached) in a bench-mounted holding fixture or equivalent. 2. Using a 3/8-inch drive ratchet and extension, remove the drain plug located on the right hand side of the transmission case.
4. Using a 12-mm double-hex head socket remove the four main case-to-flywheel housing bolts and detach the transmission from the flywheel housing.
3. Remove the CSC unit as Removal of Concentric Slave Cylinder in Chapter Section 308-01. Remove the four integral flywheel housing-to-main case bolts located between the CSC mounting bosses. WARNING: Using an 11mm spanner, restrain the steel female fitting in the CSC whilst undoing the mating tube fitting to avoid damaging the CSC
NOTE: The input shaft bearing carrier is integral within the flywheel housing. Removal will result in partial disassembly of the transmission main case. 5. Remount the transmission in the holding fixture. 6. Using a 13mm socket, position shift lever in NEUTRAL position and remove turret cover retaining bolts.
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DISASSEMBLY (Continued) 7. Using a suitable pry bar, break turret cover-to-extension housing seal by prying carefully between housing and cover. Remove turret cover.
9. Using a 15mm socket, remove the eight extension housing retaining bolts.
CAUTION: Do not attempt to remove the bonded offset lever while the extension housing is bolted in place. A lug, located at the bottom of the bonded offset lever, meshes with the detent plate preventing enough rearward movement of the bonded offset lever to allow removal.
10. Using a suitable pry bar, break extension housing-to-case seal by prying carefully between housing and case.
8. Using a suitable pin punch and hammer, remove roll pin retaining bonded offset lever to shifter shaft.
11. Remove extension housing and bonded offset lever as an assembly by sliding rearward away from case.
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DISASSEMBLY (Continued) 12. Remove offset lever, roll pin, detent spring and detent ball from extension housing detent plate.
13. Using a 10mm socket, remove shift cover retaining bolts.
15. To remove shift cover, lift it slightly and slide to filler plug side of transmission. When shift mechanism clears groove in fifth/reverse shift lever, continue lifting cover.
16. Support fifth/reverse shift rail assembly with a block of wood and drive out roll pin from fifth gear shift fork with a suitable pin punch.
14. Using a suitable pry bar, break cover-to-case seal by prying carefully between cover and case. 17. Using snap ring pliers, remove fifth gear synchronizer snap ring retainer, splined washer, reverse cone and synchronizer blocking ring from rear of countershaft.
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DISASSEMBLY (Continued) 18. Remove fifth gear, synchronizer and shift fork as an assembly.
22. Rotate fifth/reverse shift rail clockwise to disengage ball stud from fifth/reverse shift lever. Pull fifth/reverse shift rail rearward slightly and rotate shift rail counter clockwise to align ball stud with slot in case and remove shift rail.
19. Using long needlenose pliers, remove C-clip retaining fifth/reverse shift lever to lever pivot pin. 23. Press downward on speedometer gear retaining clip and slide gear off output shaft. Remove retaining clip.
20. Remove fifth/reverse shift lever pivot pin with Torx ® bit driver. Do not remove the fifth/reverse shift lever at this point. 21. Using a 22mm wrench, remove the backup lamp 24. Rotate input shaft until flat on 4th gear clutching switch. teeth aligns with countershaft. With input shaft properly aligned, remove it from case.
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DISASSEMBLY (Continued) 25. Remove fourth gear synchronizer blocking ring from the third/fourth synchronizer. NOTE: If the race sticks, it is probably misaligned in the case bore. To free the race, work the shaft back and forth in the case.
26. Remove output shaft bearing race from rear of case. To partially remove bearing race, pull rearward on output shaft until first gear stops against case.
28. Remove fifth/reverse shift lever, reverse shift fork and reverse positioning spring from case by grasping lever and lifting straight up as an assembly. If case replacement is necessary, remove reverse positioning spring anchor pin by removing the Tizz bushing from the anchor bolt head and then removing the anchor bolt.
29. Using a suitable pin punch and hammer, remove roll pin from reverse idler shaft.
30. Remove reverse idler shaft by sliding it out of 27. Tilt output shaft assembly upward and lift out of back of case. Remove reverse idler gear and case. overtravel rubber stop from case. NOTE: Observe location of shift lever, shift fork and inhibitor spring prior to removal. Also observe the rotation action of the reverse positioning spring during removal. This will be helpful during assembly.
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DISASSEMBLY (Continued) 31. Using a hammer and Locknut Staking Tool flatten 34. Remove rear countershaft bearing race from tabs on countershaft retainer at all four corners. countershaft. NOTE: If the race sticks, it is probably misaligned in the case bore. To free the race, work the shaft back and forth in case.
32. Using a T40 Torx® driver, remove four bolts from countershaft retainer. 35. Install Front Hub Remover/Replacer and Bearing Pulling Attachment or equivalent to the countershaft with the jaws behind the countershaft bearing, and remove bearing.
33. Remove countershaft retainer and shim(s).
36. Move countershaft rearward through bearing bore. Tilt assembly upward and remove from case.
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DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES
General NOTE: The following transmission subassembly procedures should be performed only when necessary. After carefully inspecting each subassembly, disassemble only those requiring component replacement or further inspection.
Disassembly 1. Using a press and Pinion Bearing Cone Remover or equivalent, remove input shaft bearing.
Input Shaft Bearing Special Tool(s) Differential Side Bearing Replacer 205-412
Pinion Bearing Cone Replacer 205-408-01
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DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES (Continued) Assembly 1. Using a press and a capped length of pipe, install input shaft bearing.
Special Tool(s) Bearing Cone Replacer 205-412
Disassembly 1. Using Bearing Cup Puller and Slide Hammer or equivalent, remove bearing cup.
Input shaft — to — output shaft bearing cup Special Tool(s) Bearing Cup Puller 205-408
Slide Hammer D80L 205-102
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DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES (Continued) Assembly 1. Using Bearing Cone Replacer, press bearing cup in input shaft pocket.
Special Tool(s) Bearing Pulley Attachment 205-408-01
CAUTION: Make sure bearing cup is fully seated.
Disassembly 1. Using Bearing Pulling Attachment or equivalent, press off input shaft-to-output shaft taper roller bearing.
Output Shaft Special Tool(s) Pinion Bearing Cone Replacer 205-411 2. Remove snap ring.
Spiral Snap Ring Replacer 308-259
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DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES (Continued) 3. Using a press and Pinion Bearing Cone Remover or equivalent, remove 3rd/4th synchronizer, 3rd speed blocking ring, and 3rd gear as an assembly.
5. Remove fifth gear snap ring.
6. Using a press and Pinion Bearing Cone Remover or equivalent, remove fifth gear.
4. Remove needle bearing assembly and spacer from output shaft.
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DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES (Continued) 10. Remove ball using a pencil magnet. 7. Remove output shaft rear bearing. NOTE: There is a snug fit between the sleeve and the output shaft.
11. Remove three-piece first gear synchronizer blocking ring assembly from output shaft. 8. Remove first gear.
9. Remove needle bearing assembly and sleeve.
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12. Remove second gear snap ring and thrust washer.
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DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES (Continued) 13. Remove second gear from output shaft.
14. Remove second gear needle bearing assembly and spacer.
16. Remove spiral snap ring and thrust washer from output shaft.
17. Remove three-piece second gear synchronizer blocking ring assembly. Remove 1st/2nd synchronizer from output shaft.
15. Disengage spiral snap ring from slot in output shaft using a small screwdriver. Assembly 1. Install 1st/2nd synchronizer assembly, and three-piece 2nd gear synchronizer blocking ring assembly onto output shaft. NOTE: Align slots in synchronizer blocking ring with tabs in 1st/2nd synchronizer. For synchronizer assembly, refer to Synchronizer Disassembly and Assembly.
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DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES (Continued) 2. Install thrust washer onto output shaft. Install spiral snap ring using Spiral Snap Ring Replacer.
5. Install second gear thrust washer and snap ring using snap ring pliers.
3. Install second gear needle bearing and spacer.
6. Install three-piece first gear synchronizer blocking ring assembly onto output shaft. NOTE: Align slot in first gear synchronizer blocking ring with tab on 1st/2nd synchronizer.
4. Install second gear onto output shaft. NOTE: Align slots in second gear with tabs on synchronizer blocking ring assembly. 7. Drop ball into output shaft. NOTE: Use pencil magnet if necessary.
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DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES (Continued) 8. While aligning notch in sleeve with ball, slide sleeve onto output shaft. Install needle bearing assembly over sleeve.
11. Lubricate fifth gear splines with petroleum jelly and position on output shaft. Using a press and a capped length of pipe, 31.75mm ID x 356mm (1 1 /4 inch ID x 14 inch) press fifth gear onto output shaft.
9. Install first gear onto output shaft. NOTE: Align slots in first gear with tabs on first gear synchronizer blocking ring assembly.
10. Install rear output shaft bearing onto output shaft. The bearing taper must face the rear of the shaft.
12. Using snap ring pliers, install fifth gear snap ring.
CAUTION: Ensure the output shaft and gear splines are carefully aligned. If splines are improperly aligned, damage could occur when the gear is pressed onto the output shaft.
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DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES (Continued) 13. Install spacer and split needle bearing assembly onto output shaft.
14. Using a press and a 1 1 /2 inch deep well socket, install 3rd/4th synchronizer, third gear synchronizer blocking ring and third gear as an assembly. NOTE: Before pressing components together, ensure the synchronizer hub faces the short end of the output shaft. Hold third gear against the synchronizer to maintain synchronizer blocking ring alignment. Ensure that 3rd speed gear is fully seated against the thrust washer after assembly.
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15. Install snap ring.
16. Press on input shaft-to-output shaft taper roller bearing. CAUTION: Make sure bearing is fully seated against snap ring.
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DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES (Continued)
Countershaft Bearing — Front Special Tool(s) Pinion Bearing Cone Replacer 205-411
1. Using a press and Remover Tube and Mainshaft Front Bearing Replacers and Countershaft Front Bearing Replacer (assembled to support case), remove bearing race with O-ring from case. CAUTION: Failure to properly support the case will result in permanent distortion of case during bearing race removal.
Remover Tube 308-262
Countershaft Front Bearing Replacer 308-262
Disassembly NOTE: Remove the front countershaft bearing race only if it is worn or damaged. If the bearing race is removed, Sealer or equivalent must be used during installation.
Assembly 1. Install O-ring onto bearing race. Coat bearing race outside diameter with Sealer or equivalent and position bearing race to case.
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DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES (Continued) 2. Using Pinion Bearing Cone Replacer and Remover/Replacer Tube, support transmission case on press. Press bearing race until flush with case.
Synchronizers Disassembly NOTE: The following procedures apply to all synchronizer assemblies. The gear synchronizers are slightly different in design. Notation is made where procedural differences occur.
NOTE: The first/second gear synchronizer is available only as an assembly with the output shaft. The synchronizer hub is pressed onto the output shaft with an interference fit; therefore, no attempt should be made to separate the hub from the shaft. The retaining springs, inserts, detent ball and spring are available for service. If the hub or sleeve is worn, the output shaft and synchronizer must be replaced as an assembly.
1. Before disassembling the synchronizer, scribe alignment marks on the sleeve and hub for assembly reference. 2. Using a screwdriver, remove the two synchronizer retaining springs. Remove the inserts.
Assembly NOTE: When assembling a synchronizer sleeve and hub, match the alignment marks made during disassembly. The sleeve and hub have an extremely close fit and must be held square during assembly to prevent jamming. Do not force the sleeve onto the hub. 1. Assemble the inserts and synchronizer retaining springs onto the sleeve and hub. The retaining springs engage the same insert but rotate in opposite directions. 2. On fifth gear synchronizer only, install the Reverse Blocking Ring into the synchronizer.
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DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES (Continued) 3. Assemble retaining springs, inserts and sleeve onto hub. Refer to illustration in Step 1 for positioning of the retaining springs and inserts.
2. Rotate shifter shaft counterclockwise. When the selector arm disengages from the selector arm plate, pull shifter shaft rearward. The selector arm roll pin will now be accessible. Remove selector arm roll pin using a 5mm (3/16-inch) diameter pin punch and remove the shifter shaft.
Shift Cover Disassembly 1. Mark shift forks for assembly reference. Position selector arm plates and selector arm in the NEUTRAL position. The gearshift selector arm plates should now be centered over the control selector arm.
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DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES (Continued) 3. Pull shifter shaft out of cover using a twisting motion.
Assembly 1. Install a new O-ring seal.
2. If disassembled, assemble the shift forks, selector arm plates and nylon inserts. WARNING: Do not assemble the 3-4 shift fork black nylon inserts or the selector arm plate onto 1-2 shift fork. NOTE: The narrow side of the C-shaped selector interlock plate has to be positioned in the shift cover slot. The control selector arm roll pin hole has to be toward the rear of the cover.
4. Remove shift forks, roll pin and shift interlock from shift cover.
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DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES (Continued) 3. Install control selector arm and selector interlock plate as an assembly.
CAUTION: Ensure the roll pin is installed slightly below the selector arm surface. Failure to 4. Position shift forks in cover. Lubricate shifter shaft countersink the roll pin may result in interference with petroleum jelly. Slide shaft through shift cover between the pin and the interlock plate during and shift components until it stops against the shifts. front of the cover. NOTE: The 1-2 shift fork is the larger fork. The shift fork offset is to face the rear of the cover. The 3-4 gear shift selector arm plate is to be positioned under the 1-2 gearshift selector arm plate. NOTE: If on disassembly, the shifter shaft is burred or nicked, remove to prevent damage to the bush coating.
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DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES (Continued) 5. Align the hole in shifter shaft and the control selector arm to install the roll pin using a 5mm (3/16-inch) pin punch.
2. Install end play shim and bearing race. NOTE: If seal is being replaced as a part of a transmission overhaul, do not install the end play shim.
Bearing Retainer Seal — Front Disassembly 1. Detach flywheel from transmission main case and remove the end play shim. 2. Using a screwdriver, carefully pry seal from flywheel housing.
Assembly 1. Using Differential Side Bearing Replacer install new seal. G34526 en
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ASSEMBLY
Transmission Assembly 1. Using a press, install front countershaft bearing onto countershaft using Pinion Bearing Cone Replacer.
3. Using a press and Cluster Gear Bearing installer and Remover Tube install countershaft rear bearing to countershaft.
4. Install rear countershaft bearing race onto countershaft. 2. Position countershaft in case. CAUTION: Failure to properly support the countershaft can result in permanent distortion of the case during bearing installation. NOTE: Support the countershaft using two pieces of 7mm (1/4 inch) bar stock.
5. Install countershaft bearing retainer to transmission housing with four 13mm bolts. NOTE: This should be done initially without any shims installed. Tighten bolts to 15-27 Nm (11-20 lb-ft).
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ASSEMBLY (Continued) 6. Measure end play using Dial Indicator with Bracketry. Remove retainer and install necessary shim(s) between countershaft retainer and rear countershaft bearing race. Verify end play is within 0.013-0.102mm. After installing countershaft retainer and shims, bend tabs on retainer over the four attaching bolts.
9. If removed, apply Pipe Sealant with Teflon ® to reverse positioning spring anchor pin threads. Install anchor pin and tighten to 8-15 Nm (6-11 lb-ft). Install Tizz bushing over anchor pin head by tapping lightly into position with hammer. 10. Align fifth/reverse shift lever, reverse shift fork and reverse positioning spring as shown.
7. Position reverse idler gear in case with shift lever groove facing rear of case. Install reverse idler shaft and rubber overtravel stop. Install shaft from rear of case and position overtravel stop between gear and shaft support.
11. Lower assembly into case and install looped end of reverse positioning spring onto anchor pin.
8. Using a 5mm (3/16-inch) pin punch, install reverse idler shaft roll pin.
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12. Position reverse idler gear into the NEUTRAL position and align reverse shift fork onto reverse idler gear. Once aligned, push downward on shift fork until fully engaged into reverse idler gear. NOTE: Observe reverse positioning spring rotation. Reverse positioning spring should rotate counter clockwise into its installed position.
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ASSEMBLY (Continued) 13. Install output shaft assembly.
16. Install fifth/reverse shift rail into transmission case by aligning ball stud with slot in case and aligning shift rail with reverse shift fork. Once ball stud enters case, rotate shift rail clockwise and push in shift rail until ball aligns with fifth/reverse shift lever. Rotate shift rail counterclockwise until ball stud fully engages shift lever.
14. Align notches in synchronizer blocking ring with inserts in 3-4 synchronizer and install synchronizer blocking ring.
17. Install fifth gear, synchronizer and shift fork as an assembly.
15. Install output shaft rear bearing race. If necessary, tap bearing race into position using a plastic tipped hammer. 18. Install fifth gear synchronizer blocking ring, Reverse Cone, spacer and snap ring. NOTE: Ensure tabs on spacer engage splines of countershaft and the tab on the reverse cone is at the 12 o’clock position to assist when installing the extension housing.
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ASSEMBLY (Continued) NOTE: Ensure lubrication funnel engages into end of countershaft gear. Before installing the pivot pin, ensure the shift rail ball stud is fully engaged with the shift lever.
21. Install speedometer gear. NOTE: The tab on the retainer clip engages a hole in the output shaft.
19. Apply Pipe Sealant with Teflon ® to the pivot pin threads and install the fifth/reverse shift lever pivot pin. Tighten pivot pin to 34-47 Nm (25-35 lb-ft) using a T50 Torx ® driver. Apply Pipe Sealant with Teflon ® to the reverse light switch and install using a 22mm socket. Tighten to 27-47 Nm (20-35 lb-ft).
CAUTION: Do not apply silicone sealer to top of transmission case surface under any circumstances, as sealant could fall into transmission and affect operation. 22. Apply 3.2mm (1/8-inch) bead of Silicone Sealer RTV Silastic 1080 or equivalent to shift cover assembly. Position cover to filler plug side of transmission and lower into position until shift forks engage synchronizers. Continue lowering cover and move into position to engage fifth/reverse shift lever. NOTE: Ensure all synchronizers are in the NEUTRAL position and that the shift forks in the cover are in the NEUTRAL position. 23. Install shift cover retaining bolts. Tighten cover retaining bolts to 8-11 Nm.
20. Using needlenose pliers, install C-clip on shift lever pivot pin.
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ASSEMBLY (Continued) 24. Apply a 3.2mm (1/8-inch) bead of Silicon Sealer RTV Silastic 1080 or equivalent on the extension housing mating surface. Apply Silicone Sealer RTV Silastic 1080 or equivalent to the lubrication funnel and install funnel into countershaft gear.
25. Coat detent spring with petroleum jelly and install in offset lever. Lubricate detent plate and install detent ball in neutral position on plate. Position bonded offset lever in extension housing with spring over detent ball.
27. Press downward on bonded offset lever to compress detent spring and push lever and housing into position. Ensure the reverse cone tag is engaged in the recess in the housing.
28. Install extension housing retaining bolts. Tighten to 47- 61 Nm (30-45 lb-ft).
26. Slide lever and extension housing into position as an assembly.
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ASSEMBLY (Continued) 29. Using a suitable pin punch, align the hole in shifter shaft with hole in bonded offset lever and install roll pin.
33. Tighten retaining bolts to 15-27 Nm (11-20 lb-ft).
34. Remount the transmission (with flywheel housing) in the holding fixture and check output shaft geartrain end play as follows: Rotate transmission to the vertical position with extension housing facing up. Mount Dial Indicator with Bracketry on the extension housing with the indicator stylus contacting the output shaft. Rotate the input and output shafts. Zero the dial indicator. NOTE: Output shaft geartrain end play must be checked and adjusted at this point.
30. Install input shaft. Align flat on sychronizer teeth with countershaft before installing input shaft. NOTE: Ensure 3-4 synchronizer blocking ring is still in proper position.
31. Install bearing race in the bearing retainer located in the back of the flywheel housing. NOTE: Do not install end play shims at this point. 32. Temporarily, attach the flywheel housing to the transmission main case.
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ASSEMBLY (Continued) Using a wood block, push upward on the 37. Reattach the flywheel housing (with shims and input shaft and note the dial indicator reading. bearing race located in the integral bearing retainer) and hand tighten the four main NOTE: A shim must be installed that is the case-to-flywheel housing bolts. Tighten the four thickness of the dial indicator reading. This integral flywheel housing-to-main case retaining will provide zero end play. bolts to specification. A pre-load of 0.01-0.1mm must be applied.
CAUTION: Thickest shim must be installed closest to the front bearing cup. 35. Detach the transmission from the holding fixture and remove the flywheel housing. Remove bearing race from flywheel housing and install the necessary shim(s).
38. Torque the four integral flywheel housing-to-main case retaining bolts to specification. Check end play.
39. Apply a 3.2mm (1/8-inch) bead of Silicone Sealer RTV Silastic 1080 or equivalent on the turret cover. 36. Apply a 3.2mm (1/8 inch) bead of Silicon Sealer RTV Silastic 1080 or equivalent to the edge of the integral bearing retainer and around the retainer bolt holes in the back of the flywheel housing.
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ASSEMBLY (Continued) 40. Position turret cover on the extension housing and tighten the retaining bolts to 24-30 Nm.
41. Install and tighten drain plug to 27-40 Nm.
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SECTION : 308-03b Manual Transmission — TR3650 VEHICLE APPLICATION : 2003.0 BA Falcon CONTENTS
PAGE
SPECIFICATIONS Specifications ......................................................................................................................308-03b-2 DESCRIPTION AND OPERATION Manual Transmission ..........................................................................................................308-03b-3 Transmission Identification ...............................................................................................308-03b-7 DIAGNOSIS AND TESTING Manual Transmission ..........................................................................................................308-03b-8 GENERAL PROCEDURES Bearings — Inspection ........................................................................................................308-03b-9 IN-VEHICLE REPAIRS Seal ...................................................................................................................................308-03b-11 Gearshift Lever and Boot ..................................................................................................308-03b-11 Gearshift Boot and retainer Assembly ..............................................................................308-03b-12 REMOVAL Transmission .....................................................................................................................308-03b-13 DISASSEMBLY Transmission .....................................................................................................................308-03b-15 DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES Input Shaft and Bearing ....................................................................................................308-03b-24 Output Shaft ......................................................................................................................308-03b-25 Countershaft Bearing ........................................................................................................308-03b-36 Synchronizers ...................................................................................................................308-03b-37 Gearshift Rail Bushing ......................................................................................................308-03b-37 Gearshift Rail and Fork .....................................................................................................308-03b-38 ASSEMBLY Transmission .....................................................................................................................308-03b-39 INSTALLATION Transmission .....................................................................................................................308-03b-51
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SPECIFICATIONS General Specifications Description Specification Inspection Standards and Tolerances Synchronizer blocking 0.5 mm ring to conical face runout Assembly Standards Input shaft end play 0.023 mm – 0.051 mm Countershaft cluster gear 0.0 mm – end play 0.076 mm Output shaft end play 0.025 mm – 0.051 mm Lubricant/Adhesive/Cleaner Specifications Premium Long-Life ESA-M1C75-B Grease XG-1-C, K or T Threadlock and Sealer WSK-M2G351-A5 E0AZ-19554-AA Black Silicone Rubber ESB-M4G92-A D6AZ-19562-BA Pipe Sealant with ESR-M18P7-A Teflon® D8AZ-19554-A Stnthetict MERCON® MOBIL 1 SYNTHETIC (ATF) Transmission Fluid ATF (Dextron III ATF E6AZ-19582-B Alternative) Lubricant Refill Capacities Stnthetict MERCON® 3.8L (8.0 pt) (ATF) Transmission Fluid E6AZ-19582-B Torque Specifications Description Gearshift lever to extension housing bolt Gear shift lever to gear shift stub shaft bolt OSS to case bolt Reverse idler gear bolt Fifth/reverse lockout bolt Clutch housing to transmission main case bolt Extension housing to transmission main case bolt Drain plug Reversing lamp switch Fill plug Transmission to engine bolt Engine plate to transmission bolt Crossmember to frame bolt Crossmember to transmission support bolt G34230 en
Description Driveshaft flange to pinion flange bolt
Nm 112
Nm 25-40 37 10 20-35 20-35 25-40 25-40 20-35 20-35 20-35 75 27 41 58
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DESCRIPTION AND OPERATION
Manual Transmission The TR3650 five-speed manual transmission features the following: The fifth speed gear functions as an overdrive gear. The forward gears are synchronized and helical cut. The reverse gear operates through a constant-mesh, fully synchronized system. The shift interlock system prevents the engagement of more than one gear. The countershaft is serviced as an assembly. An aluminum main case, extension housing and bell housing.
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DESCRIPTION AND OPERATION (Continued) Transmission Internal Components — Disassembled View
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DESCRIPTION AND OPERATION (Continued) Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37
Description Input shaft seal Shim Input shaft front bearing and cup Input shaft Input shaft pocket bearing Input shaft thrust bearing Input shaft thrust washer Retaining ring Third/fourth gear synchronizer assembly Third/fourth gear synchronizer blocking ring Third/fourth gear synchronizer spring (part of 7124) Third/fourth gear synchronizer insert (part of 7124) Third/fourth gear synchronizer hub (part of 7124) Third/fourth gear synchronizer sleeve (part of 7124) Third gear Third gear needle bearing Third gear bushing Check ball Thrust washer Second gear needle bearing Second gear First/second gear synchronizer inner cone First/second gear synchronizer outer cone Output shaft Retaining ring First/second gear synchronizer assembly First/second gear synchronizer blocking ring First/second gear synchronizer spring (part of 7124) First/second gear synchronizer hub (part of 7124) First/second gear synchronizer insert (part of 7124) First/second gear synchronizer sleeve (part of 7124) First gear needle bearing First gear Reverse clutch cone Reverse gear synchronizer assembly Reverse gear synchronizer blocking ring Reverse gear synchronizer spring (part of 7124)
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Item 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
Description Reverse gear synchronizer hub (part of 7124) Reverse gear synchronizer insert (part of 7124) Reverse gear synchronizer sleeve (part of 7124) Retaining ring Reverse needle bearing Reverse driven gear Reverse gear bushing Selector gate Mainshaft rear bearing and cup Mainshaft fifth gear Retaining ring Output shaft speed (OSS) sensor Retaining ring Shim Countershaft front bearing and cup Countershaft Countershaft rear bearing and cup Thrust bearing Countershaft fifth gear Countershaft fifth gear needle bearing Countershaft fifth gear bearing spacer Retaining ring Fifth gear synchronizer assembly Fifth gear synchronizer blocking ring Fifth gear synchronizer spring (part of 7124) Fifth gear synchronizer hub (part of 7124) Fifth gear synchronizer insert (part of 7124) Fifth gear synchronizer sleeve (part of 7124) Fifth gear clutch cone Retaining ring Reverse idler gear support Reverse idler gear shaft Reverse idler gear Reverse idler gear needle bearing Reverse idler gear bearing spacer
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DESCRIPTION AND OPERATION (Continued) Transmission Case and Shift Components — Disassembled View
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DESCRIPTION AND OPERATION (Continued) Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39
Description First/second shift rail First/second shift fork Shift fork inserts First/second shift finger Third/fourth shift rail Third/fourth shift fork Shift fork inserts Third/fourth shift finger Fifth/reverse shift rail Reverse gear shift fork Fifth gear shift fork Shift fork inserts Shift arm bearing Spacer Shift arm selector inhibitor Main shift rail Gearshift offset lever Spacer Bearing Gearshift lever Gearshift plate and spring Shipping seal Output shaft seal Extension housing bushing Extension housing Vent Fifth/reverse gear lockout Magnet Shift interlock plate Transmission main case Interlock pins Drain plug Reverse lamp switch Detent plug Detent spring Detent Clutch housing Ball stud Bearing
Transmission Identification
Item 1 2 3 4 5 6 7 8
Description Transmission assembly number Build date code–month Build date code–day Build date code–year Shift number Serial number Service repair code Identification number located on left lower side of transmission case
Transmission Identification The transmission identification tag is located under the lower bolt that retains the extension housing to the main case.
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DIAGNOSIS AND TESTING
Manual Transmission Refer to Section 308-00.
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GENERAL PROCEDURES
Bearings — Inspection
4. Inspect bearing for cracked inner race.
NOTE: If any of the following conditions exist, install a new bearing. 1. Inspect the bearing for a bent cage.
5. Inspect the bearing and raceway for etching. If etching is present, inspect the seals. 2. Inspect bearings for galling (metal smears on roller ends). Galling is caused by overheating, poor lubrication or an overload situation. If galling is found, install a new bearing and inspect the seals.
6. Inspect the bearing for heat discoloration (dark blue). If heat discoloration is evident, check the bearing and race for loss of temper. Draw a file across the component. If the file cuts the metal, there is a loss of temper. 3. Inspect the bearing for brinelling (surface indentations in the raceway).
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GENERAL PROCEDURES (Continued) 7. Inspect the bearing for fatigue spalling (metal flaking).
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IN-VEHICLE REPAIR Installation 1. Using the special tool, install the extension housing fluid seal.
Seal Special Tool(s) Installer, Transmission Extension Housing Oil Seal 308-227 (T94P-7657-A)
Slide Hammer 100-001 (T50T-100-A)
Remover, Bushing 307-001 (TOOL-1175-AC) or Equivalent
Removal 1. With the vehicle in NEUTRAL, raise and support the vehicle. For additional information, refer to Section 100-02. 2. Remove the driveshaft. For additional information, refer to Section 205-01. CAUTION: Index-mark the driveshaft flange and pinion flange, and the driveshaft slip yoke and transmission output shaft. 3. Using the special tools, remove the extension housing fluid seal.
2. Install the driveshaft. For additional information, refer to Section 205-01. CAUTION: Align the index marks. 3. Check the transmission fluid level, add fluid if necessary. 4. Lower the vehicle.
Gearshift Lever and Boot Removal and Installation 1. Place the Gearshift lever in the Neutral position gate. 2. Unscrew the gearshift knob from the gear lever. 3. Gently prise the retainer lugs of the RH top side finisher panel from the console. For additional information, refer to Section 501-12. 4. Repeat for the LH top side finisher panel. 5. Gently prise the retainer lugs of the consoles top prindle surround panel from the console. Lift vertically away from the gearshift lever. For additional information, refer to Section 501-12.
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IN-VEHICLE REPAIR (Continued) 6. Remove the upper bolt and lower nut securing the 5. Remove the centre console. For additional shift lever to the transmission and remove the information, refer to Section 501-12. lever. 6. Remove the gearshift lever boot and retainer assembly by lifting vertically away from the transmission stub lever.
7. Inspect the Gearshift lever assembly for wear or damage. To install, reverse the removal procedure with attention to the following 7. Clean and inspect the boots for wear or damage. instructions. To install, reverse the removal procedure. 8. Position the shift lever on the left hand side of the NOTE: All hardware must be correctly installed transmission lever, install and torque the nut & and torqued to specification. bolt to specification. 9. Apply locktite to the thread on the shift lever. Screw the knob onto the shift lever until it starts to tighten, continue tightening until the graphics on the knob are correctly aligned. NOTE: All hardware must be correctly installed and torqued to specification.
Gearshift Boot and Retainer Assembly Removal and Installation 1. Raise and support the vehicle. For additional information, refer to Section 100-02 for hoisting the vehicle. 2. Remove the four nuts securing the gearshift lever boot and retainer assembly to the floorpan.
3. Lower the vehicle. 4. Remove the gearshift lever as Gearshift Lever removal and installation section.
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REMOVAL
Transmission
7. Disconnect the reversing lamp switch electrical connector. Disconnect the wiring harness from the transmission.
Removal 1. Remove gearshift lever and boot as described earlier in this section. 2. With the vehicle in NEUTRAL, raise and support the vehicle. For additional information, refer to Section 100-02. 3. Remove the dual converter H-pipe. For additional information, refer to Section 309-00. 4. Mark the driveshaft so that it may be installed in the same relative position. Disconnect the shaft at the centre bearing mount, by detaching the centre bearing bracket from the centre bearing carrier (cross member) and detach the rear CV joint from the diff pinion companion flange, by undoing the bolts. Slide the driveshaft backwards, until the slip yoke slides off the output 8. Remove the starter motor. For additional information, refer to Section 303-06. shaft. Install a dust cover or extension housing seal replacer into the extension housing to 9. Remove the bolts. prevent lubricant leakage. WARNING: Failure to match marks when re assembling the driveshaft may induce driveline vibration. NOTE: Before disassembly, mark the matching points on the slip yoke and transmission output shaft. Mark the mating points on the CV flange, companion flange, nut and balance nut (if fitted). Re-assemble with matching points matched ± 1 spline, and all mating hardware in original hole.
10. Remove the starter solenoid nuts and position the wires aside.
5. Bleed the concentric clave cylinder (CSC) according to the procedure set out in section 308-01. 6. Disconnect the CSC hydraulic clutch line from wall. 11. Remove the starter motor. 12. Disconnect the wiring harness from the transmission. 13. If transmission disassembly is necessary, drain the transmission fluid.
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REMOVAL (Continued) 14. Position a transmission jack and support the transmission.
15. Remove the bolts and the transmission crossmember.
16. Lower the transmission jack until the rear of the engine rests again the bulk head. NOTE: The engine must be tilted down at the transmission and before removing the flywheel housing-to-engine bolts. Raise the vehicle’s bonnet before tilting the engine or else the bonnet may be damaged. The engine can be tilted by either: 1. jacking up the front end or 2. using a harness to pull down the rear of the motor.
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17. Remove the bolts.
18. Lower the transmission and remove the five bolts.
19. Move the transmission rearward until the input shaft clears the pressure plate housing, then lower the jack and remove the transmission. WARNING: Do not seperate transmission from vehicle engine by removing the 4 transmission case bolts. NOTE: Removal of transmission from vehicle is easier if the front of the engine is jacked up carefully to tilt the transmission down at the rear.
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DISASSEMBLY 3. Attach the transmission to the special tool.
Transmission Special Tool(s) Remover, Mainshaft Bearing 308-058 (T77J-7025-H)
Screw, Bearing Removal tube 308-092 (T84T-7025-B)
Holding Fixture, Transmission 307-003 (T57L-500-B)
Remover, Bushing 307-001 (TOOL-1175-AC)
Remover/Installer, Bearing Tube 308-024 (T75L-7025-B)
4. Remove the case plug, then rotate the transmission to a horizontal position. NOTE: Position a drain pan under the transmission. 5. Using the special tools, remove the extension housing fluid seal.
Disassembly NOTE: During disassembly, if any roll pins, retaining rings or bearings are removed, install new components. Install bearings and bearing cups as a set. 1. Remove the clutch release hub and bearing and the clutch release lever. For additional information, refer to Section 308-01. 2. Clean the transmission exterior with solvent and dry with compressed air. During disassembly, clean all components with solvent and dry with compressed air. WARNING: Make sure protective eye wear is in place.
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DISASSEMBLY (Continued) 6. Remove the bolts and the gearshift lever. NOTE: Rotate the transmission to a vertical position.
9. Using a 3.9 mm punch and a hammer, drive the split pin downward.
NOTE: Position the gearshift lever in NEUTRAL.
10. Remove the 12 bolts. 7. Inspect the gearshift offset lever insert and O-ring for wear or damage. Install a new insert as necessary.
8. Remove the bolts and the shift spring and plate. NOTE: If necessary, remove the spring and plate for disassembly.
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11. Using a flat-blade screwdriver, separate the extension housing, then remove the gearshift offset lever from the transmission case. Remove and discard the split pin from the gearshift offset lever during removal.
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DISASSEMBLY (Continued) 12. Remove the fifth/reverse gear lockout bolt.
13. Remove the fifth/reverse gear lockout.
15. Remove the OSS sensor tone wheel retaining ring if present.
16. Using the special tools, remove the OSS sensor tone wheel if present.
14. Remove the shipping seal.
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DISASSEMBLY (Continued) 17. Remove the OSS sensor tone wheel check ball.
18. Remove and discard the fifth gear synchronizer retaining ring.
19. Using a 3.9 mm punch and a hammer, remove and discard the pin from the fifth gear shift fork.
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20. Remove the fifth gear shift fork, synchronizer assembly, synchronizer cone and the fifth gear as an assembly.
21. Remove the fifth gear clutch cone.
22. Remove the fifth gear synchronizer blocking ring. Inspect the blocking ring for wear or damage. Install new blocking rings as necessary.
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DISASSEMBLY (Continued) 23. Remove the fifth gear synchronizer sleeve from the synchronizer hub.
26. Remove the check ball.
24. Remove the synchronizer inserts and the springs.
27. Using a 3.9 mm punch and a hammer, drive out the split pin, then remove the third/fourth shift finger. Discard the split pin.
25. Remove the needle bearings and the thrust washer. The fifth gear needle bearing is three separate pieces: bearing, spacer, bearing. Inspect the needle bearing for wear or damage. Install new bearings as necessary.
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28. Using a 3.9 mm punch and a hammer, drive out the split pin, then remove the first/second shift finger. Discard the split pin.
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DISASSEMBLY (Continued) 29. Remove the main shift rail and the plastic spacer.
32. Remove the three detent plugs, springs and the detents.
30. Remove the bolts and the shift interlock plate. CAUTION: Do not remove all the bolts while in the horizontal position. 33. Remove the bolts. Rotate the transmission to a horizontal position. Remove 12 bolts, leaving two opposing bolts in. Rotate the transmission to a vertical position, then remove the remaining two bolts.
31. Using a magnet, remove the interlock pins. One lock pin in the center rail, two between the rails.
34. Carefully pry the clutch housing from the transmission main case.
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DISASSEMBLY (Continued) 35. Remove the transmission main case from the clutch housing.
36. Lift the mainshaft 13 mm upward, tilt the countershaft outward and remove the countershaft.
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37. Remove the mainshaft and shift assembly.
38. Remove the input shaft. For input shaft disassembly, refer to Input Shaft and Bearing in this section.
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DISASSEMBLY (Continued) 39. Remove the shift rails and shift forks from the main shaft. For gearshift rail and fork disassembly, refer to Gearshift Rail and Fork in this section.
40. Remove the reverse idler shaft bolt. Remove and discard the seal.
43. Remove the reverse idler gear bearing. The reverse idler gear is three separate pieces: bearing, spacer, bearing. Inspect the bearing for wear or damage. Install new bearings as necessary.
44. Disassemble the clutch housing. 1. Remove the countershaft bearing cup and shim. 2. Remove the input shaft bearing cup and shim. 3. Remove the input shaft seal. Carefully pry out from the inside of the case.
41. Remove the reverse idler gear assembly. 42. Remove the reverse idler gear from the shaft. Inspect the gear for wear or damage. Install a new gear as necessary.
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DISASSEMBLY (Continued) 45. Remove the rear countershaft bearing.
46. Remove the rear countershaft bearing cup and the rear output shaft bearing cup.
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DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES
Input Shaft and Bearing Special Tool(s) Remover, Driver Pinion Bearing Cone 205-D002 (D79L-4621-A) or equivalent
Installer, Drive Pinion Bearing Cone 205-011 (T57L-4621-B)
Remover/Installer, Bearing Tube
Disassembly 1. Disassemble the input shaft. 1. Remove the third/fourth synchronizer blocking ring. 2. Remove the input shaft thrust washer. 3. Remove the input shaft thrust bearing. 4. Remove the input shaft pocket bearing. Inspect all components for wear or damage. Install new components as necessary.
Item 1 2 3 4 5
Description Synchronizer blocking ring Thrust washer Thrust bearing Thrust washer Pocket bearing
2. Using the special tool and a press, remove the input shaft front bearing assembly. Discard the bearing.
3. Inspect the input shaft and bearings for wear or damage. Install new components as necessary.
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DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES (Continued) 4. Using the special tools and a press, install the new input shaft front bearing.
CAUTION: Hand tighten the special tool to prevent gear damage. CAUTION: Support the output shaft while using the press to prevent damage to the shaft or gears. 2. Using the special tool, press fifth gear, the spacer, the output shaft bearing and reverse gear from the output shaft. Discard the output shaft bearing.
5. Install the input shaft pocket bearing, the washer, input shaft bearing and the third/fourth synchronizer blocking ring. Lubricate the bearing and bearing race with petroleum jelly.
Output Shaft Special Tool(s) Remover, Drive Pinion Bearing Cone 205-D002 (D79L-4621-A) or equivalent
3. Remove reverse gear needle bearing. Inspect the needle bearing for wear or damage. Install a new needle bearing as necessary.
Installer, Drive Pinion Bearing Cone 205-011 (T57L-4621-B)
Disassembly 1. Remove the retaining ring above fifth gear.
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DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES (Continued) 4. Remove the check ball and the blocking ring. Inspect the blocking ring for wear or damage. Install new blocking rings as necessary.
6. Remove the first gear needle bearing. Inspect the needle bearing for wear or damage. Install a new needle bearing as necessary.
7. Remove the first gear synchronizer inner cone, the first gear synchronizer outer cone and the first gear synchronizer blocking ring. Inspect all components for wear or damage. Install new components as necessary.
5. Using the special tools, press the bearing spacer, the reverse gear synchronizer cone and first gear from the output shaft. NOTE: Install the special tool with the flat side facing first gear.
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DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES (Continued) 8. Remove and discard the retaining ring. NOTE: Reposition the output shaft on the press with the input shaft end facing upward.
11. Remove the third gear. Inspect the gear for wear or damage. Install a new gear as necessary.
9. Remove the third/fourth synchronizer hub.
12. Remove the third gear needle bearing. Inspect the needle bearing for wear or damage. Install a new needle bearing as necessary.
10. Remove the third/fourth blocking ring. NOTE: Install the special tool behind second gear with the flat side of the tool facing second gear. 13. Using the special tool, remove the spacer, second gear thrust washer and second gear. Inspect the gear for wear or damage. Install a new gear as necessary.
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DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES (Continued) 14. Remove the check ball and second gear needle bearing. Inspect the needle bearing for wear or damage. Install a new needle bearing as necessary.
15. Remove the second gear synchronizer inner cone, second gear synchronizer outer cone and the second gear synchronizer blocking ring. Inspect all components for wear or damage. Install new components as necessary.
Assembly 1. Carry out the following before reassembling: Inspect the gears for broken or cracked teeth. Check for unusual wear patterns. Inspect the thrust washers for face wear, cracks, scoring and for signs of heat damage. Inspect the bearings, bearing cups and the synchronizers for wear or damage. Inspect the output shaft for scoring or worn or damaged splines. Install new components as necessary. 2. Lubricate all components with the recommended transmission fluid when reassembling. NOTE: Position the output shaft with the output end facing upward. NOTE: Install the synchronizer assembly with the deeper center flange of the synchronizer hub facing toward the rear of the output shaft. 3. Install the first/second synchronizer assembly on the output shaft, then install a new retaining ring. It may be necessary to press the hub into position on the shaft.
16. Remove the snap ring, then using the special tool, press off the first/second gear synchronizer.
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DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES (Continued) 4. Install the first gear synchronizer blocking ring. Align the blocking ring tabs with the synchronizer assembly.
5. Install the outer first gear synchronizer cone.
7. Install the first gear needle bearing. Apply petroleum jelly to the bearing.
8. Install first gear. Rotate the gear to align the gear slots with the inner cone tabs.
6. Install the inner first gear synchronizer cone. Rotate the inner cone till it is seated.
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DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES (Continued) 9. Install the reverse synchronizer cone.
11. Using the special tools, install the reverse gear bearing spacer.
10. Install the reverse gear blocking ring.
12. Install reverse gear needle bearing. Apply petroleum jelly to the bearing.
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DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES (Continued) 13. Install reverse gear. 15. Install the thrust washer. Be sure to align the slot in the washer with the check ball. Rotate the gear to align the gear slots with the inner cone tabs.
16. Install a new rear output shaft bearing, then fifth gear. Using the special tool, press both the bearing and gear into place.
14. Install the check ball. Use petroleum jelly to hold the check ball in place.
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17. Reposition the output shaft with the input end facing upward. 18. Install the second gear synchronizer blocking ring. Rotate the blocking ring until seated.
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DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES (Continued) 19. Install the second gear synchronizer outer cone and the second gear synchronizer inner cone.
21. Install second gear. Rotate the gear to align the gear slots with the inner cone tabs.
20. Install the second gear bearing. Apply petroleum jelly to the bearing.
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DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES (Continued) 22. Install the check ball. Use petroleum jelly to hold the check ball in place.
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23. Install the thrust washer. Be sure to align the slot in the washer with the check ball.
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DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES (Continued) 24. Press the bearing spacer onto the output shaft.
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25. Install the third gear bearing. Apply petroleum jelly to the bearing.
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DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES (Continued) 26. Install third gear.
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27. Install the third gear synchronizer blocking ring.
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DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES (Continued) 28. Install the third/fourth gear synchronizer body. Install the synchronizer body with the raised center facing downward. Rotate the blocking ring until seated.
Countershaft Bearing Special Tool(s) Remover, Drive Pinion Bearing Cone 205-D002 (D79L-4621-A) or equivalent
Installer, Drive Pinion Bearing Cone 205-011 (T57L-4621-B)
Disassembly 1. Cut the outer cage, then remove the outer cage and rollers.
29. Install a new retaining ring. 2. Using the special tool and a press, remove the inner bearing.
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DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES (Continued) 3. Using the special tools, install the new countershaft bearing.
Gearshift Rail Bushing Special Tool(s) Universal Puller Set 303-DS005 (D80L-100-A) or equivalent
Installer, Shift Rail Bushing 308-244 (T96P-7025-F)
Synchronizers Disassembly NOTE: This procedure applies to all synchronizer assemblies.
Slide Hammer 100-001 (T50T-100-A)
1. Scribe an alignment mark on the sliding sleeve and the hub for assembly reference. 2. Remove the sliding sleeve, then remove the synchronizer struts and the springs. Disassembly 1. Using the special tools, remove the gearshift rail bearing from the transmission case. Discard the bearing.
3. Install the synchronizer struts and the springs. 4. Install the sliding sleeve. CAUTION: Match the alignment marks made during disassembly. The sleeve and the hub have an extremely close fit. Hold the sleeve and hub square to prevent jamming. Do not force the sleeve onto the hub.
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DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES (Continued) 2. Using the special tool, install the main shift rail bearing.
3. Position the gearshift fork on the shift rail. Align the split pin hole and install a new split pin. CAUTION: Support the shift rail to prevent damage to the parts.
Gearshift Rail and Fork Disassembly 1. Using a 5/32-inch drift and a hammer, remove and discard the split pin. Slide the shift fork from the shift rail.
4. Install the gear shift fork inserts.
2. Remove the gearshift fork inserts.
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ASSEMBLY NOTE: If a new rear output shaft bearing was installed or a new rear countershaft bearing is being used, install new bearing cups.
Transmission Special Tool(s) Dial Indicator Gauge with Holding Fixture 100-002 (TOOL-4201-C) or equivalent
3. Install the rear countershaft bearing cup and the rear output shaft bearing cup. Lubricate the bearing cups and the shift rail bearing with petroleum jelly.
Holding Fixture, Transmission 307-003 (T57L-500-B)
Remover/Installer, Bearing Tube 308-024 (T75L-7025-B) 4. Install the rear countershaft bearing.
Replacer/Adapter 308-239 (T96P-7025-A)
Installer, Transmission Extension Housing Oil Seal 5. Install the reverse idler gear bearings and spacer on the shaft. 1. Lubricate all components with transmission fluid during assembly. 2. Attach the clutch housing to the special tool.
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Manual Transmission — TR3650
308-03b-40
ASSEMBLY (Continued) 6. Install the reverse idler gear on the shaft.
9. Install the front input shaft bearing cup and the front countershaft bearing cup. Do not install the shims at this time. Install the transmission main case.
7. Install the reverse idler gear into the case. 10. Install the input shaft.
8. Install a new seal on the reverse idler bolt, then install the bolt in the transmission case. 11. Install the shift rails and shift forks on the mainshaft.
NOTE: If a new front input shaft bearing or front countershaft bearing was installed, install new bearing cups.
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Manual Transmission — TR3650
308-03b-41
ASSEMBLY (Continued) 12. Install the mainshaft onto the clutch housing. The notches on the shift rail should be pointing upward. Align the shift rails in the bores.
14. Install the case with two opposing bolts.
15. Using a dial indicator gauge, measure the input shaft end play by applying an upward load on the output shaft. Record the measurement. NOTE: Rotate the transmission so that the input shaft is pointing upward. NOTE: Rotate the input shaft to seat the bearings.
13. Install the countershaft. Lift the mainshaft upward, tilt the countershaft and install.
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Manual Transmission — TR3650
308-03b-42
ASSEMBLY (Continued) 16. Rotate the transmission so that the input shaft is pointing downward.
18. Remove the two bolts and lift the transmission main case off.
17. Using the special tools, measure the countershaft gear end play by pulling upward on the countershaft. Record the measurement. NOTE: Rotate the countershaft to seat the bearings.
19. Remove the countershaft.
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Manual Transmission — TR3650
308-03b-43
ASSEMBLY (Continued) 20. Remove the mainshaft.
22. Remove the front input shaft bearing cup and the front countershaft bearing cup.
23. Using the special tools, install the new input shaft seal.
21. Remove the input shaft. 24. Using the recorded end play measurements, select and install the appropriate shims to achieve the correct end play.
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Manual Transmission — TR3650
308-03b-44
ASSEMBLY (Continued) 25. Install the front input shaft bearing cup and the front countershaft bearing cup.
27. Install the mainshaft.
26. Install the input shaft.
28. Install the countershaft.
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Manual Transmission — TR3650
308-03b-45
ASSEMBLY (Continued) 29. Clean the mating surfaces of the transmission main case and the clutch housing. Apply a bead of silicone rubber to the sealing surface on the clutch housing then install the transmission main case. Tighten the bolts in a star pattern.
31. Install the lock plate.
32. Install the detents and the detent springs.
30. Install the lock pins.
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Manual Transmission — TR3650
308-03b-46
ASSEMBLY (Continued) 33. Install the detent plugs.
36. Install the synchronizer springs and inserts.
34. Install the check ball. Use petroleum jelly to hold the check ball in place.
37. Install the sliding sleeve on the synchronizer hub. Align the pockets in the blocking ring with the struts in the synchronizer. The sliding sleeve is not reversible. Install the sleeve with the bevel edge away from the gear.
35. Install the thrust washer and the three-piece fifth gear needle bearing. 38. Install fifth gear blocking ring.
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Manual Transmission — TR3650
308-03b-47
ASSEMBLY (Continued) 39. Install the fifth gear synchronizer cone.
42. Install a new snap ring.
40. Install the fifth gear shift fork, the synchronizer 43. Install the third/fourth shift finger, then install a assembly, the synchronizer cone and fifth gear as new split pin. an assembly. Install the split pin until it is flush with the shift finger.
41. Install a new split pin. Install the pin until it is flush with the fork.
G34245 en
44. Install the control rail and the plastic spacer, then install the first/second shift finger. Install a new split pin. Install the split pin until it is flush with the shift finger.
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308-03b-48
Manual Transmission — TR3650
308-03b-48
ASSEMBLY (Continued) 45. Install the OSS sensor tone wheel check ball. Use petroleum jelly to hold the check ball in place.
48. Install the fifth/reverse gear lockout.
49. Install the bolt. 46. Place the OSS sensor tone wheel on the output shaft, aligning the slot in the OSS wheel with the check ball. Using the special tool, install the OSS sensor tone wheel.
50. Clean the mating surfaces of the transmission main case and the extension housing. Apply a bead of silicone rubber to the sealing surface of the transmission case. 47. Install a new OSS sensor tone wheel retaining ring.
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Manual Transmission — TR3650
308-03b-49
ASSEMBLY (Continued) 51. Install the extension housing and at the same time 55. Using the special tool, install a new extension install the gear shift off-set lever. housing seal. Lubricate the seal with transmission fluid.
52. Install the shift spring and bracket.
53. Install a new split pin in the gear shift off-set lever. 56. Install the shipping seal. The split pin should be flush in the gear shift off-set lever. 54. Seat the extension housing and tighten the bolts to specification. Fill the gear shift off-set lever with petroleum jelly.
57. Rotate the transmission to a horizontal position. 58. Clean the mating surfaces of the shift cover opening surface and the shift cover. Apply a bead of silicone rubber to the shift cover opening surface.
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Manual Transmission — TR3650
308-03b-50
ASSEMBLY (Continued) 59. Install the gear shift lever.
60. Install the clutch release hub and bearing and the clutch release lever. For additional information, refer to Section 308-01. NOTE: Before installing the transmission, the ball stud, the clutch release lever and the input shaft guide tube must be cleaned and lubricated. 61. Fill the transmission with transmission fluid to the specified level. Transmission capacity is 3.8 liters (8.0 pints).
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01/2003 2003.0 BA Falcon
308-03b-51
Manual Transmission — TR3650
308-03b-51
INSTALLATION
Transmission NOTE: Before installing the transmission, the ball stud, clutch release lever and the input shaft must be cleaned and lubricated. Use Motorcraft Premium Long-Life Grease XG-1-C or XG-1-K or equivalent meeting Ford specification ESA-M1C75-B. Installation 1. To install, reverse the removal procedure. For additional information, refer to Transmission in this section. Check, and as necessary, fill the transmission with transmission fluid. The total fill capacity is 3.8L (8.0 pt). 2. Apply sealant to the fill plug threads and install the fill plug. Use pipe sealant with Teflon®.
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01/2003 2003.0 BA Falcon
308-06-1
Manual Transmission External Controls
308-06-1
SECTION : 308-06 Manual Transmission External Controls VEHICLE APPLICATION : 2003.0 BA Falcon CONTENTS
PAGE
SPECIFICATIONS Specifications ........................................................................................................................308-06-2 DIAGNOSIS AND TESTING External Controls ..................................................................................................................308-06-3 Inspection and Verification ...................................................................................................308-06-3 Symptom Chart ....................................................................................................................308-06-3 Pinpoint Tests ......................................................................................................................308-06-3 REMOVAL AND INSTALLATION Gearshift Lever .....................................................................................................................308-06-5 Gearshift Boot and Retainer Assembly .................................................................................308-06-5
01/2003 2003.0 BA Falcon
308-06-2
Manual Transmission External Controls
308-06-2
SPECIFICATIONS Torque Specifications Description Gearshift lever retaining nut Gearshift lever retaining bolt Gearshift lever boot and retainer assembly retainer nut
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Nm 8.9 - 12.1 29.5 -40.3 8.9 - 12.1
01/2003 2003.0 BA Falcon
308-06-3
Manual Transmission External Controls
308-06-3
DIAGNOSIS AND TESTING
External Controls Inspection and Verification 1. Verify the customer concern. 2. Visually inspect for obvious signs of mechanical damage.
3. If an obvious cause for an observed or reported concern is found, correct the cause (if possible) before proceeding to the next step. 4. If the concern is not visually evident, verify the symptom and refer to the Symptom Chart.
Symptom Chart Condition
Source
External controls operate with excessive freeplay.
External controls do not operate freely.
External controls causes excessive cabin noise/odor.
Action
Gearshift lever damaged.
Go to PinPoint Test A.
Transmissions gearshift selector lever damaged.
Go to PinPoint Test B.
Gearshift lever fouled.
Go to PinPoint Test A.
Transmissions gearshift selector lever damaged
Go to PinPoint Test B.
Gearshift boot and retainer assembly damaged.
Go to PinPoint Test A.
Pinpoint Tests PINPOINT TEST A : ABNORMAL EFFORTS OR NOISE/ODOR Test Step A1
Result / Action to Take
CHECK THE GEARSHIFT LEVER Detach the gearshift lever from the transmission gearshift selector lever. Is the gearshift levers isolation rubber damaged?
Yes
Install a new gearshift lever. Refer to Gearshift Lever in this section
No
Go to B1
A2
CHECK FOULING OF THE GEARSHIFT LEVER Remove the gearshift lever knob/boot and insulation pad. Is the gearshift levers fouled through its shift gate?
Yes
Remove obstruction.
No
Go to B2
A3
CHECK GEARSHIFT LEVER LEAKS CABIN NOISE Remove the gearshift lever boot and retainer assembly. Is the gearshift levers boot damaged?
Yes
Install a new gearshift lever boot and retainer assembly.
No
Check boot and retainer assemblies correctly installed and hardware torqued to specification.
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Manual Transmission External Controls
308-06-4
DIAGNOSIS AND TESTING (Continued) PINPOINT TEST B : ABNORMAL TRANSMISSION GEARSHIFT SELECTION Test Step B1
Result / Action to Take
CHECK THE TRANSMISSIONS GEARSHIFT SELECTOR LEVER Detach the gearshift lever from the transmission gearshift selector lever. Is the gearshift selector lever damaged?
Yes
Install a new gearshift selector lever. Refer to Manual Transmission Section.
No
Check for obstruction.
B2
CHECK THE TRANSMISSIONS GEARSHIFT SELECTOR LEVER SHIFT GATE Remove the gearshift lever knob/boot and insulation pad. Is the gearshift gate difficult to select or binds?
Yes
Service the Transmission as internal shift mechanism damaged. Refer to Manual Transmission Section 308-00.
No
Check for obstruction.
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01/2003 2003.0 BA Falcon
308-06-5
Manual Transmission External Controls
308-06-5
REMOVAL AND INSTALLATION
Gearshift Lever
2. Remove the four nuts securing the gearshift lever boot and retainer assembly to the floorpan.
Removal and Installation 1. Place the Gearshift lever in the Neutral position gate. 2. Unscrew the gearshift knob from the gear lever. 3. Gently prise the retainer lugs of the RH top side finisher panel from the console. For additional information, refer to Section 501-12. 4. Repeat for the LH top side finisher panel. 5. Gently prise the retainer lugs of the consoles top prindle surround panel from the console. Lift vertically away from the gearshift lever. For additional information, refer to Section 501-12. 6. Remove the upper bolt and lower nut securing the shift lever to the transmission and remove the 3. Lower the vehicle. lever. 4. Remove the gearshift lever as Gearshift Lever removal and installation section. 5. Remove the centre console. For additional information, refer to Section 501-12. 6. Remove the gearshift lever boot and retainer assembly by lifting vertically away from the transmission stub lever.
7. Inspect the Gearshift lever assembly for wear or damage. To install, reverse the removal procedure with attention to the following instructions. 8. Position the shift lever on the left hand side of the transmission lever, install and torque the nut & bolt to specification. 7. Clean and inspect the boots for wear or damage. 9. Screw the knob onto the shift lever until it starts to To install, reverse the removal procedure. tighten, continue tightening until the graphics on NOTE: All hardware must be correctly installed the knob are correctly aligned. and torqued to specification. NOTE: All hardware must be correctly installed and torqued to specification.
Gearshift Boot and Retainer Assembly Removal and Installation 1. Raise and support the vehicle. For additional information, refer to Section 100-02 for hoisting the vehicle.
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01/2003 2003.0 BA Falcon
309-00-1
Exhaust System
309-00-1
SECTION : 309-00 Exhaust System VEHICLE APPLICATION : 2003.0 BA Falcon CONTENTS
PAGE
SPECIFICATIONS Specifications ........................................................................................................................309-00-2 DESCRIPTION AND OPERATION Exhaust System ....................................................................................................................309-00-3 DIAGNOSIS AND TESTING Exhaust System ....................................................................................................................309-00-4 Inspection and Verification ...................................................................................................309-00-4 Pinpoint Tests ......................................................................................................................309-00-4 GENERAL PROCEDURES Exhaust System Alignment ...................................................................................................309-00-5 REMOVAL AND INSTALLATION All Rear Muffler Assemblies ..................................................................................................309-00-6 All Intermediate Muffler Assemblies .....................................................................................309-00-6 6 Cylinder Catalyst Assembly ...............................................................................................309-00-6 8 Cylinder Catalyst Assemblies (LHS & RHS) ......................................................................309-00-6 8 Cylinder Y — Pipe Assemblies ..........................................................................................309-00-7 System Diagrams ..................................................................................................................309-00-7
01/2003 2003.0 BA Falcon
309-00-2
Exhaust System
309-00-2
SPECIFICATIONS 6 Cylinder Torque Specifications Description Catalyst assembly inlet pipe to manifold nuts. Catalyst assembly outlet pipe to intermediate muffler assembly inlet pipe bolts. Intermediate muffler outlet pipe to rear muffler inlet pipe nuts. 8 Cylinder Torque Specifications Description Catalyst assembly inlet pipes to manifold nuts (LHS & RHS). Catalyst assembly outlet pipes to Y-pipe assembly inlet pipe nuts. Y-pipe assembly outlet pipe to intermediate muffler assembly inlet pipe bolts. Intermediate muffler outlet pipe to rear muffler inlet pipe nuts. HEGO sensor to catalyst assembly inlet pipe (LHS only). XR8 Y-pipe band clamp
G86726 en
Nm 25 Nm 35 Nm 35 Nm
Nm 25 Nm 35 Nm 35 Nm 35 Nm 47.5 Nm 17 (22Max)
01/2003 2003.0 BA Falcon
309-00-3
Exhaust System
309-00-3
DESCRIPTION AND OPERATION
Exhaust System The exhaust system provides an exit for exhaust gases and reduces engine noise by passing exhaust gases through the three way catalytic converter (TWC), an intermediate muffler forward of the rear axle and a rear muffler. Rubber exhaust hanger insulators attach the exhaust system to the hanger brackets. CAUTION: Under no circumstances should non "Original Equipment" exhausts be fitted. Three Way Catalytic Converter (TWC) The three way catalytic converter (TWC) plays a major role in the emission control system. The TWC operates as a gas reactor. Its catalytic function is to speed the heat-producing chemical reaction of components in the exhaust gases in order to reduce air pollutants.
The TWC is designed to provide a long life. No maintenance is necessary for the TWC. Avoid the following conditions: Driving with a misfiring engine Continuously running the engine with a misfiring spark plug. Parking or stopping the vehicle over combustible material such as dry grass. The material can be ignited by the high temperatures of the TWC and the muffler. Heat Shields Exhaust system heat shields attached to the underbody protect the vehicle from exhaust system heat and should be inspected at regular intervals to ensure they are not dented or out of position. If a shield is damaged or shows evidence of deterioration, it should be replaced. The shields for the intermediate muffler, over-axle pipe, and rear muffler are installed separately.
Precautions WARNING: The normal operating temperature of the exhaust system is very high. Never work around or attempt to repair any part of the exhaust system until it has cooled. Use special care when working around the TWC. The TWC heats to a high temperature after only a short period of engine operation. Failure to follow these instructions may result in personal injury. WARNING: Exhaust gases contain carbon monoxide which can be harmful to health and are potentially lethal. Exhaust system leaks should be repaired immediately. Never operate the engine in enclosed areas. Failure to follow these instructions may result in personal injury. CAUTION: Do not use leaded fuel in a vehicle equipped with a TWC. CAUTION: In a vehicle that is continually misfueled, the lead in the fuel will be deposited in the TWC and completely blanket the catalyst. Lead reacts with platinum to ’’poison’’ the catalyst. Continuous use of leaded fuel can destroy the catalyst and render the TWC useless. CAUTION: The addition of lead to the TWC can also solidify the catalyst, causing excessive back pressure in the exhaust system and possibly causing engine damage. CAUTION: Extremely high temperatures of 1,100°C (2,012°F) or above due to misfiring or an over-rich fuel/air mixture will cause the ceramic base to sinter or burn, destroying the TWC.
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01/2003 2003.0 BA Falcon
309-00-4
Exhaust System
309-00-4
DIAGNOSIS AND TESTING
Exhaust System This section covers general exhaust system diagnosis, tests, adjustment and repair procedures. For exhaust system component removal, disassembly, assembly, installation, clearances, torque requirements, and bracket locations refer to the illustrations in Removal and installation section.
Inspection and Verification Inspect the inlet pipe, outlet pipe, and muffler for cracked joints, broken welds and corrosion damage (holes) that would result in a leaking exhaust system. Inspect the clamps, brackets and insulators for cracks and stripped or badly corroded bolt threads.
Pinpoint Tests Engine performance An exhaust system performance complaint, such as excessive back pressure is usually noticeable by its effect on engine performance. For diagnosis of exhaust system problems that affect engine performances, refer to section Section 303-00, Section 303-01A, Section 303-01B, Section 303-01C(engine diagnosis and testing).
Leaks External leaks in the exhaust system are often accompanied by noises or exhaust gas emitted from under the vehicle. A visual inspection of the exhaust system usually will show the location of the leak. Look for holes, ruptured joints and corroded areas in the muffler, inlet pipe and outlet pipe. Examine joints and connections for deposits that would be caused by exhaust gas leakage.
Noise/Vibration A misaligned exhaust system is usually indicated by vibration, grounding, rattling, or binding of the components. Often the associated noise is hard to distinguish from other chassis noises. Use a rubber mallet to lightly tap on exhaust components and heat shields to identify noise and vibration areas. It is important that exhaust clearances and setting procedures as shown in illustrations in Removal and installation section be adhered to whenever repairs involving the exhaust system are carried out. Inspect exhaust system welds, insulators and insulator brackets for cracks or breaks. Shake the exhaust system to identify any exhaust-to-body/chassis contact. Ensure that the insulators are in a neutral position when the exhaust system is hot, before replacing components in an endeavor to correct a noise, vibration or harshness problem.
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309-00-5
Exhaust System
309-00-5
GENERAL PROCEDURES
Exhaust System Alignment NOTE: The exhaust system must be free of leaks, binds, grounding and excessive vibration. Exhaust system vibration, grounding or binds are usually caused by: loose, broken insulators or brackets or improperly connected pipes. Any of the aforementioned conditions may cause changes to clearances of the exhaust system components. If any of these conditions exist, the exhaust system components must be checked, adjusted or replaced to make certain the specified clearances (refer to the illustrations in Removal and installation section) are maintained. Perform the following procedures to adjust the exhaust system components: 1. Loosen the securing hardware, and the pipe support brackets. 2. Progressively align the exhaust system, using the relative lateral position of the hanger brackets (exhaust/body mounted) and rubber isolators as a guide. NOTE: Exhaust hangers are designed to be under a small amount of tension when the exhaust system is cold. This allows for thermal expansion of the system during normal operation. 3. Tighten all attachments. NOTE: Tighten the exhaust manifold nuts evenly and alternately. 4. Start the engine and check the exhaust system for leaks. NOTE: Mufflers, inlet pipes and outlet pipes, gaskets, brackets, and insulators should be replaced if they are defective or become badly corroded. Do not attempt to repair these parts.
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01/2003 2003.0 BA Falcon
309-00-6
Exhaust System
309-00-6
REMOVAL AND INSTALLATION
All Rear Muffler Assemblies
6 Cylinder Catalyst Assembly
Removal and Installation
Removal and Installation 1. Remove nuts connecting catalyst assembly to WARNING: Care must be taken so as to avoid manifold. damage to exhaust system & fuel tank heat NOTE: Manifold studs and mating exhaust nuts shields. If shields are damaged or substantially are one time use parts only and must be distorted they should be replaced, and the fuel replaced. tank inspected for damage. 2. Remove bolts connecting intermediate muffler to 1. Remove the nuts connecting the intermediate catalyst assembly. Discard the gasket. muffler assembly to the rear muffler assembly. Discard the gasket. NOTE: The bolts connecting the intermediate muffler to the catalyst assembly are of a 2. Disconnect rear muffler assembly from the self-threading type that have been used to tap hangers at the front and rear of the muffler and thread directly into the catalyst assembly outlet remove by pushing muffler rearward and gently pipe flange. Conventional class 10.0 bolts with moving ’over-axle pipe’ through cavity above IRS similar geometry can be used in place of these (sedan only). self-threading bolts. 3. Installation is the reverse of the removal procedure. 3. Disconnect the catalyst assembly from the hanger on the outlet pipe and remove. NOTE: Install new gaskets at each point. 4. Installation is the reverse of the removal NOTE: Assembly is the reverse of the removal procedure. procedure. To ease reattachment of rubber NOTE: Care must be taken when attaching a isolators to hanger brackets, a mild detergent catalyst assembly to a manifold such that it is solution can be applied to the bracket. correctly aligned. To achieve this, firstly do up the NOTE: Care must be taken when attaching a nuts by hand as far as possible (using a socket catalyst assembly to a manifold such that it is with extension), and then torque the nuts up in correctly aligned. To achieve this, firstly do up the steps alternating between the two until the nuts by hand as far as possible (using a socket nominal torque is achieved. with extension), and then torque the nuts up in steps alternating between the two until the 8 Cylinder Catalyst Assemblies (LHS & nominal torque is achieved. NOTE: Upon conclusion of assembly, system should be checked for leaks and correct alignment, refer Sections on Diagnosis and Testing and General Procedures.
All Intermediate Muffler Assemblies
RHS)
Removal and Installation 1. Remove nuts connecting catalyst assembly to manifold. Both sides will require the removal of an additional nut retaining a heat shield. NOTE: Manifold studs and mating exhaust nuts are one time use parts only and must be replaced.
Removal and Installation 1. Remove bolts connecting intermediate muffler to catalyst assembly (6 cylinder) or Y-pipe assembly 2. Remove nuts connecting Y-pipe to catalyst (8 cylinder). Discard the gasket. assembly. Discard the gasket(s). NOTE: The bolts connecting the intermediate 3. Disconnect catalyst assembly from the hanger on muffler to the catalyst/Y-pipe assemblies are of a the outlet pipe and remove. self-threading type that have been used to tap 4. Installation is the reverse of the removal thread directly into the catalyst assembly outlet procedure. pipe flange (6 cylinder) or directly into weld nuts NOTE: Care must be taken when attaching a on the Y-pipe outlet flange (8 cylinder). catalyst assembly to a manifold such that it is Conventional class 10.0 bolts with similar correctly aligned. To achieve this, firstly do up the geometry can be used in place of these nuts by hand as far as possible (using a socket self-threading bolts. with extension), and then torque the nuts up in 2. Remove the nuts connecting the intermediate steps alternating between the two until the muffler assembly to the rear muffler assembly. nominal torque is achieved. Discard the gasket. 3. Disconnect intermediate muffler assembly from the hanger on the outlet pipe and remove. 4. Installation is the reverse of the removal procedure. G56318 en
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309-00-7
Exhaust System
309-00-7
REMOVAL AND INSTALLATION (Continued)
8 Cylinder Y — Pipe Assemblies Removal and Installation 1. Remove nuts connecting Y-pipe to catalyst assembly. Discard the gasket(s), and nuts. 2. Remove bolts connecting intermediate muffler to Y-pipe assembly. Discard the gasket. NOTE: The bolts connecting the intermediate muffler to the catalyst assembly are of a self-threading type that have been used to tap thread directly into weld nuts on the Y-pipe assembly outlet flange. Conventional class 10.0 bolts with similar geometry can be used in place of these self-threading bolts. 3. Remove the Y-pipe assembly. 4. Installation is the reverse of the removal procedure.
System Diagrams Sedan - 6 cylinder (ULP)
Item 1 2 3 4 5
Description M10 Nut assembly Three-way catalytic converter Intermediate muffler assembly Nut Assembly Rear muffler assembly
G56320 en
Item 6 7
Description Rubber exhaust hanger insulators Nut assembly
01/2003 2003.0 BA Falcon
309-00-8
Exhaust System
309-00-8
REMOVAL AND INSTALLATION (Continued) Sedan - 8 cylinder (ULP)
Item 1 2 3 4 5 6 7 8
Description M10 Nut assembly Three-way catalytic converter Two-way adapter Intermediate muffler assembly Nut Assembly Rear muffler assembly Rubber exhaust hanger insulators Nut assembly
G56320 en
01/2003 2003.0 BA Falcon
309-00-9
Exhaust System
309-00-9
REMOVAL AND INSTALLATION (Continued) Sedan - 6 cylinder (SFLPG)
Item 1 2 3 4 5 6 7
Description M10 Nut assembly Three-way catalytic converter Intermediate muffler assembly Nut assembly Rubber exhaust hanger insulators Rear muffler assembly Nut assembly
G56320 en
01/2003 2003.0 BA Falcon
309-00-10
Exhaust System
309-00-10
REMOVAL AND INSTALLATION (Continued) Wagon - 6 cylinder (ULP & SFLPG)
Item 1 2 3 4 5 6
Description M10 Nut assembly Three-way catalytic converter Intermediate muffler assembly Rear muffler assembly Rubber exhaust hanger insulators Nut assembly
G56320 en
01/2003 2003.0 BA Falcon
309-00-11
Exhaust System
309-00-11
REMOVAL AND INSTALLATION (Continued) Ute - 6 cylinder (ULP)
Item 1 2 3 4 5 6
Description M10 Nut assembly Three-way catalytic converter Intermediate muffler assembly Rubber exhaust hanger insulators Rear muffler assembly Nut assembly
G56320 en
01/2003 2003.0 BA Falcon
309-00-12
Exhaust System
309-00-12
REMOVAL AND INSTALLATION (Continued) Ute - 6 cylinder (SFLPG)
Item 1 2 3 4 5 6 7
Description M10 Nut assembly Three-way catalytic converter Intermediate muffler assembly Nut Assembly Rubber exhaust hanger insulators Rear muffler assembly Nut assembly
G56320 en
01/2003 2003.0 BA Falcon
309-00-13
Exhaust System
309-00-13
REMOVAL AND INSTALLATION (Continued) Ute - 8 cylinder (ULP)
Item 1 2 3 4 5 6 7 8
Description M10 Nut assembly Two-way adapter Three-way catalytic converter Intermediate muffler assembly Rubber exhaust hanger insulators Rear muffler assembly Nut Assembly Nut assembly
G56320 en
01/2003 2003.0 BA Falcon
309-00-14
Exhaust System
309-00-14
REMOVAL AND INSTALLATION (Continued) XR6 (ULP)
Item 1 2 3 4 5 6 7
Description M10 Nut assembly Three-way catalytic converter Intermediate muffler assembly Nut Assembly Rear muffler assembly Rubber exhaust hanger insulators Nut assembly
G56320 en
01/2003 2003.0 BA Falcon
309-00-15
Exhaust System
309-00-15
REMOVAL AND INSTALLATION (Continued) XR6 Turbo (ULP)
Item 1 2 3 4 5 6 7
Description M10 Nut assembly Three-way catalytic converter Intermediate muffler assembly Nut Assembly Rear muffler assembly Rubber exhaust hanger insulators Bolts x 3
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01/2003 2003.0 BA Falcon
309-00-16
Exhaust System
309-00-16
REMOVAL AND INSTALLATION (Continued) Ute – XR6 Turbo (ULP)
Item 1 2 3 4 5 6
Description Three way catalytic converter Front muffler assembly Nut assembly Rear muffler assembly Rubber exhaust hanger insulators Bolts x 3
G56320 en
01/2003 2003.0 BA Falcon
309-00-17
Exhaust System
309-00-17
REMOVAL AND INSTALLATION (Continued) XR8 (ULP)
Item 1 2 3 4 5 6 7 8 9 10
Description M10 Nut assembly Three-way catalytic converter XR8 Y Pipe Assembly Intermediate muffler assembly Nut assembly Rear muffler assembly Nut Assembly Nut assembly XR8 Y Pipe Band Clamp Rubber exhaust hanger insulators
G56320 en
01/2003 2003.0 BA Falcon
310-00-1
Fuel System
310-00-1
SECTION : 310-00 Fuel System VEHICLE APPLICATION : 2003.0 BA Falcon CONTENTS
PAGE
SPECIFICATIONS Specifications ........................................................................................................................310-00-2 DESCRIPTION AND OPERATION Fuel System ..........................................................................................................................310-00-3 Electrical Fuel Pump .............................................................................................................310-00-4 Evaporative Emission Control System ..................................................................................310-00-4 Fuel Filters ............................................................................................................................310-00-5 Fuel system shut off switch ..................................................................................................310-00-5 Fuel pressure regulator ........................................................................................................310-00-6 DIAGNOSIS AND TESTING Fuel System ..........................................................................................................................310-00-7 Inspection and Verification ...................................................................................................310-00-7 Symptom Chart ....................................................................................................................310-00-7 Pinpoint Tests ......................................................................................................................310-00-7 GENERAL PROCEDURES Pump Operation Check ..........................................................................................................310-00-9 Pressure Test .........................................................................................................................310-00-9 Fuel Flow (Volume) Test ........................................................................................................310-00-9 Draining Fuel ........................................................................................................................310-00-10 Purge Control Valve Testing ................................................................................................310-00-10 REMOVAL AND INSTALLATION Fuel Tank (Sedan) ...............................................................................................................310-00-11 Fuel Tank (Wagon) ..............................................................................................................310-00-11 Fuel Tank (Ute) ....................................................................................................................310-00-11 In — Line Filter .....................................................................................................................310-00-12 Fuel Supply and Fuel Return Lines .....................................................................................310-00-12 Vapour Lines ........................................................................................................................310-00-14 Carbon Canister ...................................................................................................................310-00-14 Fuel Module - Fuel Pump ....................................................................................................310-00-15 Sender Assembly .................................................................................................................310-00-16 Fuel Shut Off Switch ............................................................................................................310-00-17
01/2003 2003.0 BA Falcon
310-00-2
Fuel System
310-00-2
SPECIFICATIONS General Specifications Description Specification Fuel Tank Capacities — Total Sedan 68 Litres Wagon 69 Litres Ute 78 Litres Single Fuel LPG LPG Fuel Tank Manufactured by APA Industries Capacity: Sedan 93L (usable) Wagon 116L (usable) Ute 92L (usable) LPG Fuel Sender 0-176 ohms LPG Pressure Relief Relief Pressure: 2.55 Valve MPa LPG Service Line Bundy-Tube - Performed 8mm Diameter (with flexible pressure) hose at tank end on sedan) LPG Converter and Filter VIALLE - FS Type Lock Off Assembly (Special) LPG Mixer Assembly Tickford - LPG Fuel PCM For detailed electrical specifications of the fuel injection system, refer to Diagnosis and Testing, in Section 303-14. Fuel Pump (6 & 8 Cylinder) Delivery (minimum) 277 cc in 10 seconds @ 270 kPa, 12 Volts Pressure at: engine idle 225 kPa, 250 kPa I6HO engine stationary 270 kPa, Base I6 270 kPa, Base V8 400 kPa, Turbo I6 Maximum pressure drop 10% in 10 seconds on engine shut down Fuel pump resistance at < 10 ohms loom connector: Torque Specifications Description Pressure Regulator Tube Nut Fuel Tank Retaining Shield – Sedan Fuel Tank Retaining Strap – Wagon/Ute Sender Unit/Pump Screws – All LPG Flared Connections LPG Converter Bracket to Spring Tower G345270 en
Description LPG Idle Solenoid to Converter LPG Converter to Mounting Bracket LPG Tank to Floor Mounting Bolts (Sedan) LPG Tank to Floor Mounting Studs (Wagon) LPG Service Valve to Tank LPG AFL to Tank LPG Pressure Relief Valve LPG Gauge (AXIOM)
Nm 16 7 50 50 5 5 60 5
Nm 27 35 28 1.9 – 2.5 37 Upper: 35 Lower: 15 01/2003 2003.0 BA Falcon
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Fuel System
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DESCRIPTION AND OPERATION
Fuel System
pump assembly is mounted in the top of the tank. The tank is secured to the underbody by two steel straps. Nylon tubing with a wear resistant outer sheath form the fuel lines. The vapour line is a nylon tube. These lines connect the tank to the main underbody lines. The carbon canister is mounted on the tank. A nylon tube connects it to the central spigot of the pump top. Another nylon line joins the canister outlet to the main body lines. The canister has a corrugated nylon breather hose which is clipped into a cross member to reduce ingestion of water or dust into the canister. Ute
Sedan The fuel tank on sedan models is a two piece moulding with a separate steel filler neck (joined by rubber hose). The tank is located beneath the floor of the left hand side rear passenger. The top of the filler neck is located in the left hand rear quarter panel. The filler neck is fixed to the side rail with a specially coated bolt that ensures electrical grounding to eliminate electrostatic charge. The fuel pump assembly is mounted in the tank and is accessible beneath a plastic plug under the rear cushion on the LHS of the vehicle. The fuel level sender arm assy. is mounted remotely from the pump on the internal baffle inside the tank. It is serviceable and is electrically connected via the fuel pump wiring connector. Nylon tubing form the fuel lines. The vapour vent line is a large diameter corrugated nylon tube and is attached to the Fuel Limit Vent Valve (FLVV) on the top of the tank. It vents directly into the canister. A nylon purge line then connects the canister back to the main underbody lines. The canister has a corrugated nylon breather hose which is clipped into a cross member to reduce ingestion of water or dust into the canister. The tank is secured to the underbody by a large galvanized steel stamping which also acts as a shield. The carbon canister is mounted on the body adjacent to the tank on the other side of the exhaust pipe and above the IRS. Wagon The fuel tank on wagon models is a one piece moulding with an integral filler neck. It is located beneath the wagon load floor, rearward of the axle. The top of the filler neck is located in the left hand rear quarter panel. The tank is electrically grounded via the metal end of the filler neck to the body via a grounding wire. The fuel gauge sender unit and fuel G345271 en
Item Description 1 Pressure/Return Lines 2 Tank 3 Rear Wiring Assembly The fuel tank on ute models is a one piece moulding with an integral filler neck. It is located beneath the ute load floor, between the rear of the cabin and forward of the axle. The filler neck is located in the left hand rear quarter panel. The tank is electrically grounded via the metal end of the filler neck to the body via a grounding wire in the pump loom. The fuel gauge sender unit and fuel pump assembly is mounted in the top of the tank. The tank is secured to the underbody by two straps. Nylon tubing with a wear resistant outer sheath form the fuel lines. The vapour line is a nylon tube. These lines connect the tank to the main underbody lines. The carbon canister is mounted on the tank. A nylon tube connects it to the central spigot of the pump top. Another nylon line joins the canister outlet to the main body lines. The canister has a corrugated nylon breather hose which is clipped into a cross member to reduce ingestion of water or dust into the canister. All models Steel tubing, 8.0 mm O/D for fuel delivery and return and 6.3 mm O/D for vapour, forms the main underbody lines. The tubes are coated with zinc PVF 01/2003 2003.0 BA Falcon
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DESCRIPTION AND OPERATION (Continued) for corrosion protection. (The main body harness also contains one or two 4.9 mm brake lines) Elastomer lined nitrile rubber hoses connect the engine fuel rail to the main underbody lines. The wagon also includes a washer line to connect the washer bottle to the windscreen nozzle. A fuel filter is installed in the delivery line and attached to the LHS side rail roughly in line with the B pillar. The filter consists of a paper filtering element in a stainless steel casing. The filter is a sealed unit and is replaced as an assembly when required. The fuel system supplies the fuel injectors with filtered fuel at a controlled pressure. The Powertrain Control Module (PCM) controls the fuel pump and the on/off duration (pulse width) and timing of the fuel injectors. Fuel Injection PCM The electronic fuel injection system supplies the correct amount of fuel to the engine as required for the operating conditions. Each cylinder has an individual fuel injector controlled sequentially to inject the fuel at the optimum point in the engine cycle. The Powertrain Control Module (PCM) adjusts the fuel injection pulse width, delivering a precise quantity of fuel into the intake port above the inlet valve. Fuel is injected into the cylinders in the same sequence as the ignition firing order. As the fuel is injected into a closed port, the period that each charge remains in the port is even for all cylinders, ensuring optimum mixture throughout the engine. Fuel System Components The fuel system consists of the following components. Fuel Tank Fuel Pump Fuel Supply and Return Lines Fuel Filter Fuel Rail Fuel Injector Fuel Pressure Regulator Fuel Shut off Switch
the system after the engine is shut down. The pressure retention helps to prevent hot starting problems. System pressure is controlled by a pressure regulator valve mounted on the fuel rail. All Falcon models have the electric pump mounted in a Modular Reservoir Assembly (MRA). The MRA has an integral reservoir in which the fuel pump rests to ensure that the pump pickup is submerged in fuel at all times during extreme vehicle manoeuvres and attitudes when the fuel level in the tank is low. The reservoir is spring loaded to maintain the pump and sender is always in contact with the bottom of the fuel tank (for improved low fuel usage and fuel gauge accuracy). A filtering element is located in the fuel pump reservoir to prevent contaminants which could damage internal components of the pump. The electrical system has a fuel pump control relay which is controlled by the engine management PCM. When the ignition switch is ’OFF’ the contacts of the PCM and fuel pump relays are open. When the ignition switch is first turned to the ON position, the PCM power relay is energized, closing its contacts. With the ignition switch ’ON’ and prior to moving it to ’START’ fuel pump operation will be audible. The fuel pump is powered via the contacts of the fuel pump relay. If the ignition switch is not turned to the START position, the PCM will open the ground circuit after approximately one second. Opening the ground circuit de-energizes the fuel pump relay which, in turn, de-energizes the fuel pump. This circuitry provides for pre-pressurization of the fuel system. When the ignition switch is turned to the START position, the PCM operates the fuel pump relay to provide fuel for starting the engine while cranking. After the engine starts and the ignition switch is returned to the ON position, power to the fuel pump is again supplied through the fuel pump relay. The PCM senses engine speed and shuts off the fuel pump by opening the ground circuit to the fuel pump relay when the engine stops or is below 120 rpm.
Evaporative Emission Control System
A large percentage of overall emissions can consist of petrol vapours that might escape from the fuel tank. These evaporative losses occur not only when the The fuel supply system incorporates an electric fuel vehicle is operating but also when the vehicle is pump mounted inside the fuel tank. parked. In fact most vapours are lost when the vehicle Both the normal 6 cylinder and 8 cylinder vehicles use is parked. a single stage turbine type pump with a minimum These losses have been eliminated by providing a output, at 13 volts, of 110 litres per hour at 270 kPa. sealed fuel tank system. With such a system, fuel Some Tickford vehicles and high performance vapours are trapped and directed to the engine for vehicles may have fuel pumps with higher flow rates burning in the normal combustion process. and a higher pressure regulator on the engine fuel The system consists of the following components rail. fuel tank The pump has a check valve inside the outlet port. vapour lines The function of this valve is to maintain pressure in
Electrical Fuel Pump
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DESCRIPTION AND OPERATION (Continued) carbon canister canister purge control valve fuel tank filler cap These components form the Fuel Expansion and Vapour Collection System and the Vapour Vent and Storage System. Fuel Expansion and Vapour Collection All fuel tanks are is designed to leave a volume void or space above the fuel when the tank is filled to capacity: Sedan 68 litres Wagon 69 litres Ute 78 lites Filled to capacity is generally when the fuel bowser nozzle shuts off. This space allows for the expansion of the fuel and the collection of vapours. Trickle filling the tank beyond rated capacity will damage the emission system. To prevent this, DO NOT fill past the first bowser shut off click. Vapour Vent and Storage Sedan: In addition to the fuel vapours generated in the tank the vapour generated during refueling are vented through the Fuel Limit Vent Valve (FLVV) and the Roll Over Valve (ROV) to the carbon canister where they are stored prior to being consumed in the engine.
control valve when engine operating conditions are favourable. When the purge valve is open, manifold vacuum is applied to the canister. Fresh air is drawn through the canister from the corrugated nylon tube on the atmospheric port. As the fresh air is drawn through the carbon bed it releases the vapour from the granules and carries it into the engine to be consumed in the combustion process. Filler Cap The filler cap incorporates a two way pressure/vacuum relief valve. The cap functions as a check valve under normal operating conditions. It allows air to enter the tank as fuel is used while preventing vapours to escape to the atmosphere. IT IS VERY IMPORTANT THAT THE CORRECT CAP IS USED. The cap opening pressure have been varied since the EA Falcon in 1988 to improve vapour management. To indicate the difference the colour of the cap was changed. Black...... 2.5 kPa 1988 to 1998 Grey....... 4.5 kPa 1998 to 2002 Green..... 11 kPa 2002 CAUTION: It is very important that the correct cap is used.
Fuel Filters
Pressure in the tank will force vapour into the canister The FLVV and the ROV prevents the canister from To prevent the fuel injectors becoming clogged or receiving liquid fuel in the event of a vehicle roll over contaminated with foreign material, the fuel system accident. contains four levels of filtering: The FLVV controls the rated liquid capacity of the Fuel Pump: A filter screen is mounted on the tank. intake side of the fuel pump. The filter is part of the assembly and cannot be replaced separately. Wagon & Ute: The fuel vapours generated in the tank are vented through the vapour line to the carbon Fuel Filter Assembly: The fuel filter assembly is canister where they are stored prior to being located in the fuel supply line between the fuel consumed in the engine. pump and the fuel rail. The fuel filter assembly must be periodically replaced according to the Pressure in the tank will force vapour into the canister maintenance schedule. via the central spigot on the pump unit. The upper filler neck is vented via a nylon line back to the tank. Fuel Pressure Regulator: A filter is located on the inlet side of the fuel pressure regulator. The A rollover valve is installed in the central spigot. The filter is part of the assembly and cannot be valve prevents the canister from receiving liquid fuel in replaced separately. the event of a vehicle roll over accident. Fuel Injectors: A mesh screen on the inlet side of Carbon Canister the fuel injector prevents foreign debris and The canister contains a quantity of activated carbon materials from entering the fuel injector granules for storage of fuel vapours and filters to mechanism. The filter is part of the assembly and prevent ingress of particulate matter into the engine. It cannot be replaced separately. is mounted on or near the tank. Pressure and vacuum in the fuel tank forces vapours through the vapour line into the canister where it is adsorbed by the carbon granules. Purging of the vapours from the canister is controlled by a signal from the PCM that varies the duty cycle (frequency of opening and closing) of the solenoid type purge G345274 en
Fuel system shut off switch
All Barra models are fitted with a switch that cuts off fuel supply to the engine in the event of an accident. Sudden vibrations such as collisions when parking may also activate this switch.
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DESCRIPTION AND OPERATION (Continued) Fuel pressure regulator The fuel pressure regulator works with the fuel pump to maintain a steady pressure relationship between the fuel line side of the injectors and the intake manifold. The regulator is a spring loaded diaphragm. The spring keeps the appropriate amount of pressure in the fuel system. When there is a high vacuum in the intake manifold, such as at high rpm, the pressure in the fuel system must be reduced. When there is low pressure in the intake manifold, such as at low speed or full throttle operation, the pressure in the fuel line must be increased. In order to maintain desired fuel pressure, excess fuel is returned to the tank by a separate line from the pressure regulator.
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DIAGNOSIS AND TESTING
Fuel System Inspection and Verification WARNING: Fuel supply lines will remain pressurized for long periods of time after engine or pump shut down. Use care to prevent personal injury or combustion of fuel when disconnecting fuel lines. CAUTION: Do not run the fuel pump in a dry condition, to do so will damage internal components of the pump.
Ensure that there is fuel in the tank. NOTE: If Diagnostic Trouble Code P0230 is displayed during the PCM Self Test the fuel pump relay actuating circuit is faulty. This fault must be rectified before carrying any further fuel delivery tests. To carry out pressure and volume tests it is first necessary to install a remote control switch in the power line to the pump. Detach the loom connector from the base of the fuel pump relay. Connect the switch across terminals 57 (BK) and 787 (BK/Y) of the loom connector.
Symptom Chart NOTE: Please note the following assumptions: Battery voltage has been checked and verified as 12V Starter motor is cranking DTC 0232 on PCM not flagged Condition
Source
Able to crank (ie starter motor working) but engine does not catch
Action
Fuel Pump Fuel shut off switch Fuel relay in PDB Wiring, circuitry Ignition coils, spark plugs
Go to Pinpoint test A
Pinpoint Tests PINPOINT TEST A : ABLE TO CRANK (IE. STARTER MOTOR WORKING) BUT ENGINE DOES NOT CATCH Test Step A1
Result / Action to Take
CHECK IF FUEL SHUT OFF SWITCH IS "ACTIVATED" (O/C BETWEEN FUEL PUMP AND POWER FROM PDB) Turn key to ACC or ON. Is fuel shut off switch activation light on cluster illuminated?
Yes
Go to A2
No
Press fuel shut off switch button, then retry starting vehicle. Fuel shut off switch is accessed via scuff plate in front passenger foot well.
A2
LISTEN FOR FUEL PUMP OPERATION Turn key to ON and for fuel pump. Fuel pump should make buzzing or Yes clicking noise when operational. Check ignition coils and spark plugs NB: two people are required for this test: 1 person to turn key, 1 No person to listen to fuel pump under car. Go to A3 Is fuel pump operational?
A3
CHECK FUEL FUSE IN PDB Check if fuel fuse in PDB is blown. Is fuel fuse in PDB blown?
Yes
Replace fuel fuse with a new fuse, then retry starting vehicle.
No
Go to A4
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DIAGNOSIS AND TESTING (Continued) Test Step A4
CHECK VOLTAGE SUPPLY TERMINAL OF FUEL RELAY SOCKET IN PDB Remove fuel relay from PDB Measure voltage of fuel relay socket terminal (on PDB) circuit 1059 to grond Is 12V measured on terminal?
A5
Result / Action to Take
Yes
Check wiring between fuel fuse and fuel relay socket terminal (on PDB) circuit 1059.
No
Go to A5
CHECK PDB RELAY Turn key to OFF position. Place finger on fuel pump relay in PDB Turn key to ON and feel for activation "click" from fuel relay. NB: two people are required for this test: 1 person to turn key, 1 person to place finger on fuel relay.
Yes
Replace Fuel relay and retest for correct operation.
No
Go to A6
Is fuel relay activating?
A6
CHECK VOLTAGE ACROSS FUEL PUMP Check voltage across fuel pump. Refer to Section 310-00 for instructions to access fuel pump
Yes
Is voltage across fuel pump 12V?
No
Problem with fuel pump. Replace fuel pump
Go to A7
A7
CHECK IF FUEL SHUT OFF SWITCH IS CONNECTED TO HARNESS Remove scuff plate in front passenger foot well. Is fuel shut off switch connected to harness?
Yes
Connect fuel shut off switch to harness, then retry starting vehicle.
No
Go to A8
A8
CHECK CONTINUITY OF FUEL SHUT OFF SWITCH Disconnect fuel shut off switch. Check continuity of fuel shut off switch Does fuel shut off switch function as expected?
Yes
Fuel shut off switch is faulty. Replace fuel shut off switch and retry starting vehicle.
No
Go to A9
A9
CHECK VOLTAGES SUPPLIED TO FUEL SHUT OFF SWITCH Measure voltage of circuit 787A at Fuel shut off switch terminal on harness. Is 12V measured?
Yes
There is a wiring break between fuel relay socket terminal (on PDB) and connector of fuel shut off switch (on harness). Repair harness and retest for correct operation.
No
There is a wiring break between the connector of fuel shut off switch (on harness) and fuel pump connector (on harness). Repair harness and retest for correct operation.
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GENERAL PROCEDURES 2. Start the engine if possible and note the fuel pressure at idle. 1. Detach the fuel delivery line (the line coming from If the engine cannot be started install a remote the filter) from the fuel rail. Place the end of the control switch at the relay. delivery line in a container. Operate the switch and note pressure. Specification: 2. Switch ignition on. The pump should deliver fuel for one second. Switch ignition off. 270 kPa Base I6 3. If the pump does not run, detach the wiring 300 kPa Base V8 connector from the pump end of the loom. On 400 kPa Turbo I6 sedan this connector is located beneath the plastic cover which is under the rear seat cushion. 3. If the pressure reading is low slowly close off the fuel delivery test line between the gauge and the On wagon the connector is accessible via a fuel rail while operating the pump. Pressure rubber grommet in the floor of the luggage space. should increase to at least 400 kPa. On utes the connector may be accessible under If pressure does not increase a faulty fuel pump is the vehicle via the extended wiring loom. indicated. 4. Connect a voltmeter across the loom terminals. Switch on the ignition while observing the meter. Fuel Flow (Volume) Test The meter should read battery voltage for approximately one second then drop to zero. WARNING: Engine must be switched off Failure to do this indicates a fault in the power during this test. supply circuit. 1. Disconnect the fuel return line from the steel line 5. Check the pump for continuity. Connect an (lower dash panel) and place the end of the ohmmeter across the terminals of the pump lead. flexible hose into a graduated container. (Specifications - less than 10 ohms.) 2. Operate the remote control switch for 10 seconds. NOTE: Do not attempt to detach the fuel pump lead from the pump bracket. 3. Remove the measuring container and check contents against specification:277 cc. Pressure Test NOTE: Fuel volume must be at nominal regulated pressure. See specifications listed in Pressure 1. ’T’ The fuel pressure gauge (refer Special Tools Test of General Procedures in this chapter. section) into the fuel delivery line. Fuel System Pressure Retention
Pump Operation Check
Item 1 2 3
Description Fuel Pressure Gauge Quick Connect Fitting Pressure Line
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1. Operate the remote control switch for 10 seconds and note fuel pressure. Maximum pressure drop permissible is 10% in 10 seconds. A pressure drop in excess of this figure indicates a leak in the pressure system. 2. Check by closing off the pressure line just before the gauge. No pressure drop - leak in pressure line to pump or in non-return valve of pump. Pressure continues to drop - leak in injectors, pressure regulator or fuel rail connections. To determine source of pressure leak close off the fuel return line. No pressure drop - replace pressure regulator. Pressure continues to drop - check fuel rail connections and test injectors. 3. Remove the pressure gauge and reconnect fuel lines. 4. Check for fuel leaks. 5. Remove the remote control switch and install the loom plug in the base of the relay.
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GENERAL PROCEDURES (Continued)
Draining Fuel If the fuel pump is operational then it should be used if it is necessary to drain fuel from the tank. Disconnect fuel return line at main underbody lines and attach a transparent drain tube. Run engine to facilitate expedient fuel removal. Air bubbles in fuel stream will indicate low fuel level. CAUTION: Care should be taken to ensure fuel pump is not run dry. 1. In situations where the fuel pump is not functioning then: Use a nylon 5 mm OD tube carefully inserted down the filler neck, past the tank check valve to the bottom of the tank to siphon the fuel. Sedan 1. With the vehicle on a level surface and the fuel tank no more than 1/2 full it is not necessary to remove any fuel from the tank.
Purge Control Valve Testing 1. Detach the solenoid valve. 2. Apply 250 mm Hg vacuum to one port of the valve. 3. Apply 12V across the solenoid terminals. Vacuum should collapse immediately. If this does not happen, renew the valve. NOTE: All hardware must be correctly installed and torqued to specification.
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REMOVAL AND INSTALLATION
Fuel Tank (Sedan)
Installation 1. Raise tank into straps and latch bolt/nut assy. into body mounting brackets. 2. Connect the pump sender electrical loom to the pump top connector. 3. Replace tank attaching bolts at filler neck and torque to 15Nm. 4. Replace floor mounted air flow through vent. 5. Reconnect earth lead located on filler neck. 6. Torque fixing bolts at fuel tank straps to 25 - 30 Nm. 7. Reconnect balance line. 8. Reconnect vapour and fuel lines at main underbody lines (QFCs).
Removal 1. Drain the fuel from the fuel tank into a suitable container. 2. Disconnect vapour and fuel lines at main underbody lines (QFC’s). Quick Fit Connectors (QFC) is normally removed by pushing the QFC further on (approx 1mm), squeezing the knurled pads together and then pulling QFC off. 3. Disconnect balance line. 4. Disconnect vent and purge lines at canister (QFC). 5. Disconnect fuel filler hose and clamp. 6. Disconnect electrical connector on top of pump. Fuel Tank (Ute) 7. Remove IRS module Refer to Section 204-02a. Removal 8. Remove Tank shield bolts and nuts. 1. Drain the fuel from the fuel tank into a suitable 9. Lower tank carefully to ground. container. NOTE: Do not allow the tank to hang from the fuel 2. Raise vehicle. lines, wiring or filler neck during removal. 3. Remove driveshaft. Installation 4. Disconnect parkbrake cable at the adjuster. 1. Position the tank and shield under the vehicle and 5. Remove rear calipers. loosly attach with bolts and nuts. 6. Remove the U bolts and spring plate on both LH 2. Align tank and shield via holes in shield and and RH sides and slide rear axle back towards dimples in tank. rear of vehicle as far as possible. 3. Tighten bolts and nuts to specification. 7. Disconnect two fuel Quick Fit Connectors and the 4. Connect the wiring plug. fuel vapor line connector at the end of the body 5. Reconnect balance line. mounted fuel and brake harness assy. 6. Connect vapour and fuel lines to the main body 8. Disconnect balance line. lines. 9. Disconnect wiring for fuel sender/pump from 7. Connect rubber hose on filler neck to tank. upper cross-member. 8. Connect vent and purge lines to canister. 10. Remove 13 mm bolts that retain the fuel tank straps. 9. Fill the tank, start the engine, and check all connections for leaks. 10. Reinstall IRS.
Fuel Tank (Wagon) Removal 1. Drain the fuel from the fuel tank into a suitable container. 2. Disconnect vapour and fuel lines at main underbody lines (QFC’s). 3. Disconnect balance line. 4. Remove floor mounted air flow through vent. 5. Remove tank attaching bolts at filler neck. 6. Disconnect earth lead located on filler neck. 7. Loosen fixing bolts at fuel tank straps. 8. Support tank and lower sufficiently to allow the pump sender electrical loom to be disconnected. 9. Lower tank and remove from vehicle.
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Item 1 2 3
Description Chassis Fuel Tank Assembly Strap Bolt
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REMOVAL AND INSTALLATION (Continued) 11. Carefully maneuver tank out of position and lower 6. Tighten the retaining strap nuts. to the ground.
Item 1
Description Fuel Tank Assembly
12. Remove pump, Refer to Pump Removal and Installation in this section. Installation 1. Loosely hang the tank in the vehicle by the tank straps. 2. To ensure correct position of the tank when the tank straps are fully tightened it is recommended that some liquid soap or detergent be smeared on the tank strap rubber insulators. 3. Reconnect the fuel pump wiring at the cross member. 4. Reconnect balance line. 5. Reconnect the fuel line quick connect fittings to the main fuel and brake harness on the body. The return fuel line has a piece of silver tape adjacent to the quick fit connector.
Item 1 2 3
Description Neck Collar Tank Nut M8x20 Corflex
7. Fill the tank with fuel and check for leaks and fuel gauge.
In — Line Filter Removal 1. Raise the vehicle on a hoist. 2. Remove fuel filter line retaining nipples. 3. Loosen filter retaining clamp and slide filter rearward to remove from the vehicle. Installation 1. Install the filter in the retaining clamp with the arrow on the can in the direction of fuel flow. 2. Fit and tighten fuel line retaining nipples to 32 Nm. 3. Run engine and check for fuel leaks. 4. Lower vehicle.
Fuel Supply and Fuel Return Lines Removal 1. With the vehicle on a level surface and the fuel level below the bottom of the filler neck it is not necessary to remove any fuel from the tank.
Item 1 2 3
Description Pressure/Return Lines Tank Rear Wiring Assembly
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REMOVAL AND INSTALLATION (Continued) 2. Disconnect the line at each end and remove the line from the holding clips along the underbody.
Item 1 2 3 4 5
Item 1 2
Description Fuel tube return Fuel vapour hose Fuel tank to vapour hose Rear brake lines Fuel tube return
Description Fuel Tube Assembly Blind Rivet 4.8 x 13.8
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Item 1 2 3 4 5
Description Fuel Tube Assembly Vapour Fuel Hose Fuel Tube Assembly Fuel Line Support Bracket Rivet
Item 1 2 3 4
Description Fuel Tube Assembly Ventilation to Storage Canister Rear Tube Front Upper to Engine Tube Return Fuel Line Assembly
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REMOVAL AND INSTALLATION (Continued)
Item 1 2 3 4 5
Item 1 2 3
Description Rivet Fuel Tube Assembly Vapour Line Delivery Line Return Line
Description Fuel Tank Assembly Fuel Lines Bracket
Item 1 2
Description Fuel Tubing Shield Screw
Item 1 2 3 4
Description Fuel Tank Filler Pipe Assembly Bolt M6x25 Cobra Clamp Pipe End
Installation 1. Position the lines in the underbody clips and tighten the clips. Fill the tank, start the engine, and check for leaks.
Vapour Lines The vapour lines can be replaced similarly to the fuel lines.
Carbon Canister The carbon canister is good for the life of the vehicle; however the canister must be replaced if punctured, subjected to crushing, corrosion or contamination by any liquid such as oil, fuel or water.
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REMOVAL AND INSTALLATION (Continued) 5. Disconnect the fuel module assembly electrical harness. 6. Remove the three fuel lines using AU601 from the fuel module assembly.
Item 1 2 3 3
Description Tube Return Fuel Tube Fuel Tube Assembly RR BrakeTube Assembly
7. Unscrew all six fuel module bolts using a Philips screwdriver.
Fuel Module - Fuel Pump Special Tool(s) Quick connect removal special service tool AU601
Removal 1. Record radio presets and disconnect the negative terminal of the battery. 8. Remove fuel module retainer and fuel module 2. Relieve fuel system pressure. Refer to the Fuel assembly from the fuel tank. Pressure Relief in the General Procedure section 9. Disconnect (Blue/Black) sender electrical of this chapter. connector from the fuel module. 3. Drain fuel tank. Refer to Draining Fuel in the NOTE: After removing the fuel module assembly, General Procedure section of this chapter. cover the fuel tank to prevent any contamination of fuel. 4. Remove the rear seat cushion. Installation 1. Replace original gasket from top of fuel tank with a new gasket. CAUTION: Fuel module gasket must always be replaced with a new gasket before installing a new fuel module assembly. 2. Reconnect (Blue/Black) sender electrical connector to new fuel module assembly. 3. Reinstall fuel module assembly to the fuel tank.
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REMOVAL AND INSTALLATION (Continued) 4. Screw fuel module retainer onto fuel module assembly and fuel tank with bolts, tightening to 2.2±0.3Nm.
Sender Assembly Removal 1. Remove the Fuel Module, Refer to Fuel pump Removal and Installation in this section. CAUTION: Do not allow any portion of the float arm to bend. Be sure the 90º bend near the pivot of the float arm is intact. A deformed float arm will result in an inoperative sending unit. 2. Remove the sender assembly from the bracket by moving it to forward and to the side.
5. Connect the three fuel lines to the fuel module assembly. 6. Connect the electrical harness to the fuel module assembly.
3. Rotate the sender assembly and manovour out.
7. Replace the rear seat cushion.
8. Refill the fuel tank. 9. Reconnect the battery and reset the radio presets and the clock.
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REMOVAL AND INSTALLATION (Continued) Installation 1. Reverse the removal process.
Fuel Shut Off Switch Removal 1. Remove left front scuff plate. Please see Section 501-05 for scuff plate installation and removal instructions. 2. Unscrew Fuel shut off switch.
Installation 1. Reverse the removal process.
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Acceleration Control
310-02-1
SECTION : 310-02 Acceleration Control VEHICLE APPLICATION : 2003.0 BA Falcon CONTENTS
PAGE
SPECIFICATIONS Specifications ........................................................................................................................310-02-2 DESCRIPTION AND OPERATION Acceleration Control ..............................................................................................................310-02-3 Acronyms and Abbreviations ...............................................................................................310-02-3 DIAGNOSIS AND TESTING Acceleration Control ..............................................................................................................310-02-4 Inspection and Verification ...................................................................................................310-02-4 Symptom Chart ....................................................................................................................310-02-4 Connector Circuit Reference ................................................................................................310-02-5 Pinpoint Tests ......................................................................................................................310-02-8 REMOVAL AND INSTALLATION Accelerator Pedal and APM unit — Adjustable Pedals ......................................................310-02-11 Accelerator Pedal and APM unit — Fixed Pedals ..............................................................310-02-12 Adjustable Pedal Indexing ..................................................................................................310-02-14
01/2003 2003.0 BA Falcon
310-02-2
Acceleration Control
310-02-2
SPECIFICATIONS Torque Specifications Description Carrier Plate Bolts (fixed accelerator pedal only) Adjustment Motor Retaining Bolts (adjustable pedal) Pedal Box Housing Brake Booster Retaining Nuts Accelerator Gearbox Torx Head Screws (adjustable pedal only) APM Mounting Bolts
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Nm 6 ± 0.5 5 ± 0.5 22.5 ± 3.4 22.5 ± 3.4 2.5 ± 0.5 6 ± 0.5
01/2003 2003.0 BA Falcon
310-02-3
Acceleration Control
310-02-3
DESCRIPTION AND OPERATION
Acceleration Control Acronyms and Abbreviations APM PCM BEM Step Over MSC PPS
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Accelerator Pedal Module Powertrain Control Module Body Electronic Module Height Difference Between Brake and Accelerator Pedal Memory Seat Controller Pedal Position Sensor
01/2003 2003.0 BA Falcon
310-02-4
Acceleration Control
310-02-4
DIAGNOSIS AND TESTING
Acceleration Control Inspection and Verification 1. Verify the customer concern. 2. Visually inspect for obvious signs of mechanical or electrical damage.
Mechanical Electrical Accelerator Pedal Fuse(s) Accelerator pedal pad Relay(s) Adjustment Wiring harness mechanism Electrical connector(s) Fuel injection pump Accelerator pedal position sensor APM MSC PCM 3. If an obvious cause for an observed or reported concern is found, correct the cause (if possible) before proceeding to the next step. 4. If the cause is not visually evident, verify the symptom and refer to Symptom Chart.
Symptom Chart Symptom Chart Condition Excessive Effort Required Too Depress Accelerator Pedal
Engine Idle Speed Higher Than Specification
Accelerator Pedal Does Not Return Freely
No Engine Response when Accelerator Pedal Pushed
Unable to Adjust the Accelerator Pedal
Accelerator and Brake Pedal "step over" (height difference) Incorrect
Source
Action
Pedal Binds
Go to PinPoint Test A
Foreign Object Effecting the APM
Go to PinPoint Test A
Worn or Damaged APM
Go to PinPoint Test A
APM Return Spring Damaged
Go to PinPoint Test B
Incorrect Signal from APM
Go to PinPoint Test B
PCM Issue
Refer to PCM Diagnosis Section.
APM Return Spring Damaged
Go to PinPoint Test B
Foreign Object Caught in the APM
Go to PinPoint Test A
APM Electrical Connection
Go to PinPoint Test D
PCM Issue
REFER to Section 303-14.
APM Faulty
Go to PinPoint Test D
APM Electrical Connection
Go to PinPoint Test D
Faulty Potentiometer (memory only)
Go to PinPoint Test D
Memory settings Incorrect (memory only)
Go to PinPoint Test D
Adjustment Cable
Go to PinPoint Test C
Adjustment Issue
Go to PinPoint Test C
Symptom Chart -(For adjustable pedal box only) Condition Unable to adjust the accelerator pedal
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Source
Action
Unconnected Adjustment motor
CHECK the connection between the motor and the MSC
Disengaged adjustment gear box in the carrier plate
RECONNECT adjustment gear box
01/2003 2003.0 BA Falcon
310-02-5
Acceleration Control
310-02-5
DIAGNOSIS AND TESTING (Continued) Condition
Source
Step over between brake pedal and accelerator pedal
Action
Faulty Potentiometer (Memory Pedal Box Only)
REPLACE potentiometer
Incorrect memory settings (Memory Pedal Box Only)
RESET memory
Incorrect-adjustment
Refer to Assembly and Disassembly of Accelerator Pedal Indexing.
NOTE: Do not run to stall on the accelerator transmission. Unit is designed to stall through brake transmission.
Connector Circuit Reference CONNECTOR C - 395 PEDAL BOX HARNESS NOTE: Depending on the vehicle level some of the terminals listed below will be blank. High series connector shown. Values given are with connector C-395 connected, ignition on and back probing the terminals.
Pin Number(s) 1 2 3 4 5
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Circuit Designation/Description 10AB (Green/Red) Brake and Cruise switch (High) 1489 (Red) Pedal adjusting motor - A 1490 (White) Pedal adjusting motor - B 57 H (Black) Clutch switch 511 (Blue/Green) Cruise control deactivation switch signal 10Y (Green/Red) Brake switch - signal 1491 (White) Pedal position sensor - B 1491A (Blue/Yellow) Pedal position sensor - A BLANK 92 (Blue/Yellow) Clutch switch - signal
Normal Condition/Measurement 12 - 14 Volts Using adjustment switch - Centre =0 Volts, Upwards = 12-14 Volts. Downwards = 0.1 Volt Using adjustment switch - Centre =0 Volts, Upwards = 0.1 Volt. Downwards = 12-14 Volts N/A 12-14 Volts (Brake pedal pushed - 0 Volts) 0 Volts (Brake pedal pushed - 12-14 Volts) N/A N/A
N/A
01/2003 2003.0 BA Falcon
310-02-6
Acceleration Control
310-02-6
DIAGNOSIS AND TESTING (Continued) CONNECTOR C - 379 PEDAL ADJUSTMENT MOTOR NOTE: Ignition to be "ON" for Voltage Tests.
Pin Number(s) 1 2
Circuit Designation/Description Normal Condition/Measurement 1489 (R), 1494 (L) Voltage less than 2 Volts 1490 (W), 1495 (R) Voltage less than 2 Volts
CONNECTOR C - 317 HARNESS TO APM NOTE: Voltage values with the connector C-317 disconnected. Ignition On.
Pin Number(s) 1 2 3 4 5 6 7 8
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Circuit Designation/Description EMPTY 3011 (B-O) GROUND 3835 (Y-W) PPS1 OUT 3837 (GR-Y) GROUND 3015 (W-R) PPS3 OUT 3010 (BR) VREF (+) 3836 (Y-L) VREF (+) 3012 (W) PPS2 OUT
Normal Condition/Measurement 0 VOLTS 0 VOLTS 0 VOLTS 0 VOLTS 5 VOLTS 5 VOLTS 0 VOLTS
01/2003 2003.0 BA Falcon
310-02-7
Acceleration Control
310-02-7
DIAGNOSIS AND TESTING (Continued) APM CONNECTOR TERMINALS NOTE: To remove this connector from the APM, pull the Red plastic tab upwards, then use a small flat blade screw driver between the Red tab and connector body to push a retainer inwards. Remove connector gently away from the APM Turn the Ignition Off. DO NOT move throttle pedal while measuring continuity.
APM Resistance Reading from Pin to Pin Pin Number(s) Circuit Designation/Description 1-2 Terminal 1 and 2 1-3 Terminal 1 and 3 1-5 Terminal 1 and 5 1-6 Terminal 1 and 6 1-7 Terminal 1 and 7 1-8 Terminal 1 and 8 2-3 Terminal 2 and 3 2-5 Terminal 2 and 5 2-6 Terminal 2 and 6 2-7 Terminal 2 and 7 2-8 Terminal 2 and 8 3-5 Terminal 3 and 5 3-6 Terminal 3 and 6 3-7 Terminal 3 and 7 3-8 Terminal 3 and 8 5-6 Terminal 5 and 6 5-7 Terminal 5 and 7 5-8 Terminal 5 and 8 6-7 Terminal 6 and 8 6-8 Terminal 6 and 8 7-8 Terminal 7 and 8
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Closed Throttle 1.9 kΩ 6.2 Ω 2.5 kΩ 1.3 kΩ 1.7 kΩ 2.1 kΩ 1.8 kΩ 3.6 kΩ 1.0 kΩ 1.0 kΩ 2.1 kΩ 2.5 kΩ 1.3 kΩ 1.3 kΩ 2.1 kΩ 3.0 kΩ 3.0 kΩ 4.5 kΩ 3.0 kΩ 3.0 kΩ 3.0 kΩ
Wide Open Throttle 1.2 kΩ 6.2 Ω 3.0 kΩ 1.3 kΩ 1.3 kΩ 2.8 kΩ 1.2 kΩ 3.6 kΩ 1.8 kΩ 1.8 kΩ 3.7 kΩ 3.0 kΩ 1.3 kΩ 1.3 kΩ 2.8 kΩ 2.5 kΩ 2.5 kΩ 4.8 kΩ 3.0 kΩ 2.7 kΩ 2.7 kΩ
01/2003 2003.0 BA Falcon
310-02-8
Acceleration Control
310-02-8
DIAGNOSIS AND TESTING (Continued) Pinpoint Tests PINPOINT TEST A : PEDAL "FEEL" CAUTION: Tests to be carried out with the Engine not running. Test Step A1
OBSTRUCTION AT APM Inspect the APM for any obstructions such as carpet or a poorly fitted floor mat.
NOTE: A Pedal end stop is built into the APM. It should be clear of the carpet at all times.
Did you find an obstruction?
A2
Result / Action to Take
Yes
Remove the obstruction and recheck. If problem still exists, Go to PinPoint Test A2.
No
Replace the APM. Refer to Removal and Installation instructions in this chapter.
EXCESSIVE EFFORT REQUIRED Very slowly apply the Pedal all the way to Full throttle. Did the Pedal movement appear Rough or Sticking?
Yes
Replace the APM. Refer to Removal and Installation instructions in this chapter.
No
Go to A3
A3
EXCESSIVE FORCE EVALUATION Yes
Is Excessive force (greater than 4 kg) required to operate the Accelerator pedal?
Replace the APM. Refer to Removal and Installation instructions in this chapter.
No
Go to A5
A4
PEDAL RETURN TOO SLOW Check if the Accelerator pedal is too slow in returning to the Idle position. Did the pedal return to idle but too slowly (greater than 0.5 Seconds)?
Yes
Replace the APM. Refer to Removal and Installation instructions in this chapter.
No
Go to A5
A5
LIGHT PEDAL FEEL Check to verify if the Accelerator pedal feel is too light.
Yes
Replace the APM. Refer to Removal and
NOTE: Do not compare other vehicle model as the pedal efforts are Installation instructions in this chapter. different from model to model
Is the force to initiate movement of the Accelerator pedal less than1 kg force?
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No
APM Operating correctly.
01/2003 2003.0 BA Falcon
310-02-9
Acceleration Control
310-02-9
DIAGNOSIS AND TESTING (Continued) PINPOINT TEST B : IDLE SPEED ISSUE NOTE: Step 2, Engine running, Automatic transmission vehicle in Park, Manual transmission vehicle in Neutral and Handbrake engaged. Test Step B1
Result / Action to Take
ENGINE SPEED TOO HIGH Check for an obstruction that could be holding the Accelerator pedal open. Did you find an obstruction?
Yes
Remove obstruction and recheck. If problem remains, Go to B2.
No
Go to B2
B2
PEDAL RETURN TO IDLE Hold the Accelerator pedal down until the Engine speed is 2000 RPM (vehicle tachometer). Release the Accelerator pedal and check the vehicles Tachometer for the specified idle speed. Did the Engine RPM return to the specified speed at idle?
Yes
APM idle speed return okay.
No
Carry out Check of the APM. Go to PinPoint Test D.
PINPOINT TEST C : ADJUSTABLE ACCELERATOR PEDALS ONLY Test Step C1
Result / Action to Take
NO ACCELERATOR RESPONSE - PART 1 Check to see if the electric wiring connector C-379 is connected to the Yes pedal adjust motor. Go to C2 Is C-379 connected?
No
Reconnect the connector and retest.
C2
NO ACCELERATOR RESPONSE - PART 2 Check to see if the electric wiring connector C-395 is connected. Is C-395 connected?
Yes
Go to C3
No
Reconnect the connector and retest.
C3
ADUSTMENT CABLE Check the adjustment cable for jamming, crushed, twisted or caught condition. Did any of the above occur?
Yes
Remove the adjustment cable (Refer to Section 308-01). Grasp the inner cable to see if it turns freely, if not replace the cable.
No
Go to C4(memory only-see note) or Go to C5 (non memory)
C4
STEP OVER HEIGHT CHECK PART 1 Yes
Measure the Step over height between the Brake and Accelerator pedal.
Go to section 206-06 pinpoint test E.
Is the measured height distance more than 40mm?
No
Go to C5
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Acceleration Control
310-02-10
DIAGNOSIS AND TESTING (Continued) Test Step C5
Result / Action to Take
STEP OVER HEIGHT CHECK PART 2 Measure the Step over height between the Brake and Accelerator pedal. Is the measured height distance less than 30mm?
Yes
Rectify the pedal Indexing. Refer to procedure in this chapter.
No
Step Over height okay, no further work required.
PINPOINT TEST D : ELECTRICAL CHECK Test Step D1
Result / Action to Take
WIRING TO APM Yes
Carry out an inspection of the electrical connector C-317 between the vehicle wiring harness and the APM.
Go to D2
Were the electrical connectors correctly, joined?
No
Re-attach electrical connectors and confirm that the fault no longer exists.
D2
APM CONTINUITY CHECK Disconnect the vehicle harness electrical connector from the APM. Using a Multimeter check the continuity of the APM terminals as outlined. Refer to resistance APM connector reference for terminal layout. Were the readings to specification?
D3
Yes
Go to D3
No
Replace the APM. Refer to Removal and Installation instructions in this chapter.
VEHICLE CONNECTOR TO APM Disconnect connector C-317. Ignition ON. Carry out electrical checks by back probing the terminals housed in connector C-317. Were the terminal input / outputs correct?
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Yes
APM circuit okay.
No
Carry out testing of the faulty terminal / circuit. Consult the wiring diagrams.
01/2003 2003.0 BA Falcon
310-02-11
Acceleration Control
310-02-11
REMOVAL AND INSTALLATION
Accelerator Pedal and APM unit — Adjustable Pedals Removal CAUTION: The adjustable pedal system must be indexed whenever the brake pedal assembly or the accelerator pedal assembly is serviced. 1. Remove pedal box from car. To remove pedal box see section Section 206-06. 2. Remove accelerator gearbox screws.
4. Remove accelerator pedal assembly by first rotating and then pulling to side as shown. CAUTION: When removing accelerator pedal assembly keep accelerator adjustment gearbox and accelerator mechanism aligned at all times.
5. Remove bolts / nuts to separate Carrier plate from APM unit.
3. Remove pivot pin using flat head screwdriver.
Installation 1. Loosely reinstall the bolts / nuts to the Carrier Plate and APM unit.
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01/2003 2003.0 BA Falcon
310-02-12
Acceleration Control
310-02-12
REMOVAL AND INSTALLATION (Continued) 2. Install the pivot pin to align the Carrier Plate and APM unit.
3. Tighten the bolts / nuts to the Carrier Plate and APM unit to the specified torque.
4. Remove the pivot pin. 5. Install the accelerator pedal assembly by sliding to the side and then rotating into position as shown. CAUTION: When installing the accelerator pedal assembly keep accelerator adjustment gearbox and accelerator mechanism aligned at all times.
6. Install the pivot pin.
7. Install the accelerator gearbox screws to the specified torque.
8. Install the pedal box to the car. Refer to pedal box installation in Section 206-06. CAUTION: The adjustable pedal system must be indexed whenever the brake pedal assembly or the accelerator pedal assembly is serviced.
Accelerator Pedal and APM unit — Fixed Pedals Removal 1. Remove pedal box from car. To remove pedal box see Section 206-06.
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Acceleration Control
310-02-13
REMOVAL AND INSTALLATION (Continued) 2. Remove nut and bolt holding accelerator pedal assembly to pedal box.
5. Remove bolts / nuts to separate the Carrier Plate from the APM unit.
3. Remove pivot pin using flat head screwdriver.
Installation 1. Loosely reinstall the bolts / nuts to the Carrier Plate and APM unit.
4. Remove accelerator pedal assembly. 2. Install the pivot pin to align the Carrier Plate and APM unit.
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01/2003 2003.0 BA Falcon
310-02-14
Acceleration Control
310-02-14
REMOVAL AND INSTALLATION (Continued) 3. Tighten the bolts / nuts to the Carrier Plate and APM unit to the specified torque.
7. Install the accelerator pedal assembly to the pedal box screw to the specified torque.
4. Remove the pivot pin. 5. Install the accelerator pedal assembly by sliding to the side and then rotating into position as shown.
8. Install the pedal box to the car. Refer to pedal box installation in Section 206-06.
CAUTION: When installing the accelerator pedal assembly keep accelerator adjustment gearbox and accelerator mechanism aligned at all times.
CAUTION: The adjustable pedal system must be indexed whenever the brake pedal assembly or the accelerator pedal assembly is serviced.
Adjustable Pedal Indexing Removal and Installation CAUTION: The adjustable pedal system must be indexed whenever the brake pedal assembly or the accelerator pedal assembly is serviced. CAUTION: If the fuse box is removed the battery must be disconnected first. NOTE: Access to the drive cable is made easier by removing the fuse box. 1. Adjust pedals to approx mid position and disconnect the adjustment cable.
6. Install the pivot pin.
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310-02-15
Acceleration Control
310-02-15
REMOVAL AND INSTALLATION (Continued) 2. Operate the switch until the accelerator pedal reached its upper limit of travel.
5. Detach the drive cable from the brake pedal assembly.
3. Connect the drive cable to the brake pedal assembly.
6. Operate the switch until the accelerator pedal is adjusted to its lower limit of travel.
4. Operate the switch until the brake pedal is in the stall position at the lower limit of travel.
7. Adjust the accelerator pedal back 2- 3 mm.
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01/2003 2003.0 BA Falcon
310-02-16
Acceleration Control
310-02-16
REMOVAL AND INSTALLATION (Continued) 8. Reconnect the drive cable to the brake pedal assembly.
9. Check the the brake and accelerator pedals are correctly set. Step over height should be between 30 and 40 mm.
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01/2003 2003.0 BA Falcon
412-00-1
Climate Control System — General Information
412-00-1
SECTION : 412-00 Climate Control System — General Information VEHICLE APPLICATION : 2003.0 BA Falcon CONTENTS
PAGE
DESCRIPTION AND OPERATION Climate Control System — General Information ...................................................................412-00-2 Climate Control System .......................................................................................................412-00-2 DIAGNOSIS AND TESTING Climate Control System — General Information ...................................................................412-00-4 Acronyms and Abbreviations ..............................................................................................412-00-4
01/2003 2003.0 BA Falcon
412-00-2
Climate Control System — General Information
412-00-2
DESCRIPTION AND OPERATION
Climate Control System — General Information Climate Control System The 2002 model year Falcon is fitted with an all new heater/ventilation/air conditioning (HVAC) system. Features of the new system are: All electric control of the HVAC system with manual selections available on the manual climate control (MCC) and manual/automatic selections available on the Automatic Climate Control (ACC). Intelligent microprocessor control of the unit is built into all systems. Filtering of all air passing through system with a standard mesh filter and the option of a finer pollen filter. Light weight high performance heat exchangers. Dual zone temperature control is standard on some models. The heater housing only differs from the heater/air conditioning system in that no evaporator is fitted.
Manual over-ride of automatic control mode is able to be selected at any time. The air conditioning system includes a software strategy to protect the compressor and to notify the dealer of a degradation in air conditioning performance caused by low refrigerant charge or A/C system blockage.
Control Components The HVAC unit incorporates a HIM (HVAC Integrated Module) that controls all aspects of the units operation. The HIM is connected to the CAN (Controller Area Network) serial data bus through which flow all sensor and command inputs required to operate the climate control system. Operator commands are input into the ICC. The ICC then passes the command input through the CAN to the HIM. The HIM takes the information and performs the required actions, and outputs the appropriate information for the ICC display screen. The HIM also monitors some vehicle operating data for optimisation of Climate Control System performance.
Heating/Ventilation/Air Distribution The new unit features heating to the rear occupants through the console if the Floor mode is selected by the front occupants. However, if the front occupants select face mode, the rear occupants will only receive non-heated air through the console. Unlike previous units where airflow to the rear is only available in face mode, airflow to the rear is maintained in all modes except full demist. The blower fan speed is now able to be more finely selected. On the Manual Climate Control, the blower fan speed dial can select 14 operable speeds. On the Automatic Climate Control, in AUTO mode the fan speed is continuously variable to maintain the optimum comfort setting while with manual override, there are 10 operable speeds available.
Air Conditioning A single zone manual (SZMCC) and a dual zone automatic conditioning system (DZACC) are available. All systems are provided with intelligent microprocessor control. Climate Control System operation selections are available via the buttons and dials on the Interior Command Centre (ICC) and selections are displayed on the ICC display screen. In the case of automatic climate control, the system automatically adjusts the operation mode of the system to provide a set comfort under all operating conditions. Dual zone allows different comfort settings for driver and passenger.
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01/2003 2003.0 BA Falcon
412-00-3
Climate Control System — General Information
412-00-3
DESCRIPTION AND OPERATION (Continued) Feature Mode Actuation Air Mix Actuation Low Series Air Mix Actuation High Series
AU Falcon Vacuum Cable Electric
Control logic Low Series
Fixed logic in Interface Module
Control logic High Series Water Tap Air Filter
Intelligent software control in Interface Module Yes No
Blower fan control
4 Speed conventional Resistor
Dual Zone ACC compatible Rear Foot Heating A/C performance monitor
No Semi None No
A/C compressor protection
Yes
HVAC Interface Mount Points
AU Falcon 2 - Cowl 2 - Dash
Sound Insulator
Drain
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Barra Electric - Integrated HIM module Electric - Integrated HIM module Electric - Integrated HIM module + DZ actuator Intelligent software control incorporated into HIM Intelligent software control incorporated into HIM Not required Filter mesh standard, Pollen filter optional 14 detent fan speed control integrated in HIM Yes Yes Via console outlet Yes - software strategy to detect A/C performance degradation. Yes - more substantial than AU
Barra 3 - Cowl 1 - Dash 2 - Floor Bracket Two piece Insulator one fitted with Integrated Assy with HVAC -Fixing HVAC - Fixed with fir tree clips posts on case, locating guide ribs Cut away around pass throughs around all pass throughs and mount points Spacer rings on all mount points Solid drain on passenger side with Solid drain on centreline with laminated foam seal. laminated foam seal
01/2003 2003.0 BA Falcon
412-00-4
Climate Control System — General Information
412-00-4
DIAGNOSIS AND TESTING
Climate Control System — General Information Acronyms and Abbreviations NOTE: The following acronyms will be used throughout this section. A/C ACC ACPT BEM CAN DTC DZ ECU EEC EVT HIM HTR HVAC ICC MAX MCC MIN MSG N/A PCM PID RPM SZ
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Air Conditioning Automatic Climate Control Air Conditioning Pressure Transducer Body Electronics Module Controller Area Network Diagnostic Trouble Code Dual Zone Electronic Control Unit Electronic Engine Control (part of PCM) Evaporator Vent Temperature HVAC Integrated Module Heater Heating, Ventilation & Air Conditioning Interior Command Centre Maximum Manual Climate Control Minimum Message Not Applicable Powertrain Control Module Parameter Identifier Revolutions Per Minute Single Zone
01/2003 2003.0 BA Falcon
412-02-1
Heating and Ventilation
412-02-1
SECTION : 412-02 Heating and Ventilation VEHICLE APPLICATION : 2003.0 BA Falcon CONTENTS
PAGE
SPECIFICATIONS Specifications ........................................................................................................................412-02-2 DESCRIPTION AND OPERATION Heating and Ventilation .........................................................................................................412-02-3 Air Conditioning ....................................................................................................................412-02-4 Dual Zone Automatic Climate Control System ....................................................................412-02-4 Distribution Modes ...............................................................................................................412-02-6 Air Filtering ...........................................................................................................................412-02-8 HVAC Ducting ......................................................................................................................412-02-8 Acronyms and Abbreviations ...............................................................................................412-02-9 DIAGNOSIS AND TESTING Heating and Ventilation .......................................................................................................412-02-10 Inspection and Verification .................................................................................................412-02-10 Symptom Chart ..................................................................................................................412-02-10 PID Chart ...........................................................................................................................412-02-12 DTC Chart ..........................................................................................................................412-02-13 Pinpoint Tests ....................................................................................................................412-02-13 REMOVAL AND INSTALLATION Blower Fan Assembly .........................................................................................................412-02-20 HVAC Assembly .................................................................................................................412-02-20 HVAC Case Scroll ...............................................................................................................412-02-21 Heater Core Assembly ........................................................................................................412-02-22 Case Assy — Recirc Door Complete ..................................................................................412-02-22 HIM Assy .............................................................................................................................412-02-24 Actuator — Electric Airmix (ACC only) ...............................................................................412-02-26 Shaft — Airmix Door DZ/SZ ................................................................................................412-02-27 Dual Zone Sub Harness .....................................................................................................412-02-28 Filter and Cover Assembly — Mesh (Standard Fitment) ....................................................412-02-28 Filter — Particle (Optional Fitment) ....................................................................................412-02-29 Vent Outlet Register — Outboard Register ........................................................................412-02-29 Vent Outlet Register — Centre Register .............................................................................412-02-30 Vent Outlet Register — Floor Console Register .................................................................412-02-30 Floor Console Duct .............................................................................................................412-02-31
01/2003 2003.0 BA Falcon
412-02-2
Heating and Ventilation
412-02-2
SPECIFICATIONS General Specifications Description Lubricants HVAC Lever Cam Grease Engine Coolant
A/C System O-Ring Lubrication A/C System O-Rings
Specification Dow Corning Molykote PG 54 Silicon Grease Do not top up the cooling system with tap water. Use only Ford Specified Coolant at a Ratio of 30 50 % PAG ND-Oil 8 Refrigerant O-Ring, green HNBR, Evaporator Outlet (large) - part no. BA19S710A Evaporator Inlet (small) part no. BA19S710B
Torque Specifications Description HVAC Mounting Upper Bolts (4) HVAC Mounting Lower Nuts (2) Evaporator Tube to A/C Tube Clamping Bolt HVAC Case Hi / Lo Plastic Self Tapping Screws Heater Tube Clamp Retaining Screw Evaporator Plastic End Plate HIM to HVAC Self Tapping Screws Blower Motor to HVAC Self Tapping Screws
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Nm 6-8 9 - 12 12.7 - 17.3 1.1 - 1.5 1.1 1.1 1.1 1.1 -
1.5 1.5 1.5 1.5
01/2003 2003.0 BA Falcon
412-02-3
Heating and Ventilation
412-02-3
DESCRIPTION AND OPERATION
Heating and Ventilation
Manual Climate Control System
Instrument Panel
The airflow volume and direction can be regulated with the controls on the instrument panel and by adjusting the instrument panel. Instrument panel and rear console adjustable vents The airflow can be turned on or off with the rotary controls at the side of the vents. Vents should be either fully open (top detent position) or fully closed (bottom detent position).
Item 1 2 3 4 5 6 7 8 9 10
Description Air Conditioning Button Air Distribution Buttons Air Distribution Buttons Air Distribution Buttons Fan Speed Dial Recirculated Mode Rear Window Demist Air Distribution Buttons Air Distribution Buttons Temperature Control Dial
Blower fan speed selector The rotary blower fan speed selector is used to adjust the blower fan speed. At the lowest setting the fan is off, unless A/C is selected. Outside air will still enter the cabin if fresh air is selected, even with the blower off.
The direction of the airflow can be adjusted horizontally and vertically within the swivelling range of the air vanes and vents.
NOTE: The blower fan will only operate with the ignition in the ON position. Temperature Control The temperature of the air maybe adjusted using the temperature control dial. Turn the dial clockwise to increase heating. Turn the dial anti-clockwise to G34251 en
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412-02-4
Heating and Ventilation
412-02-4
DESCRIPTION AND OPERATION (Continued) decrease heating. Turning the dial fully anti-clockwise will toggle "A/C MAX" mode, which provides maximum occupant cooling, by switching on the air conditioning and selecting recirculated air inlet and face level air outlet. When turning the dial clockwise after selecting A/C MAX, fresh air will automatically be selected while the other A/C MAX modes will remain unchanged.
Dual Zone Automatic Climate Control System
NOTE: The heater maintains warmth only when the engine is operating. Full heating is only available when the engine is at normal operating temperature
Air conditioning Press the A/C button to select the air conditioner on/off. NOTE: If the blower fan is off and A/C is turned on the fan will automatically come on to the lowest speed. A/C MAX mode is selected by turning the temperature control dial fully anti-clockwise to the A/C MAX position. A/C MAX automatically switches on the air conditioner, selects the Recirculated Air inlet mode and Face Level air outlet mode. These modes can be manually overridden.
Item Description 1 Temperature Control LHS 2 Windscreen Demist 3 Air Distribution Mode Button 4 Rear Window Demist 5 Temperature Control RHS 6 Air Conditioning Button 7 On/Off Auto Mode Button 8 Fan Speed Dial 9 Recirculated Mode The dual zone automatic climate control system automatically controls heating, cooling and fan speed to maintain the desired level selected between 18 ºC and 30 ºC when operated in the ’AUTO’ mode. The selected comfort setting (eg. 22ºC) is automatically maintained when ’AUTO’ mode is selected. Driver and front passenger have independent comfort settings. 22 ºC is the recommended comfort setting for most users. A microcomputer and sensors monitor cabin, outside air, air conditioner evaporator and engine temperatures as well as the strength of direct sunshine on the interior of the vehicle. Instrument panel face level vents should be adjusted to direct airflow to suit personal comfort.
Automatic Operation
The A/C MAX graphic will continue to be displayed while the temperature control dial is set to A/C MAX and the Recirculated Air inlet mode is retained. NOTE: The air conditioner will only operate with the engine running.
After starting the engine, if ’Off’ is displayed in the control panel display window, press the ’AUTO’ button to turn the system on. Adjust the comfort level to the desired temperature using the ’Temperature control’ buttons. After starting the engine, if ’AUTO’ appears in the display window, the system will automatically adjust to that comfort level without any further assistance.
NOTE: To maximise cooling efficiency, select A/C MAX and select a high fan speed setting G34251 en
01/2003 2003.0 BA Falcon
412-02-5
Heating and Ventilation
412-02-5
DESCRIPTION AND OPERATION (Continued)
’Auto’ mode automatically controls air source, air distribution, fan speed, air conditioning and temperature. From time to time you may notice the air distribution mode and fan speed changing. This is the system’s normal mode of operation whereby it selects the mode of air distribution and fan speed most appropriate to maintain the selected comfort setting. When starting the vehicle on a cold day with a cold engine, air discharge is delayed until the engine begins to reach operating temperature. Simultaneously, the blower fan speed will increase to assist warm air circulation throughout the cabin. As the interior air warms to the preselected comfort setting, the fan speed will then decrease. The OFF button will turn the automatic climate control system off but will allow fresh air to enter the cabin through the instrument panel vents. Fan speed and air distribution may be controlled in the off mode.
different setting until the driver’s setting is no longer ’LOW’ or ’HIGH’. When the driver changes the setting from ’LOW’ or ’HIGH’, both passenger and driver settings are controlled together by the driver until the passenger adjusts their temperature setting. When the vehicle is started, the passenger and driver settings are set at the previously set driver’s setting. If the driver then adjusts the temperature setting, both passenger and driver settings are controlled together by the driver until the passenger adjusts their temperature setting. The passenger setting can be re-linked to the driver setting at any time by holding down the auto button for more than 2 seconds. NOTE: The heater maintains warmth only when the engine is operating. Full heating is only available when the engine is at normal operating temperature.
Blower fan speed selector The blower fan speed selector is used to adjust the blower fan speed. To turn the fan off completely, press the "OFF" button. NOTE: The blower fan will only operate with the ignition in the ON position.
Semi-Automatic operation If desired, you may override the automatic control system and operate some features manually (such as fan speed and air distribution). Manually selecting such features when in ’Auto’ mode will change the system to ’Semi-auto’. Full automatic control can be resumed at any time by pressing the ’Auto’ button. Outside Air Temperature
Dual zone temperature control Dual zone temperature control allows the driver and front passenger to set independent air temperatures according to personal preference. NOTE: This does not allow independent distribution modes or fan speed, only temperature. The rear console vent outputs correspond to all Climate Control outputs as set by the driver and front passenger. The temperature may be set within the range of 18ºC to 30ºC, in 0.5ºC increments. If a temperature below 18ºC is selected, then ’LOW’ is displayed. If a temperature above 30ºC is selected, then ’HIGH’ is displayed. If the driver selects either ’LOW’ or ’HIGH’, the passenger setting is also changed to ’LOW’ or ’HIGH’ and the passenger is unable to choose a G34251 en
A sensor under the passenger-side exterior mirror monitors outside temperature. This is displayed in the message display window. Correct operation of the sensor relies on air moving across the sensor. Therefore, at low vehicle speed, or operating the vehicle for a short period of time, the display may differ slightly from the true outside air temperature.
Windscreen demist In the event that fast demisting of glass is required, press the demist button. Air is directed to the windscreen and side window vents to demist glass. The air conditioner and blower fan will operate, the fresh air mode will be selected and heating (if available) will be used. When the glass is demisted, press the AUTO button to return to automatic climate control.
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Heating and Ventilation
412-02-6
DESCRIPTION AND OPERATION (Continued)
Heated rear Window Demister
Air Conditioning
With the ignition ON, press the switch to turn the demister on. The graphic on the Interior Command Centre screen will appear. To turn off, press the switch again, otherwise the demister will automatically turn itself off after approximately 15 minutes.
Press the ’A/C’ button to toggle the air conditioner on/off. Note: if the fan is off and A/C is turned on the fan will automatically come on to the lowest speed. NOTE: If the system is OFF and the A/C is turned ON the system will return to ’AUTO’ operation.
To switch off, press the switch again, otherwise the demister will automatically turn itself off after approximately 15 minutes.
NOTE: If the system is OFF and the A/C is turned ON the system will return to ’AUTO’ operation.
Distribution mode selector
NOTE: The air conditioner will only operate with the engine running.
May be used to direct the air to particular groups of outlet vents. Press the button repeatedly up or down until the desired setting is shown in the display window. Information on distribution modes can be found later in this section.
NOTE: To maximise cooling efficiency, select AUTO operation.
Distribution Modes Distribution modes can only be selected with the ignition on.
Face level Air is directed to the adjustable instrument panel vents and the centre console vents (for rear seat passengers). The vents may be adjusted for direction and flow or may be individually closed if desired.
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Heating and Ventilation
412-02-7
DESCRIPTION AND OPERATION (Continued)
Face level/footwell
Windscreen demist/footwell
Air is directed to the adjustable instrument panel vents, centre console vents (for rear seat passengers) and front footwell vents. If heating is selected, heated air is directed to the front footwell vents and partially heated air is directed to the face level vents. The warmer the setting, the warmer the air to face If full cooling is selected, cool air is delivered to face and footwell vents.
Air is directed to the windscreen and side window vents to aid in glass demisting Air is also directed to the front footwell vents. and centre console vents (for rear seat passengers).
Footwell
Windscreen demist
Air is directed to the front footwell vents, centre console vents (for rear seat passengers) and a small amount is also directed to the windscreen and side window vents to reduce glass misting or fogging.
When windscreen demist mode is selected, the A/C and fresh air modes are automatically selected for glass demisting. Also, the blower fan will automatically start at the lowest fan speed if the fan was not already running. For maximum demisting, highest heating and highest fan setting should also be used. NOTE: A/C and fresh air mode can be manually overridden but demist efficiency will be reduced.
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Heating and Ventilation
412-02-8
DESCRIPTION AND OPERATION (Continued) finer pollen filter is also available, as an accessory item, from your Ford dealer. Fresh or recirculated air is controlled by pressing the NOTE: Extended operation of the climate control recirculated mode button. Pressing the button will system in a recirculated air mode may lead to a alternate between fresh and recirculated air modes. A reduction in air quality in the cabin. The air in the graphic indicating the selected mode will appear on cabin should be periodically refreshed by selecting the display. fresh air settings. In normal circumstances, the fresh air mode should To clean the standard mesh filter, blow through mesh be selected to maintain the quality of air inside the with compressed air and wash with luke warm water. vehicle and to prevent the build-up of stale air or For the optional pollen filter (where fitted), the filter odours, and to reduce windscreen misting. cannot be washed. When serviced, the pollen filter To prevent the ingress of dust, odours or fumes, should be replaced. If the filter is blown through with select the recirculated air mode. The recirculated air mode can also be used to allow the air conditioner to compressed air, rather than replaced, the air quality and airflow quantity may be degraded. more effectively cool the vehicle’s cabin. Do not use
Fresh/Recirculated air selector
the recirculated air mode if vehicle occupants are smoking as tobacco odours may remain.
HVAC Ducting The fresh air intake to the HVAC unit enters the plenum chamber through the cowl grilles underneath the windscreen wipers. The recirculated air intake to the HVAC unit is inside the cabin behind the glove box and directly below the LH plenum chamber. The HVAC fresh air entry is attached to the plenum chamber with a foam seal. Outlet air from the HVAC unit can exit into the instrument panel duct, to the floor vent outlets or to the floor console duct. The HVAC unit is attached to the floor console duct with a foam seal. Between the HVAC unit and the firewall at the locations where the heater and evaporator tubes pass through, foam pads are fitted around the tubes to seal the firewall openings.
Air Filtering The air selector system is fitted with a fine mesh particle filter to exclude leaf debris, dust and dirt. A
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412-02-9
DESCRIPTION AND OPERATION (Continued) HVAC Air Distribution Outlets
Item Description 1 Fresh air intake 2 HVAC air outlet to front screen demist 3 HVAC air outlets to face vents 4 Floor and console ducts 5 Recirculated air intake The instrument panel duct directs outlet air to the demist/screen, face centre and face side LH/RH vent outlet registers. The instrument panel duct is an integral part of the instrument panel and is not a separately serviceable item. If the duct is faulty, the complete instrument panel must be replaced. The floor console duct is removed from the vehicle as part of the floor console assembly. The duct can then be separated from the console. Refer to Removal & Installation procedure later in this section.
Acronyms and Abbreviations The following acronyms will be used throughout this section. A/C ACC CAN DTC ECU G34251 en
HIM HTR HVAC ICC MAX MCC MIN MSG N/A PID RPM EATC EEC PCM BEM ACPT SZ DZ
HVAC Integrated Module Heater Heating, Ventilation & Air Conditioning Interior Command Centre Maximum Manual Climate Control Minimum Message Not Applicable Parameter Identifier Revolutions Per Minute Electronic Air Temperature Control Electronic Engine Control Powertrain Control Module Body Electronics Module Air Conditioning Pressure Transducer Single Zone Dual Zone
Air Conditioning Automatic Climate Control Controller Area Network Diagnostic Trouble Code Electronic Control Unit 01/2003 2003.0 BA Falcon
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Heating and Ventilation
412-02-10
DIAGNOSIS AND TESTING
Heating and Ventilation Inspection and Verification Check these items before entering Diagnostics.
Topic Vehicle Battery Voltage Engine to be running Record all DTC’S present Ensure that a false DTC has not been set because of prior work on the vehicle. Example: If the LHF door (ACC vehicle) was removed at a body shop, Ambient temperature sensor DTC will be set. When referring to a Temperature / Resistance table. When using pressure gauges Vacuum pump must pull down to -100 kPa (30 in/hg)
Specification Greater than 12 Volts In all Tests Before Clearing Customer may have to be questioned on the vehicle history if a DTC root cause component cannot be found. Place an accurate electronic Thermometer near to the Sensor in question. Ensure that they are correctly calibrated and that the needles rest on Zero with no Refrigerant in the lines and the gauge valves open. Change the Vacuum pump oil approximately every 15 evacuations, to improve pull down time.
Symptom Chart Condition No airflow in selected mode
Insufficient airflow in selected mode
Airflow direction incorrect
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Source
Action
ICC
Go to Section 413-08.
Evaporator Core Ice-Up
Go to Section 412-03, Pinpoint test D.
Intake Air Filter Restriction
Go to PinPoint Test I.
Mode (HIM)
Go to PinPoint Test D, E, F, G, H, J.
Low Battery Charge
Refer to Section 412-04, Go to PinPoint Test H.
CAN Message Failure
Refer to Section 412-04, Go to PinPoint Test M.
Plenum Area Restriction
Go to PinPoint Test A.
Blower Motor
Go to section 412-04, Pinpoint test L.
Plenum Area Restriction
Go to PinPoint Test A.
Instrument panel/console duct restriction
Go to PinPoint Test B.
Mode (HIM)
Go to PinPoint Test D, E, F, G, H, J.
Evaporator Core Ice-Up
Go to section 412-03, Pinpoint test D.
Intake Air Filter Restriction
Go to PinPoint Test I.
Low Blower Voltage
Go to section 412-04, Pinpoint test H.
Fresh / Recirc Door Jammed
Go to PinPoint Test D.
Sun Load Sensor
Refer to section 417-01.
Mode (HIM)
Go to PinPoint Test D, E, F, G, H, J.
Linkage Disconnect
Go to PinPoint Test D, E, F, G, H, J.
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Heating and Ventilation
412-02-11
DIAGNOSIS AND TESTING (Continued) Condition Blower motor not operating on selected speed
A/C not cold
Heating ineffective
Smell from HVAC through vents
Noise
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Source
Action
ICC
Go to Section 413-08.
Can Message
Refer to Section 412-04, Go to PinPoint Test M.
Blower Input Function
Refer to Section 412-04, Go to PinPoint Test L.
ICC
Refer to Section 413-08.
Driver side Actuator Motor
Go to PinPoint Test H.
Passenger side Actuator Motor
Go to PinPoint Test G.
Low Refrigerant Charge
Refer to Section 412-03.
A/C Compressor Not Engaging
Refer to Section 412-03, Go to PinPoint Test A & B.
Evaporator Temperature Sensor
Refer to Section 412-04, Go to PinPoint Test B.
Evaporator Core Ice-Up
Go to section 412-03, Pinpoint test D.
Mode (HIM)
Go to PinPoint Test D, E, F, G, H, J.
Ambient Air Sensor
Refer to Section 412-04, Go to PinPoint Test A.
Cabin Temperature Sensor
Refer to Section 412-04, Go to PinPoint Test P.
Blower Motor
Refer to Section 412-04, Go to PinPoint Test L.
Passenger side temperature Hotter than Drivers side
Go to PinPoint Test K.
Sun Load Sensor
Refer to section 417-01.
Passenger side Actuator Motor
Go to PinPoint Test G
Driver side Actuator Motor
Go to PinPoint Test H.
Heater Core Issue/Engine cooling issue
Go to PinPoint Test C.
Mode (HIM)
Go to PinPoint Test D, E, F, G, H, J.
Ambient Air Sensor
Refer to Section 412-04, Go to PinPoint Test A.
Cabin Temperature Sensor
Refer to Section 412-04, Go to PinPoint Test P
ICC
Refer to Section 413-08.
Leaking Heater Core
Go to PinPoint Test C.
Blocked Heater Core/Engine Cooling system
Go To section 303-03.
Leaking Evaporator Core
Go to section 412-03, Pinpoint test E.
Evaporator Core Ice-Up
Go to section 412-03, Pinpoint test D.
Intake Air Filter Contaminated
Go to PinPoint Test I.
Mode (HIM)
Go to PinPoint Test D, E, F, G, H, J.
Vehicle Carpet Wet
Visual inspection to verify if the HVAC drain hose is blocked or misaligned with the hole in Transmission tunnel.
Blower Motor
Go to section 412-04, Pinpoint test L.
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412-02-12
DIAGNOSIS AND TESTING (Continued) Condition
Source
ICC Display
Orifice Tube
Refer to Section 412-03.
Low Refrigerant Charge
Refer to Section 412-03.
Heater Core "Gurgle" Sound/Engine Cooling system bleed issue
Refer to section 303-03.
Ambient temperature display inaccurate
Go to section 412-04 Pinpoint test A.
Display character fault
Refer to section 413-08.
Display illumination fault
Refer to section 413-08.
Acronym
PID Chart The following table lists all PID’s utilised by the WDS service tool to access specific functions within the HIM. Acronym CCNT
Description
Number of Continuous Trouble Codes Set NTCSDT Number of Trouble Codes Set due to Diagnostic Test A_CT Evaporator Temperature ETSFD External Temperature Sensor Filtered Data EXT_TEMP External Temperature From Sensor (unfiltered) PBDAP Passenger Blend Door Actual Position PBDTP Passenger Blend Door Target Position BLENDDR Driver Blend Door Position BLENTP Driver Blend Door Target Position BLOWVOL HVAC Blower Voltage BLOWAP Blower Motor Speed - Actual Position BLOWTP Blower Motor Speed - Target Position LEFTOT Passenger’s Display Set Temperature G34252 en
HIM Configuration ACC MCC HTR YES YES YES
RIGHTOT MC_VREF HIM_STAT CONPROV
YES YES
YES CANDSV
YES YES
N/A
YES
N/A
N/A
RECIRDS RECIRDTP
YES
N/A
N/A
CCACTM MOD_ID
YES YES
YES CCMODE
YES YES
YES
YES
N/A
N/A
YES
N/A
N/A
YES YES
YES
YES YES
YES
YES YES
YES
BEM_MSG
CDU_MSG
PCM_MSG
ACCS YES
Action
N/A
N/A
CAL_VER
Description Driver’s Display Set Temperature Vehicle Battery Voltage ECU Diagnostic Operating State Configuration and Programming Version CAN Diagnostic Specification Version Recirculation Door Actual Position Recirculation Door Target Position Climate Control Actuator Modes Module Configuration Check Climate Control Mode GEM - Body Electronics Module CAN Message Receive Status ACM - Interior Control Center Module CAN Message Receive Status PCM - Powertrain Control Module CAN Message Receive Status AC Compressor Cycling Request EEprom Calibration Version
HIM Configuration ACC MCC HTR YES N/A N/A YES YES
YES
YES YES
YES
YES YES
YES
YES YES
YES
YES YES
YES
YES YES
YES
YES YES
YES
YES YES
YES
N/A
YES
N/A
YES YES
YES
YES YES
YES
YES YES
YES
YES YES
N/A
YES YES
YES
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DIAGNOSIS AND TESTING (Continued) Acronym
Description
HIM Configuration ACC MCC HTR CAL_VRAM Calibration Version YES YES YES Currently Loaded in RAM.
DTC Chart Refer to DTC chart in Section 412-04.
Pinpoint Tests PINPOINT TEST A : PLENUM CHAMBER AIR RESTRICTION (ACC / MCC / HTR) CAUTION: Take all the standard safety procedures when dealing with A/C system refrigerant, including Eye protection and Gloves. NOTE: REFER to SECTION 412-02 SYMPTOM CHART BEFORE PROCEEDING Test Step A1
Result / Action to Take
VISUAL INSPECTION - ABOVE COWL GRILLES Inspect the cowl panel grilles (LH and RH) below the windscreen wiper arms for evidence of airflow obstruction. Was there debris, dust or insects on the top of the cowl grille obstructing intake air to the cabin?
Yes
Remove the airflow obstruction, and blow out any debris using compressed air.
No
Go to A2
A2
VISUAL INSPECTION - BELOW COWL GRILLES Remove the cowl panel grilles (LH and RH). Refer to section 501-02. Inspect the plenum inlet chamber below the cowl grilles for evidence of airflow obstruction. Was there debris, dust or insects in the plenum inlet chamber obstructing intake air to the cabin?
Yes
Remove the airflow obstruction, and blow out any debris using compressed air.
No
Plenum chamber air intake was not restricted.
PINPOINT TEST B : INSTRUMENT PANEL/ CONSOLE DUCT RESTRICTION (ACC/MC/HTR) CAUTION: Take all the standard safety procedures when dealing with A/C system refrigerant, including Eye protection and Gloves. Refer to Section 412-03 for the complete Safety Precautions. NOTE: The instrument panel duct (incorporating demist/screen, face centre and face side ducts) is an integral part of the instrument panel, and is not a separately serviceable item. If the duct is faulty, the complete instrument panel must be replaced (Refer to section 501-12). NOTE: REFER to SECTION 412-02 SYMPTOM CHART BEFORE PROCEEDING Test Step B1
Result / Action to Take
VISUAL INSPECTION - VENT OUTLETS
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Inspect the demist vent outlets for evidence of airflow obstruction, including a dash mat or other item which may cover the vent outlet.
Yes
Is there evidence of airflow obstruction at any demist vent outlets?
No
Remove the airflow obstruction.
Go to B2
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DIAGNOSIS AND TESTING (Continued) Test Step B2
Result / Action to Take
Airflow TEST - VENT OUTLETS Run the engine and switch on the ACC with blower fan operating at maximum speed. Whilst selecting the air outlet modes using the ICC button, check for air delivery at all vent outlets (demist/screen, face front, face side LH/RH, floor LH/RH and rear console).
Yes
Instrument panel duct is not restricted.
No
Go to E & F
Is airflow supplied to each vent outlet?
PINPOINT TEST C : HEATER CORE LEAKING CAUSING “SMELL” (ACC / MCC / HTR) CAUTION: If the Heater Core is to be removed, ensure that the Heater core tubes are "capped" to avoid any Coolant spillage onto the vehicle interior. NOTE: NOTE: REFER to SECTION 412-02 SYMPTOM CHART BEFORE PROCEEDING Test Step C1
Result / Action to Take
COOLING SYSTEM PRESSURE Conduct engine cooling system pressure test. Refer to section 303-03 Yes for test procedure. No Cooling system leakage evident. Does the cooling system hold pressure?
No
Go to C2
C2
VISUAL INSPECTION Start Engine, select Full heat and Highest Blower Fan speed at the ICC. Run Engine for a minimum of 10 Minutes.
Yes
Replace the Heater core. Refer to removal and installation instructions in this section.
No From under the vehicle inspect the A/C drain tube for evidence of Engine coolant. Is there evidence at the drain tube of Coolant? The Heater core is not the cause of the Coolant leakage or Smell.
PINPOINT TEST D : ACTUATOR — RECIRCULATE DOOR (ACC / MCC / HTR) CAUTION: If carrying out a "feel" test for door movement, care should be taken to avoid injury to your Hand from moving parts such as blower motor, levers, etc. NOTE: NOTE: REFER to SECTION 412-02 SYMPTOM CHART BEFORE PROCEEDING Test Step G34252 en
Result / Action to Take 01/2003 2003.0 BA Falcon
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Heating and Ventilation
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DIAGNOSIS AND TESTING (Continued) Test Step D1
VISUAL INSPECTION - RECIRC DOOR LEVER TO HIM CAM Remove the Glove Box. Refer to Section 501-12. Remove Air Intake Filter. Carry out a visual inspection to see if the Recirc door cam is connected to the HIM BLACK lever pin, Is the lever connected?
D2
Result / Action to Take
Yes
Go to D2
No
Using a flat blade screwdriver, gently move / prise the HIM lever pin into the recirc door cam.
VISUAL INSPECTION - RECIRC DOOR OPERATION Check for full door movement to Fresh and Recirc while pushing the ICC Button with visual inspection or by inserting your hand through the Air Intake Filter opening. Is the Fresh / Recirc Door moving fully from fresh to recirc?
Yes
System OK Clear DTC Perform HVAC On - Demand Self Test refer to section 412-04
No
Go to section 412-04 Pinpoint test C.
PINPOINT TEST E : ACTUATOR SCREEN/FACE DOOR (ACC / MCC / HTR) CAUTION: If carrying out a "feel" test for door movement, care should be taken to avoid injury to your Hand from moving parts such as blower motor, levers, etc. NOTE: NOTE: REFER to SECTION 412-02 SYMPTOM CHART BEFORE PROCEEDING Test Step E1
Result / Action to Take
VISUAL INSPECTION - SCREEN / FACE DOOR OPERATION Check for full door movement to Screen and Face while pushing the ICC Button. Check for air delivery from Face and Screen modes alternatively with blower operating at full speed. Are the Screen and Face modes selectable?
Yes
System OK Clear DTC Perform HVAC On-Demand Self Test. Refer to Section 412-04.
No
Go to E2
E2
VISUAL INSPECTION - HIM LEVER TO HVAC CAM Remove the Glove Box. Refer to Section 501-12. Using a mirror and a torch view the lever area between the HIM and the HVAC to see if the HIM BLUE and GREEN lever pins are slotted into the HVAC lever cams. Were the HIM lever pins slotted into the HVAC lever cams?
Yes
Go to Section 412-04 , Section D.
No
Remove the instrument panel. Refer to Section 501-12. Remove and Install the HIM ensuring that HIM levers and HVAC cams are connected. Refer to removal and installation instructions in this section.
PINPOINT TEST F : ACTUATOR — FLOOR/CONSOLE (ACC / MCC / HTR) CAUTION: If carrying out a "feel" test for door movement, care should be taken to avoid injury to your Hand from moving parts such as blower motor, levers, etc. NOTE: REFER to SECTION 412-02 SYMPTOM CHART BEFORE PROCEEDING Test Step
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Result / Action to Take
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DIAGNOSIS AND TESTING (Continued) Test Step F1
Result / Action to Take
VISUAL INSPECTION - FLOOR / CONSOLE DOOR OPERATION Check for door movement to Floor while pushing the ICC Button. Check for air delivery from floor with blower operating at full speed.
Yes
NOTE: It is usual for airflow from rear console while Floor / Heating is selected.
System OK Clear DTC Perform HVAC On-Demand Self Test. Refer to Section 412-04.
Is the Floor mode selectable?
No
Go to F2
F2
VISUAL INSPECTION - HIM LEVER TO HVAC CAM Remove the Glove Box. Refer to Section 501-12. Using a mirror and a torch view the lever area between the HIM and the HVAC to see if the HIM YELLOW lever pin is slotted into the HVAC cam. Was the HIM lever pin slotted into the HVAC cam?
Yes
Refer to Section 412-04, Go to PinPoint Test F.
No
Remove the instrument panel. Refer to Section 501-12. Remove and Install the HIM ensuring that HIM levers and HVAC cams are connected. Refer to removal and installation instructions in this chapter.
PINPOINT TEST G : ACTUATOR — PASSENGER AIR TEMPERATURE MIX (ACC / MCC /HTR) CAUTION: If carrying out a "feel" test for door movement, care should be taken to avoid injury to your Hand from moving parts such as blower motor, levers, etc. NOTE: This actuator is utilized to control air temperature to both passenger and driver by the single zone (SZ) manual climate control system. It is used to control only the passenger side air temperature for dual zone (DZ) automatic climate control system. H (High) and L (Low) settings are not possible via the passenger temperature rocker switch on ACC system. NOTE: REFER to SECTION 412-02 SYMPTOM CHART BEFORE PROCEEDING Test Step G1
Result / Action to Take
VISUAL INSPECTION - PASSENGER AIR MIX DOOR OPERATION Check for full door movement to full Hot and full Cold while operating the ICC button. (For MCC, set dial control to Hot then Cold. For ACC, select H then L by drivers temperature setting rocker switch.) Does the passenger air mix door move to full Hot and full Cold positions?
Yes
System OK Clear DTC Perform HVAC On-Demand Self Test. Refer to Section 412-04.
No
Go to G2
G2
VISUAL INSPECTION - HIM TO TEMP DOOR SHAFT Remove the Glove Box. Refer to Section 501-12. Using a mirror and a torch view the lever area between the HIM and the HVAC to see if the HIM is connected to the temperature door shaft. Was the HIM connected to the temperature door shaft?
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Yes
Go to Section 412-04, pinpoint test E.
No
Remove the instrument panel. Refer to Section 501-12. Remove and Install the HIM ensuring that temperature door shaft coupling is connected to the HIM. Refer to removal and installation instructions in this chapter.
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412-02-17
DIAGNOSIS AND TESTING (Continued) PINPOINT TEST H : ACTUATOR — DRIVER AIR TEMPERATURE MIX (ACC) CAUTION: If carrying out a "feel" test for door movement, care should be taken to avoid injury to your Hand from moving parts such as blower motor, levers, etc. NOTE: This actuator is utilized to control air temperature to the driver side only for dual zone (DZ) automatic climate control system. NOTE: REFER to SECTION 412-02 SYMPTOM CHART BEFORE PROCEEDING Test Step H1
Result / Action to Take
VISUAL INSPECTION - DRIVER AIR MIX DOOR OPERATION Check for full door movement to full Cold and full Hot while operating the ICC button. (Select C then H by the Drivers temperature setting rocker switch.)
Yes
System OK Clear DTC Perform HVAC On-Demand Self Test. Refer to Feel the face outlet temperature change temperature from Cold to Hot Section 412-04. using your hand. Does the driver temperature change from Cold to Hot?
H2
H3
No
Go to H2
VISUAL INSPECTION - DRIVERS SIDE ACTUATOR TO SHAFT Yes
From under the Drivers side, view the Driver’s actuator shaft in between the airmix actuator and the HVAC, for movement while changing the temperature from Hot to Cold using the ICC button.
Go to H3
Did the shaft turn when Hot to Cold selected?
Refer to Section 412-04, Go to PinPoint Test G.
No
VISUAL INSPECTION - DRIVERS SIDE SHAFT MOVEMENT Set the ICC to face mode. Remove the ICC. Refer to Section 413-08. Insert your hand through the ICC opening and try turning the temperature door shaft. Does the shaft turn?
Yes
Broken shaft, replace the HVAC Door Module. Refer to removal and installation instructions in this chapter.
No
Refer to Section 412-04, Go to PinPoint Test G.
PINPOINT TEST I : INTAKE AIR FILTER RESTRICTION (ACC / MCC / HTR) CAUTION: Do not use "Hot" water to clean the standard mesh Filter. Do not use any water to clean the optional pollen filter. NOTE: REFER to SECTION 412-02 SYMPTOM CHART BEFORE PROCEEDING Test Step
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Result / Action to Take
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DIAGNOSIS AND TESTING (Continued) Test Step I1
Result / Action to Take
AIR INTAKE INSPECTION Remove the Glove Box. Refer to Section 501-12.
Yes
Standard mesh filter - using Compressed air, "blow" any contamination from the mesh Filter. Was there Debris, Dust or Insects obstructing airflow through the Rinse the mesh Filter under Luke warm water. Optional Pollen Filter. If heavily contaminated Intake Air Filter? Replace Filter. If mildly contaminated, use compressed air to "blow" out any contamination. NOTE: Cleaning rather than replacing the optional pollen filter may degrade the air quality and airflow quantity. Remove the Intake Air Filter, refer to section 412-01.
No
Air Intake Filter not the cause of the airflow restriction.
PINPOINT TEST J : HIM LEVER TO FLOOR/CONSOLE DOOR ROD INSPECTION (ACC / MCC / HTR) CAUTION: Do not alter the mode position, with your hand on the rod otherwise your hand could become jammed and cause skin damage. NOTE: REFER to SECTION 412-02 SYMPTOM CHART BEFORE PROCEEDING Test Step J1
Result / Action to Take
VEHICLE SETUP Remove the Glove box. Refer to Section 501-12. Start Engine. At the ICC select Face Mode. Locate and follow the Rod with your hand from the HIM all the way to the Floor door lever. Is the rod connected to the Floor door lever?
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Yes
Ensure that the plastic rod retainer clip is in place at the Floor door lever end. Then refer to chapter Section 412-04, Go to PinPoint Test F.
No
Reconnect rod into the Floor door lever and secure with the retaining clip.
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Heating and Ventilation
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DIAGNOSIS AND TESTING (Continued) PINPOINT TEST K : PASSENGER SIDE TEMPERATURE WARMER THAN THE DRIVERS SIDE (ACC / MCC) CAUTION: Take all the standard safety procedures when dealing with A/C system refrigerant, including Eye protection and Gloves. NOTE: If the A/C suction (low side) pressure is lower than specification because of a low refrigerant charge, the refrigerant "super heat" increases and cooling in the evaporator may be irregular, causing the passenger side temperature to "feel’ warmer. NOTE: REFER to SECTION 412-02 SYMPTOM CHART BEFORE PROCEEDING Test Step K1
Result / Action to Take
VERIFICATION - VEHICLE SET-UP Start Engine. Run vehicle at operating temperature. Set ICC to full Cold (Low, L) Passenger / Driver side (ACC) or Full Cold (MCC). Select Fresh air intake mode.
Yes
Go to K2
No
HVAC System Temperature "split" is to specification. System Okay.
Put bonnet up. Ensure A/C compressor is engaged (Refer 412-03). ACC - Select manual override - Face mode. MCC - Select Face mode. Select the highest blower fan speed. Insert a thermometer into the Face vent, drivers side. Allow the temperature reading to stabilise (stay at one constant temperature) Take a reading. Quickly insert the thermometer into the passenger side Face vent and allow to stabilise. Take a reading. Is the difference in temperature between the Passenger side and Drivers side greater than 10 Degrees?
K2
REFRIGERANT PRESSURE LOW Yes
Connect A/C Manifold Gauge set (High & low side pressure gauges) as per section 412-03. Conduct A/C System Performance test for low A/C pressures as per section 412-03.
Perform HVAC On - Demand Self Test refer to section 412-04. Go to PinPoint Test B.
Were the A/C system pressure readings to specification?
No
Refer to section 412-03. Conduct an A/C System Leak test for possible refrigerant leakage. Discharge, repair as required, evacuate and recharge the A/C system.
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REMOVAL AND INSTALLATION
Blower Fan Assembly
HVAC Assembly
Removal 1. Disconnect electrical connector. 2. Undo three screws. 3. Lower the Blower Fan assembly and remove.
Removal 1. Recover refrigerant from the A/C system. Refer to Section 412-03. 2. Drain engine coolant. Refer to Section 303-03. 3. Disconnect A/C tubes, Refer to Section 412-03. CAUTION: Evaporator O-rings and tube ends should be capped to prevent damage and contamination. 4. Disconnect Heater hoses.
5.
Item 1 2
Description Electrical Connector 3 Screws
6. 7. 8.
CAUTION: Cap the heater tube ends to prevent coolant spillage onto the vehicle interior. Remove Instrument Panel, Refer to Section 501-12. Disconnect blower harness. Disconnect HIM main harness (power) Disconnect HIM main harness (control).
Installation 1. Refit components in reverse order. CAUTION: Ensure correct alignment of cooling air guide.
Item 1 2 3
Description HIM Main power harness Evaporator sensor elec connector HIM Main control harness
9. Undo the four nuts and two bolts used to retain the HVAC Assembly mountings to the firewall.
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REMOVAL AND INSTALLATION (Continued)
10. Carefully work the firewall insulation off and over each speed nut with a screw driver. NOTE: A small amount of firewall insulation around the mounting points may be damaged at removal stage, but this is not deemed to be a problem. 11. Carefully remove the HVAC assembly from the passenger side of the vehicle. NOTE: On removal of the HVAC, if a large section of firewall insulation is damaged, repair before re-installing the HVAC Assembly.
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Installation 1. Refit components in reverse order.
HVAC Case Scroll Removal 1. Undo one Screw (HIM).
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Heating and Ventilation
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REMOVAL AND INSTALLATION (Continued) 2. Undo one Screw (Heater Tubes).
3. Undo five Screws (Case-Scroll).
4. Remove Case Scroll.
2. Remove two screws used to retain the tube shield to HVAC.
3. Remove shield-heater tubes.
4. Slide out the Heater Core. CAUTION: Care should be taken when withdrawing heater core to prevent bending of pipes (High stress may result at joint between tank and pipe if end of pipes used as "handles") Installation 1. Refit all previously removed components in reverse order.
Installation 1. Refit components in reverse order. CAUTION: Ensure correct alignment between tongue and groove of mating parts.
Heater Core Assembly
CAUTION: When inserting heater core ensure that core "bottoms out" before fitting shield heater tube. Also ensure that foam seal is not distorted or damaged so as to affect integrity of air seal between case and core.
Case Assy — Recirc Door Complete Removal 1. Remove the HVAC Assembly.
Removal 1. Remove HVAC Assembly, as outlined in the Removal and Installation procedure in this section.
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REMOVAL AND INSTALLATION (Continued) 2. Remove Seal-A/C Tubes.
3. Remove one Screw from the A/C tube retaining plate.
6. Undo five Screws retaining the recirc door housing to the HVAC Assembly.
7. Push in HIM Recirc Lever. CAUTION: Beware not to disengage slider block from HIM recirc lever and ensure part is greased when reassembled (see specifications in this chapter).
Item 1 2
Description Screw AC tube retaining plate
4. Remove Plate-A/C Tubes. 5. Remove Mesh Filter and Cover Assembly or Particle Filter as outlined in this section.
8. Remove Case-Recirc.
Installation 1. Refit components in reverse order. CAUTION: Ensure correct alignment between tongue and groove of mating parts.
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Heating and Ventilation
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REMOVAL AND INSTALLATION (Continued)
HIM Assy Removal 1. Remove Instrument Panel, Refer to Section 501-12. 2. Disconnect HIM electrical connectors.
5. Disengage Rod from the Floor Door lever. NOTE: Retain the rod and clip for reuse.
6. Disengage and withdraw Airmix Coupler. NOTE: Use a flat screw driver and carefully prise airmix coupler off passenger airmix shaft. Item 1 2 3
Description HIM Main power harness Evaporator sensor elec connector HIM Main control harness
3. Disconnect HIM electrical connectors. Harness driver side actuator (ACC only)
7. Push in HIM Recirc Lever. CAUTION: Excessive force will damage airmix shaft flange. CAUTION: If airmix shaft accidentally is withdrawn from case follow procedure in Shaft-Airmix Door DZ/SZ, Steps 1-5. 4. Remove the three Screws used to retain the HIM to HVAC.
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REMOVAL AND INSTALLATION (Continued) 8. Rotate and remove HIM. NOTE: Ensure alignment of airmix shaft with HIM coupling and alignment of tab with centre case.
3. If scroll fitted, align heatsink into scroll opening.
4. Align airmix coupler (1 to 2, 4 to 3). Installation 1. Fit rod floor door to HIM in reverse order to removal procedure.
CAUTION: Top mounting peg must be located.
5. Align face and demist cams with HIM levers. 2. Depress airmix coupling into installation position. NOTE: At this stage the HVAC cam levers should be greased before installing HIM. Refer specifications in this chapter,
6. Rotate HIM and engage airmix hub into heater case (tilt HIM onto heater).
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Heating and Ventilation
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REMOVAL AND INSTALLATION (Continued) 7. Insert 3 screws (2 screws if SCROLL Assembly is not yet fitted).
Actuator — Electric Airmix (ACC only) Removal 1. Set driver side temp to full cold, face mode. NOTE: If setting the drivers temp is not possible. The HIM would have to be removed. 2. Remove Instrument Panel, Refer to Section 501-12.
8. Check that the airmix shaft is correctly fitted into airmix door (refer installation procedure for Shaft-Airmix Door DZ/SZ in this section). 9. Rotate airmix door to align keyway with airmix coupling to fully engage airmix shaft. 3. Disconnect Dual Zone Sub Harness at the actuator. 4. Undo three screws retaining the actuator to HVAC.
10. Reconnect electrical connectors.
Item 1 2 3
Description HIM Main power harness Evaporator sensor elec connector HIM Main control harness
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Heating and Ventilation
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REMOVAL AND INSTALLATION (Continued) 5. Using flat screw driver between the airmix shaft 2. Gain access to airmix shaft via face outlet flange and actuator carefully prise off the actuator. opening. CAUTION: Excessive force will damage airmix shaft flange.
3. Rotate airmix door to position shown in picture. Installation CAUTION: If airmix shaft is accidentally withdrawn from case the procedure outlined in Shaft-Airmix Door DZ/SZ steps 1 - 5 need to be followed prior to installation of actuator. 1. Align keyway and refit actuator in reverse order.
NOTE: Shown with HIM removed. 4. Insert airmix shaft ensuring keyway is correctly aligned.
Shaft — Airmix Door DZ/SZ Removal and Installation NOTE: The Shaft-Airmix door is not a serviced item. 1. Remove the instrument panel (refer to section 501-12). Remove the HIM (refer to this section). Open the face door.
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REMOVAL AND INSTALLATION (Continued) 5. Maintain force on airmix shaft end and ensure airmix door is depressed fully as shown in sketch thus correctly aligning airmix door to shaft.
Dual Zone Sub Harness Removal 1. Refer to HVAC Assembly removal procedure in this section and follow steps 1 - 12 inclusive. 2. Disconnect harness connector from Actuator-Electric Airmix.
4. Unclip Harness and remove.
Installation 1. Refit components in reverse order.
Filter and Cover Assembly — Mesh (Standard Fitment) Removal 1. Refer to glove compartment removal procedure, Section 501-12 to gain access to Filter. 2. Slide Mesh Filter and Cover assembly to open position (LH side).
3. Disconnect harness connector from HIM. 3. Pull out Filter-assembly.
Installation 1. Refit components in reverse order. G34257 en
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REMOVAL AND INSTALLATION (Continued)
Filter — Particle (Optional Fitment)
Vent Outlet Register — Outboard Register
Removal Removal and Installation 1. Refer glove compartment removal procedure, Section 501-12 to gain access to Filter. 1. Peel off door seal over area covering end cap of 2. Slide Cover and Seal Assembly to open (LH side). instrument panel. 2. Remove end cap.
3. Remove Cover & Seal Assembly. 3. Remove trim spear from instrument panel. Care must be taken with trim removal or inboard retainer clip will be broken.
4. Pull out Particle Filter. 4. Remove three screws/self tappers from registers. Ease register on inboard top edge to dislodge clip and remove register.
Installation 1. Refit components in reverse order.
5. Assemble in reverse order.
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REMOVAL AND INSTALLATION (Continued)
Vent Outlet Register — Centre Register
Installation 1. Position Air Register.
Removal 1. Remove Interior Command Centre and Remote Key Receiver taking all precautions described in section 413-08. 2. Remove wire harness from Air Register.
2. Tighten 3 X M5 screws to 1.5 Nm, top centre screw first.
3. Remove 3 X M5 screws from Air Register.
3. Reposition wire harness to Air Register.
4. Remove Air Register.
4. Install the Remote Key Receiver and the ICC. Refer to Section 413-08.
Vent Outlet Register — Floor Console Register Removal and Installation 1. Close flaps on register.
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REMOVAL AND INSTALLATION (Continued) 2. Pry register out of lower retainer clips first, then top clips.
4. Invert console and ease rear section away from main body.
3. Remove register. 5. Remove eight retaining screws locating duct to console. 4. On assembly of register, enter lower clips first and roll register into place.
Floor Console Duct Removal and Installation The floor console duct is removed from the vehicle as part of the floor console assembly. The duct can then be separated form the console. 1. Remove floor console and duct assembly (Refer to section 501-12). 2. Remove vent outlet floor console register (Refer to procedure in this section). 3. Lift console lid and remove two rearmost screws. 6. Carefully spread console at front to allow duct clearance over locating lugs. Spread rear of console at rear and lift out duct.
7. To install, reverse the steps 1-6.
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Air Conditioning
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SECTION : 412-03 Air Conditioning VEHICLE APPLICATION : 2003.0 BA Falcon CONTENTS
PAGE
SPECIFICATIONS Specifications .........................................................................................................................412-03-3 DESCRIPTION AND OPERATION Air Conditioning Safety Precautions ......................................................................................412-03-4 Climate Control System .......................................................................................................412-03-5 A/C Compressor and Clutch Assembly ................................................................................412-03-6 A/C Compressor Pressure Relief Valve ...............................................................................412-03-6 A/C Condenser Core ............................................................................................................412-03-6 Refrigerant Lines ..................................................................................................................412-03-7 A/C Evaporator Core ............................................................................................................412-03-7 A/C Orifice Tube Assembly ..................................................................................................412-03-8 Refrigerant Dye ....................................................................................................................412-03-8 Suction Accumulator ............................................................................................................412-03-8 A/C Cycling Switch (evaporator thermistor) .........................................................................412-03-8 A/C Pressure Cut-Off Switch (Pressure Transducer) ..........................................................412-03-9 Quick Joint Connection ........................................................................................................412-03-9 Air Conditioning Joint Design .............................................................................................412-03-10 Charge Port Valves ............................................................................................................412-03-11 Engine Cooling Fans (Condenser Fans) ...........................................................................412-03-11 DIAGNOSIS AND TESTING Air Conditioning ....................................................................................................................412-03-12 Inspection and Verification .................................................................................................412-03-12 A/C Functional Inspection Chart ........................................................................................412-03-12 A/C Fault Symptom Chart ..................................................................................................412-03-12 Air Conditioning System Performance Test .......................................................................412-03-18 A/C System Leak Test .......................................................................................................412-03-22 A/C System Noise Test ......................................................................................................412-03-23 Module Configuration .........................................................................................................412-03-24 WDS Parameter Identifier (PID) chart ................................................................................412-03-24 WDS Diagnostic Trouble Code (DTC) chart ......................................................................412-03-25 A/C disable strategy chart ..................................................................................................412-03-27 Connector Circuit Reference ..............................................................................................412-03-28 Air Conditioning & HVAC Relay and Fuses .......................................................................412-03-31 Pinpoint Tests ....................................................................................................................412-03-31 GENERAL PROCEDURES Manifold Gauge Set Connection ..........................................................................................412-03-39 Electronic Leak Detection ....................................................................................................412-03-40 Fluorescent Dye Leak Detection ..........................................................................................412-03-40 A/C System Discharging and Recovery ...............................................................................412-03-42 A/C System Evacuation and Charging ................................................................................412-03-42 Refrigerant Oil Replacement Quantity .................................................................................412-03-43 Replenishment of Refrigerant Oil .........................................................................................412-03-44 A/C System Flushing ...........................................................................................................412-03-44
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Air Conditioning
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(Continued) REMOVAL AND INSTALLATION A/C Hose/Tube Pad Fitting ..................................................................................................412-03-45 O-Ring Removal and Lubrication .........................................................................................412-03-46 Air Conditioning (A/C) Compressor — I6 Engine .................................................................412-03-46 Air Conditioning (A/C) Compressor — V8 Engine ...............................................................412-03-47 Compressor Clutch, Compressor Pressure Relief Valve and Compressor Shaft Seal .......412-03-48 Air Conditioning (A/C) Compressor Bracket ........................................................................412-03-48 Evaporator Core ...................................................................................................................412-03-49 Orifice Tube Assembly .........................................................................................................412-03-50 Quick Joint Clamp ................................................................................................................412-03-52 Suction Accumulator ............................................................................................................412-03-54 Pressure Cut-off Switch (Pressure Transducer) ..................................................................412-03-55 Condenser Assembly ...........................................................................................................412-03-56 Condenser Inlet Hose Assembly (Discharge Hose) ............................................................412-03-57 Compressor Inlet Hose Assembly (I6 & V8 — Suction Hose) and Accumulator Outlet Tube Assembly (V8 — Suction Tube) ...........................................................................................412-03-57 Condenser to Evaporator tube assembly (A/C liquid line) ...................................................412-03-58 Evaporator clamp (E-Clamp) ...............................................................................................412-03-59 Air Conditioning Cycling Switch (evaporator thermistor) .....................................................412-03-59 Engine Cooling Fans (Condenser Fans) .............................................................................412-03-60
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Air Conditioning
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SPECIFICATIONS General Specifications Description Specification A/C compressor 10S17C Displacement 188 cc Cylinder bore 32.0 mm (1.26 in) Cylinder stroke 23.38 mm (0.92 in) Rotation Clockwise Magnetic clutch Air gap between pulley 0.35 mm - 0.60 mm and hub (0.014 in 0.024 in) A/C cycling switch (evaporator thermistor) Manual Climate Control Air outlet vent 6.00°C max temperature cycling Switching temperatures differential will increase as the blower fan speed reduces. Automatic Climate Control Air outlet vent 6.00°C max temperature cycling Switching temperatures differential will increase as temperature selection becomes hotter. A/C pressure relief valve Open 3,430 - 4,100kPa (497 595psi) A/C pressure cut-off switch (pressure transducer) low pressure cut-out 200kPa high pressure cut-out 3,170kPa Lubricants PAG Compressor Oil 200cc (supplied in comp) ND-Oil 8 (250 cc can AY19L000A) Refrigerant R-134a 650 ± 50g ( YN-19) Torque Specifications Description A/C compressor bolt (black colour) upper front mount A/C compressor bolts (gold colour) A/C compressor bracket bolts - I6 A/C compressor bracket bolts - V8 A/C liquid line - front LH apron body clamp bolt A/C liquid line - rear LH body saddle clamp nut A/C liquid line - nut joint A/C compressor - suction & discharge hose bolts Suction accumulator bracket nuts
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Description Suction accumulator & A/C liquid line evaporator E-clamp bolt Suction tube (V8) clamp - side rail screw Suction hose/tube clamp - spring tower nut A/C condenser core - A/C liquid line & discharge hose bolts A/C condenser core bracket - radiator bolts Discharge hose clamp - radiator support bolt Discharge hose clamp (V8) - cross member bolt O-Ring Specifications Description Refrigerant O-Ring, green/blue evaporator inlet (small) Refrigerant O-Ring, green/blue evaporator outlet (large) Refrigerant O-Ring, black discharge hose/tube (small) Refrigerant O-Ring, black suction hose/tube (large)
Nm 15 6 35 10 7 8 8
Part No BA19S710B BA19S710A V890158S V890157S
Nm 23 23 48 28 10 8 23 10 8
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Air Conditioning
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DESCRIPTION AND OPERATION
Air Conditioning Safety Precautions WARNING: To avoid accidental deployment and possible injury, the air bag system backup power supply must be depleted before repairing any climate control components. To deplete the backup power supply, disconnect the battery positive cable and wait one minute. Failure to follow these instructions may result in personal injury. Use only R-134a refigerant WARNING: R-134a is classified as a safe refrigerant, but misuse can make it dangerous. The following precautions must be observed. Failure to follow these instructions may result in personal injury. Always wear safety goggles when repairing an air conditioning system. Avoid contact with liquid refrigerant R-134a. R-134a vaporizes at approximately -25°C (-13°F) under atmospheric pressure and it will freeze skin tissue. Never allow refrigerant R-134a gas to escape in quantity in an occupied space. R-134a is non-toxic, but it will displace the oxygen needed to support life. Allow the engine to cool sufficiently prior to carrying out maintenance or serious burns and injury can occur. CAUTION: To avoid damaging the vehicle or A/C components, the following precautions must be observed: Do not add R-12 refrigerant to an A/C system that requires the use of R-134a refrigerant. These two types of refrigerant must never be mixed. Doing so can damage the A/C system. A number of manufacturers are producing refrigerant products that are described as direct substitutes for refrigerant R-134a. The use of any unauthorized substitute refrigerant can severely damage the A/C components. If repair is necessary, use only new or recycled refrigerant R-134a. Do not remove the sealing caps from a new component until ready to install.
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Refrigerant oil will absorb moisture from the atmosphere if left uncapped. Do not open an oil container until ready to use, and install the cap immediately after using. Store the oil in a clean, moisture-free container. Air conditioning O-rings are made from a material compatible with refrigerant and refrigerant oil. Always use the correct replacement air conditioning O-ring, or A/C system leakage may occur. If an A/C O-ring is not supplied with A/C hose assembly, coat the refrigerant O-ring with oil before assembling. When installing a refrigerant line, avoid sharp bends. Position the line away from the exhaust or any sharp edges that can chafe the line. Tighten threaded fittings only to specifications. The aluminum fittings used in the refrigerant system will not tolerate overtightening. When disconnecting a fitting, use a wrench on both halves of the fitting to prevent twisting of the refrigerant lines or tubes. Do not open a refrigerant system or uncap a new component unless it is as close as possible to room temperature. This will prevent condensation from forming inside a component that is cooler than the surrounding air. CAUTION: To avoid contamination of the A/C system: Keep service tools and the work area clean. Never open or loosen a connection before discharging the system. When loosening a connection, if any residual pressure is evident, allow it to leak out before opening the fitting. Before charging, evacuate a system that has been opened to install a new component or a system that has discharged through leakage. Seal open fittings with a cap or plug immediately after disconnecting a component from the system. Clean the outside of the fittings thoroughly before disconnecting a component from the system.
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Air Conditioning
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DESCRIPTION AND OPERATION (Continued) Climate Control System Clutch Cycling Orifice Tube Refrigerant System Components (“The refrigerant cycle”)
Item 1 2 3 4 5 6 7
Description Evaporator thermistor Suction Accumulator assembly A/C Orifice Tube A/C Charge Port (high pressure side) A/C Pressure Tranducer High pressure high temperature refrigerant vapour High pressure moderate temperature liquid refrigerant
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Item 8 9 10 11 12 13 14
Description Low pressure low temperature liquid refrigerant Low pressure low temperature refrigerant vapour Condenser core Compressor + Clutch assembly Compressor bracket A/C charge port (low pressure side) Evaporator Core
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Air Conditioning
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DESCRIPTION AND OPERATION (Continued) The A/C refrigerant system is a clutch cycling orifice tube type. The system consists of the following components: A/C compressor/clutch assembly A/C condenser core A/C evaporator core A/C charge port valve (high pressure side) A/C charge port valve (low pressure side) connecting refrigerant lines suction accumulator The refrigerant system operation is controlled by the following: A/C evaporator core orifice A/C cycling switch (evaporator thermistor) A/C compressor pressure relief valve A/C pressure cut-off switch (pressure transducer) The refrigerant system incorporates an A/C compressor controlled by an A/C cycling switch. The A/C cycling switch senses A/C evaporator core temperature to control A/C compressor operation. An A/C compressor pressure relief valve is installed in the A/C discharge hose assembly to protect the refrigerant system against excessively high refrigerant pressures. An A/C evaporator core orifice is installed in the condenser to evaporator line (A/C liquid line) to meter the liquid refrigerant into the A/C evaporator core.
A/C Compressor and Clutch Assembly
The 10S17C A/C compressor has the following characteristics: a 10-cylinder swashplate design displacement of 188cc A two-piece lip-type seal is used to seal the shaft opening in the assembly. Five double-acting pistons operate within the cylinder assembly. The pistons are actuated by a swashplate that changes the rotating action of the shaft to a reciprocating force. Reed-type discharge valves are located between the cylinder assembly and the head at each end of the A/C compressor. The A/C compressor uses PAG Compressor Oil ND-Oil8 or equivalent (meeting Ford specification WSH-M1C231-B). This oil contains special additives necessary for the A/C compressor. The magnetic A/C clutch has the following characteristics: It drives the compressor shaft. When battery positive voltage (B+) is applied to the A/C clutch field coil, the clutch disc and hub assembly is drawn toward the A/C clutch pulley. The magnetic force locks the clutch disc and hub assembly and the A/C clutch pulley together as one unit, causing the compressor shaft to rotate. When B+ is removed from the A/C clutch field coil, springs in the clutch disc and hub assembly move the clutch disc away from the A/C clutch pulley.
A/C Compressor Pressure Relief Valve An A/C compressor pressure relief valve is incorporated in the compressor A/C body to: relieve unusually high refrigerant system discharge pressure buildups of (3.43MPa [497 psi] and above). prevent damage to the A/C compressor and other system components. avoid total refrigerant loss by closing after the excessive pressure has been relieved.
A/C Condenser Core The A/C condenser core has the following NOTE: Internal A/C compressor & compressor clutch characteristics: It is an aluminum fin-and-tube design heat components are not repaired separately. Install a new exchanger located in front of the vehicle radiator. A/C compressor only as an assembly. It cools compressed refrigerant gas by allowing air NOTE: Installation of a new suction accumulator is to pass over the fins and tubes to extract heat and required when repairing the air conditioning system by condensing gas to liquid refrigerant as it is when there is physical evidence of system cooled. contamination from a failed A/C compressor, damage to the suction accumulator, evidence of the A/C system being open to the atmosphere/leaking or evidence of moisture absorption.
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Air Conditioning
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DESCRIPTION AND OPERATION (Continued) Refrigerant Lines
A/C Evaporator Core
NOTE: Installation of a new suction accumulator is required when repairing the air conditioning system when there is physical evidence of system contamination from a failed A/C compressor, damage to the suction accumulator, evidence of the A/C system being open to the atmosphere/leaking or evidence of moisture absorption. The condenser to evaporator line (A/C liquid line) contains high pressure liquid refrigerant upstream of the A/C evaporator core orifice. This orifice tube can be serviced by disconnecting liquid line from the body and undoing the nut joining both halves of the liquid line. The liquid line incorporates a high pressure charge port valve which is only used in the vehicle assembly plant. The condenser inlet hose (discharge hose) contains high temperature high pressure refrigerant vapour. This discharge hose incorporates an A/C pressure cut-off switch (pressure transducer) which disables the compressor in the event of excessively high or low system pressures, and selects low or high condenser fan speeds. The compressor inlet hose (suction hose) contains low temperature low pressure refrigerant vapour. In the V8 vehicle, the suction hose is attached to a suction tube via a quick-connect clamp. For all models, the suction hose/tube is attached to the suction accumulator via a quick-connect clamp. The suction hose incorporates a low pressure charge port valve which is used for all A/C system servicing. The BA Falcon 6-cylinder petrol/LPG compressor inlet hoses (suction hoses) from Feb 2004 have been standardised (BA-19997-D) and this is different to the early level of BA Falcon petrol/LPG suction hoses (BA-19997-A and BA-19997-C), both in the hose material and routing. All hose/tube assemblies contain refrigerant O-rings which are retained in a recessed groove. These O-rings seal against leakage using radial compression once the joint is fully assembled and further tightening of the fitting bolt or tube nut will not improve the sealing performance. These O-rings are black in colour and made of a special material compatible with refrigerant and refrigerant oil. Use only black genuine Ford refrigerant O-rings for replacement. On the evaporator inlet and outlet tube joints, green/blue refrigerant O-rings are fitted. Again, these O-rings are made of a special material compatible with refrigerant and refrigerant oil, and are different dimensions to the black refrigerant O-rings. Use only green/blue genuine Ford refrigerant O-rings for replacement in these locations.
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The A/C HVAC assembly contains the A/C evaporator core. The A/C evaporator core is the plate/fin type with a unique refrigerant flow path. A mixture of refrigerant and oil enters the evaporator core through the A/C evaporator core inlet tube and is routed so it flows through the core tubes and channels from driver to passenger side of the core.
The Refrigerant Flow path follows the flow shown.
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Air Conditioning
412-03-8
DESCRIPTION AND OPERATION (Continued) The BA Falcon suction accumulator from December 2003 (BA-19C808-B, post December 2003) has a different mounting to the earlier version of BA Falcon accumulator (BA-19C808-A, pre December 2003). Both the later level accumulator bracket and the welded body apron brackets have been revised, and the later level accumulator bracket cannot be fitted to the earlier level body bracket. The suction accumulator is mounted via the A/C accumulator bracket onto the LH body apron. The inlet tube of the suction accumulator is connected to the A/C evaporator outlet tube. The outlet tube of the accumulator is connected to the A/C suction hose/tube assembly. After entering the inlet of the suction accumulator, heavier oil-laden refrigerant contacts an internally mounted dome (which serves as an umbrella) and NOTE: Install a new A/C orifice tube assembly drips down onto the bottom of the canister. whenever a new A/C compressor is installed. A small diameter oil bleed hole, in the bottom of NOTE: The red orifice tube can not be interchanged the vapour return tube, allows the accumulated with different colour orifice tubes from previous heavier liquid refrigerant and oil mixture to models. re-enter the compressor suction line at a controlled rate. The A/C orifice tube has the following characteristics: As the heavier mixture passes through the small located at the nut joint in the A/C liquid line diameter liquid bleed hole, it has a second chance (condenser to evaporator line). to vapourise and recirculate through the A/C color-coded red. compressor without causing compressor damage an orifice diameter of ~1.5 - 1.6mm (~0.060in). due to liquid slugging. changes the high-pressure liquid refrigerant into a A fine mesh screened filter fits tightly around the low-pressure liquid. bottom of the vapour return tube to filter out refrigerant system contaminant particles. filter screens are located on the inlet and outlet ends of the orifice body A desiccant bag is mounted inside the canister to absorb any moisture which may be in the the inlet filter screen acts as a strainer for the refrigerant system. liquid refrigerant flowing through the A/C evaporator core orifice. A/C Cycling Switch (evaporator O-ring seals on the A/C evaporator core orifice thermistor) prevent the high-pressure liquid refrigerant from bypassing the A/C evaporator core orifice. The evaporator sensor is located on the driver’s side of the evaporator core towards the lower face of the Adjustment or repair cannot be made to the A/C core. The tip of the thermistor contains a sensor which orifice tube assembly. If damaged or blocked, a new A/C orifice tube assembly must be installed. is connected via a harness to the HIM (HVAC Integrated Module). The sensor is located in an Refrigerant Dye optimized position on the core face and controls compressor “ON”/“OFF” set point as air off R-134a fluorescent tracer dye has been added to the temperature changes. A/C system of this vehicle, supplied in the The HIM Module changes the set point depending on accumulator. The refrigerant dye has a limited life of blower fan speed and thus prevents core ice up. ~500 hours of air conditioning operation. Varying the fan speed also varies the set point for Leak checking can be performed with an ultra-violet cycling the compressor clutch. It is not necessary to lamp and viewed through ultra-violet glasses. remove the evaporator core when replacing the thermistor. Suction Accumulator The position of the thermistor in relation to the NOTE: Installation of a new suction accumulator is evaporator air off airflow is critical for efficient required when repairing the air conditioning system operation of the refrigeration system. It is therefore when there is physical evidence of system vital that the correct removal and replacement contamination from a failed A/C compressor, damage procedure is followed as incorrect positioning of the to the suction accumulator, evidence of the A/C thermistor sensor will adversely effect efficiency, and system being open to the atmosphere/leaking or could also result in core ice up. evidence of moisture absorption.
A/C Orifice Tube Assembly
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01/2003 2003.0 BA Falcon
412-03-9
Air Conditioning
412-03-9
DESCRIPTION AND OPERATION (Continued) A/C Pressure Cut-Off Switch (Pressure Transducer)
been a 2 minute delay since engagement + evaporator thermistor registers less than 10ºC + there are no engine/transmission cooling requirements for high speed fan.) The condenser fan is also engaged automatically if there are engine/transmission cooling requirements, even if the A/C switch is off. In both low and high speeds, both condenser fans operate together.
Quick Joint Connection
The A/C pressure transducer is used to interrupt A/C compressor operation in the event of high or low system discharge pressures. The A/C pressure cut-off switch is mounted on the high pressure discharge hose assembly. CAUTION: It is necessary to discharge the refrigerant system to remove the A/C pressure cut-off switch. If the compressor discharge pressure drops below 200kPa, the pressure transducer sends a signal to the EEC which disengages the A/C compression. If the compressor discharge pressure rises to approximately 3,170kPa, the pressure transducer sends a signal to the EEC which disengages the A/C compressor. When the pressure drops to approximately 2,570kPa, the pressure transducer signal via the EEC allows the A/C compressor to re-engage. The pressure transducer is also used for condenser fan control. When the A/C switch is engaged below a set vehicle speed, the condenser fan is engaged automatically if the compressor discharge pressure is high. When the compressor discharge pressure reaches approximately 2,100kPa, the pressure transducer signal via the EEC engages the high-speed fan control. When the pressure drops to approximately 1800 kPa, the pressure transducer signal via the EEC engages the low speed fan control. (If there has
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Item Description 1 Male fitting 2 O-ring, suction 3 Female fitting 4 Quick joint clamp The quick joint connection is a refrigerant line coupling held together with a plastic clamp. The plastic clamp has locking tabs that grip the tube shape and hold tubes together. The o-ring seals are black in colour and made of a special material compatible with refrigerant & refrigerant oil. Use only black refrigerant O-Rings in this location. A special service tool is required to remove the quick joint connector. Its insertion is important to proper removal of the quick joint. Male fitting (suction hose) must be fully inserted into female fitting. Lubricate o-rings with refrigerant oil to make smooth insertion.
01/2003 2003.0 BA Falcon
412-03-10
Air Conditioning
412-03-10
DESCRIPTION AND OPERATION (Continued)
Item 1 2 3
Description Female fitting Male fitting O-Ring seals
Quick joint clamp wraps around the tube connection. Interlocking tabs on clamp hold clamp in place. Quick joint clamp clicks shut.
If gap exists, clamp cannot be closed. Clamp can rotate freely on tube joint until A/C system is charged with refrigerant. Alignment of clamp guide to quick joint clamp removal tool is required for clamp removal.
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Item 1 2 3 4
Description Clamp interlocking tabs Stopper lever Quick joint clamp removal tool Clamp guide
Air Conditioning Joint Design In the A/C system, there are 3 types of joints: radial seal pad fitting or nut joint Compression seal 45° taper joint Radial seal quick connect joint For all radial seal joints, the O-ring is retained in a recessed groove. The O-ring seals against leakage using radial compression once the joint is fully assembled, and further tightening of the fitting bolt or tube nut will not improve the sealing performance. Full insertion of the tube joint is critical to prevent O-ring damage. All retained O-rings are black refrigerant O-rings made from a special material compatible with refrigerant and refrigerant oil. All quick-connect joints use two black retained refrigerant O-rings for sealing. At the evaporator inlet and outlet tube joints, green/blue refrigerant O-rings are used in a 45° taper compression seal. Again, these O-rings are made of a special material compatible with refrigerant and refrigerant oil, and are different dimensions to the black refrigerant O-rings. In addition, the evaporator tube green/blue refrigerant O-rings are different dimensions from previous models. Prior to making any hose/tube connections, lubricate the O-ring with compressor oil to avoid refrigerant leakage. Fine fibre and dust can affect seal performance. When disassembling joints, keep O-rings capped to prevent O-ring damage, contamination and moisture ingression.
01/2003 2003.0 BA Falcon
412-03-11
Air Conditioning
412-03-11
DESCRIPTION AND OPERATION (Continued) The fitting is an integral part of the refrigeration line or component. Special couplings are required for both the high-side and low-side charge ports. The Schraeder-type valve core can be replaced if the seal leaks. Always install the appropriate A/C charging valve cap on the charge port valves after repairing the refrigerant system. The high pressure charge port cap located on the liquid line charge port is smaller than the low pressure charge port cap located on the suction hose/tube.
Engine Cooling Fans (Condenser Fans) The vehicle is fitted with dual electric cooling fans mounted in a fan shroud directly behind the radiator assembly. These fans are used for both engine cooling and air conditioning condenser cooling. The fans are controlled by three relays via the Powertrain Control Module, and when required, operate at low speed (1400 rpm) or high speed (2300 rpm) depending on the engine and A/C cooling demands. Refer to Wiring section and Engine Cooling section 303-03 for further details.
Charge Port Valves The high-pressure charge port valve is located on the A/C liquid line (condenser to evaporator line). The low-pressure charge port valve is located on the suction hose or tube assembly.
Item 1 2 3 4 5 6
CAUTION: When the ignition is ON, the fans may start without warning. CAUTION: During service operations ensure that the fan is not rotated in a direction opposing normal operation (designated by an arrow on the fan blade), or this may damage the motor. For more information refer to section 303-03.
Description A/C charging valve cap (low pressure) A/C suction hose/tube Charge port valve O-ring seal A/C liquid line A/C charging valve cap (high pressure)
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01/2003 2003.0 BA Falcon
412-03-12
Air Conditioning
412-03-12
DIAGNOSIS AND TESTING
Air Conditioning Inspection and Verification In order to correctly diagnose the root cause of the fault, it is advisable that the technician follow the following Air Conditioning System Fault Test process.
System fault A/C Cooling fault
System test A A/C System Functional Inspection test, then
System test B A/C Fault Symptom Chart, then
System test C A/C System Performance test or A/C system leak test or A/C system noise test, then
System test D WDS tester or Pinpoint tests
A/C Functional Inspection Chart A/C component A/C system A/C compressor
Compressor drive belt A/C discharge hose A/C suction hose A/C liquid line - before orifice tube A/C liquid line - after orifice tube Condenser fan Suction accumulator System blower fan speed & temperature selection
Result for Inspection Pass System Fault for Inspection Fail Good cooling performance from Refer to A/C Fault Symptom Chart system Engages with A/C on (comp clutch Wiring fault, refer pinpoint test A centre turns) ICC fault, refer 413-08. A/C cooling fault, refer A/C Fault Symptom Chart. Does not slip or whip when A/C is Accessory drive fault, refer 303-05 engaged Hot to touch with A/C on A/C cooling fault, conduct A/C Performance test Cold to touch with A/C on A/C cooling fault, conduct A/C Performance test Hot to touch with A/C on A/C cooling fault, conduct A/C Performance test Cool to touch with A/C on A/C cooling fault, conduct A/C Performance test Air flow across condenser A/C cooling fault, conduct A/C Performance test Wiring fault, refer pinpoint test F Cold to touch with A/C on A/C cooling fault, conduct A/C Performance test Air flow and cooling as Blower fault, refer 412-04 selectedOperates at all fan speeds Air distribution fault, refer 412-02 A/C cooling fault, refer A/C Fault Symptom Chart
A/C Fault Symptom Chart Symptom No A/C cooling
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Possible Cause Area If Comp clutch engages… Refrigerant fault
Possible Root Cause If Comp clutch engages… Low A/C system charge
Confirmation Test
Conduct A/C Performance test
Possible Fix
Recharge A/C system to specification
01/2003 2003.0 BA Falcon
412-03-13
Air Conditioning
412-03-13
DIAGNOSIS AND TESTING (Continued) Symptom
Possible Cause Area
Poor compressor performance
If Comp clutch is not engaging… Electrical fault
Possible Root Cause A/C system refrigerant blockage Inefficient compressor pumping Loose comp drive belt Slipping comp. clutch If Comp clutch is not engaging… Fuse or disconnected wire Comp clutch field coil open circuit WAC relay open circuit ICC display or control fault HIM / CAN / BEM / EEC / PCM fault
Compressor or clutch fault
Refrigerant fault Insufficient A/C cooling
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Refrigerant fault
Blower fan not operating Insufficient battery voltage Comp clutch slipping
Confirmation Test Conduct A/C Performance test A/C Cooling fault, refer 412-03 Visual Inspection Refer 303-05 Visual inspection
Wiring fault, refer to Pinpoint test A Refer to Pinpoint test A for clutch Refer to Pinpoint test B for Relay ICC fault, refer 413-08 Pinpoint test for each Part Refer to 412-04, 413-08 or 303-14 Pinpoint test for Blower fan, 412-04 Refer to section 412-04 Visual inspection for clutch slip
Possible Fix Replace blocked component Replace Compressor assembly Tighten drive belt Replace Compressor assembly
Repair circuit Replace Compressor assembly Replace relay Refer to 413-08 Refer 412-04, 413-08 or 303-14 Refer 412-04 Refer 412-04
Replace Compressor assembly Excessive clutch air Visual inspection for Replace gap clutch engagement Compressor assembly Compressor seized Hand turn Replace compressor Compressor assembly Low A/C system Conduct A/C Recharge A/C charge Performance test system to specification Low A/C system Conduct A/C Recharge A/C charge due to Performance test system to improper initial and Leak test specification charge Air in A/C system Conduct A/C Recharge A/C due to poor Performance test system to evacuation specification Contaminant in A/C Conduct A/C Recharge A/C system due to poor Performance test system to quality refrigerant specification
01/2003 2003.0 BA Falcon
412-03-14
Air Conditioning
412-03-14
DIAGNOSIS AND TESTING (Continued) Symptom
Possible Cause Area
Possible Root Cause Excessive A/C system charge Excessive refrigerant oil
Refrigerant flow fault
Orifice tube blocked/restricted Orifice tube bypassed, missing or damaged O-ring Incorrect orifice tube A/C hose/tube flow restriction
Confirmation Test
Possible Fix
Conduct A/C Performance test
Recharge A/C system to specification Check repair Drain compressor, history, conduct A/C Replace Performance test Accumulator, Recharge refrigerant oil to specifications Inspect orifice tube Replace orifice tube Inspect orifice tube
Replace orifice tube
Inspect orifice tube Replace orifice tube Inspect for hose & Replace faulty part tubing restrictions, kinks, delamination Air flow heat pick-up Air duct heat pick-up Air distribution fault, Refer to 412-02 fault fault after refer to 412-02 evaporator Air inlet heat pick-up Air distribution fault, Refer to 412-02 fault before refer to 412-02 evaporator Air mix door position Air distribution fault, Refer to 412-02 fault refer to 412-02 Air mix door leak Air distribution fault, Refer to 412-02 refer to 412-02 Fresh/recirc door Air distribution fault, Refer to 412-02 position fault refer to 412-02 Fresh/recirc door Air distribution fault, Refer to 412-02 leak refer to 412-02 Poor evaporator Restricted air flow Inspect Evaporator Replace Evaporator performance through evaporator core, Refer to this (clogged or chapter damaged fins) Restricted air flow to Air Distribution fault, Refer to 412-02 evaporator (filter or refer 412-02 duct) Blower fan not Blower fault, refer to Refer to 412-04 operating correctly 412-04, Pinpoint test L Evaporator Conduct Pinpoint Replace Evaporator refrigerant flow test 412-03-D blocked/restricted Poor compressor Inefficient Conduct A/C Replace performance compressor Performance test Compressor pumping assembly Slipping comp drive Visual Inspection of Tighten Belt belt Belt Slipping comp. Visual Inspection of Replace clutch clutch operation Compressor assembly
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01/2003 2003.0 BA Falcon
412-03-15
Air Conditioning
412-03-15
DIAGNOSIS AND TESTING (Continued) Symptom
Possible Cause Area
Poor condenser performance
Possible Root Cause Insufficient refrigerant oil quantity causing comp seizure Insufficient refrigerant oil transfer from blocked accumulator oil pick-up Condenser refrigerant flow blocked/restricted Restricted air flow to condenser
Restricted air flow through condenser (clogged or damaged fins) Engine overheating
Cooling fan fault
Incorrect operation of A/C cooling
Excessive A/C high pressure compressor cut-out
Possible Fix
Assess oil amount Add oil as specified in system, using A/C or replace Noise test compressor if damaged Assess oil return, Replace using A/C Noise test Accumulator and replacement of accumulator Conduct A/C performance test
Replace condenser
Assess air flow across condenser and compare against equivalent vehicle Assess air flow through condenser and inspect fins
Remove restriction
Engine cooling fault, refer to 303-03 Radiator Engine cooling fault, overheating refer to 303-03 Hot air re-circulating Prevent hot air through condenser re-circulating and compare A/C performance before and after modification Incorrect cooling fan Test fan operation operation for refer to Pinpoint test condenser pressure F conditions One or both cooling Test fan operation fans refer to Pinpoint test open-circuited/not F operating Incorrect cooling fan Engine Cooling operation for fault, refer to 303-03 condenser pressure conditions Excessive A/C Conduct A/C system charge performance test Condenser refrigerant flow blocked/restricted Orifice tube blocked/restricted
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Confirmation Test
Conduct A/C performance test
Clean / Repair fin damage or replace condenser Refer to 303-03 Refer to 303-03 Prevent re-circulation with correct air deflector and seals Repair fault, replace part Replace cooling fans Refer to 303-03
Recharge A/C system to specification Replace condenser
Check for Replace orifice tube temperature difference before and after orifice tube location
01/2003 2003.0 BA Falcon
412-03-16
Air Conditioning
412-03-16
DIAGNOSIS AND TESTING (Continued) Symptom
Possible Cause Area Uneven cooling Passenger vent outlet air warmer than driver vent outlet air A/C compressor cycles too frequently A/C compressor excessive cycle on time
A/C will not switch off- electrical fault
Abnormal Noise
A/C will not switch off- comp clutch fault Noisy with A/C not operating
Noisy with A/C off, blower fan on
Noisy with A/C operating
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Possible Root Cause Low A/C system charge
Confirmation Test
Evaporator thermistor incorrectly located Restricted air flow through evaporator
Go to section 412-02, Pin point test K, conduct A/C system performance test & A/C leak test Inspect thermistor location refer to this chapter Inspect evaporator surface
Restricted air flow to Evaporator Air/Moisture in A/C system
Air Distribution fault refer to this chapter Conduct A/C Performance test
Possible Fix Recharge A/C system to specification Reassemble thermister Clean evaporator or replace
Improve air flow to evaporator Recharge A/C system to specification A/C system Conduct A/C Replace blocked refrigerant blockage Performance test part and Recharge A/C system to specification HIM / can / EEC / Electrical fault, refer Refer to 412-04, BEM / PCM fault to 412-04, 413-08 or 413-08 or 303-14 303-14 ICC display or ICC fault, refer to Refer to 413-08 control fault 413-08 Comp. clutch relay Pinpoint test B Replace relay Evaporator Pinpoint test 412-04 Repair fault, replace thermistor short part circuit/calibration fault Evaporator Inspect thermistor Reassemble thermistor location refer to this thermister incorrectly located chapter Insufficient clutch air Visual inspection of Replace gap Air gap Compressor assembly Drive belt Visual inspection of Replace belt loose/worn Belt Comp. clutch Conduct A/C noise Replace bearing fault test, Hand turn Compressor clutch rotor assembly Blower motor fault Blower fault, refer to 412-02 Blower fan out of Blower fault, refer to balance 412-02 Worn/damaged Conduct A/C noise Replace compressor test Compressor assembly Comp. clutch Visual Inspection of Replace engagement or magnetic clutch Compressor disengagement fault assembly Slipping drive belt Visual Inspection for Tighten drive belt belt 01/2003 2003.0 BA Falcon
412-03-17
Air Conditioning
412-03-17
DIAGNOSIS AND TESTING (Continued) Symptom
Control component fault
Possible Cause Area
Intermittent A/C operation
Possible Root Cause A/C component resonance/rattling Comp. discharge pulsation noise transfer to body Excessive compressor noise due to overcharged system Refrigerant flow hiss/gurgle due to overcharged system Refrigerant flow hiss/gurgle due to A/C liquid line noise transmission Refrigerant flow hiss/gurgle due to faulty orifice tube Intermittent power to clutch
Pressure transducer Open-circuit fault Short circuit Calibration fault Cabin temperature sensor fault
Open-circuit Short circuit Calibration fault
Ambient temperature sensor fault
Open-circuit Short circuit Calibration fault
Sun Load sensor fault
Open-circuit Short circuit Calibration fault
Evaporator Thermistor fault
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Open Circuit
Confirmation Test
Possible Fix
Conduct A/C noise test and detect noise source Conduct A/C noise test
Isolate noise source Isolate noise condition
Conduct A/C Performance test to judge overcharged
Recharge A/C system to specifications
Conduct A/C Performance test to judge overcharged Conduct A/C noise test and detect noise source
Recharge A/C system to specification, Isolate/replace A/C liquid line
Conduct A/C noise test
Replace orifice tube and/or liquid line
Compressor wiring fault, refer to Pinpoint test A Go to Pinpoint test C Go to Pinpoint test C Go to Pinpoint test C Go to section 412-04 Go to section 412-04 Go to section 412-04 Go to section 412-04
Repair circuit
Go to section 412-04 Go to section 412-04 Go to section 417-01 Go to section 417-01 Go to section 417-01 Go to Pinpoint test G
Repair fault, replace part Replace sensor
Repair fault, replace part Repair fault, replace part Replace sensor Repair fault, replace part Repair fault, replace part Replace sensor Repair fault, replace part
Repair fault, replace part Repair fault, replace part Replace sensor Repair fault, replace part
01/2003 2003.0 BA Falcon
412-03-18
Air Conditioning
412-03-18
DIAGNOSIS AND TESTING (Continued) Symptom
Possible Cause Area
ICC display screen or button fault
Possible Root Cause Calibration fault Not working, Incorrect operation
For additional information, refer to Section 412-00.
Air Conditioning System Performance Test NOTE: This test is used to ascertain the maximum cooling capability of the air conditioning system.
Vehicle preparation: NOTE: Check the following items before carrying out the test - adjust as necessary. 1. No heat pickup when the A/C controls are in the full cold position. 2. The engine cooling fans for correct operation and providing adequate condender airflow. 3. Condenser and Radiator core fin condition (obstruction by insect, grass, screens etc.). 4. Full Recirculation air mode is achieved. 5. Compressor drive belt tension. 6. Face level air outlet mode achieved. 7. Temperature door is achieving full cold position. 8. Correct operation of Automatic Climate Control system (Perform diagnosis self-test). 9. Engine coolant level in radiator supply tank.
Confirmation Test Go to Pinpoint test G Refer to 413-08
Possible Fix Replace sensor Refer 413-08
3. Insert a thermometer (or temperature measuring device) into one of the Centre Face Level Registers. Monitor the Register air outlet temperature and record only when it is stable. (ie: When the temperature has stopped falling). Allow a minimum of 5 minutes for the Register air temperature to stabilise before taking readings. 4. Monitor the pressure gauge readings and record stabilised pressures. NOTE: Pressure modulations even when the system has stabilised is normal. 5. If the system cycles, record the maximum and minimum vent temperatures, maximum discharge pressure, minimum suction pressure and approximate clutch on and off time in seconds. NOTE: Cycling should only occur at lower ambient temperatures. (Refer to Recommended Compressor Cycle Times overpage.)
6. Record the Ambient air temperature of the day away from direct sunload using the air temperature measuring device. 7. For the air register vent temperatures, if the system was cycling, calculate the average of the maximum and minimum temperatures. Use the AVERAGE register temperature for comparison against the normal values on the graph. If the Test Conditions: system was not cycling, compare the measured 1. Engine Idling at operating temperature with the vent temperature against the normal values on transmission in Park with the handbrake applied. the graph. 2. Vehicle doors closed with all windows fully 8. Next, compare these temperature and pressure opened and bonnet raised. readings with Normal values between the upper and lower limits shown in the graphs below. Using 3. An R134 Manifold Gauge set connected to the this information and the Diagnostics table, the high and low side service port connections. likely cause of capacity loss can be diagnosed. 4. The vehicle positioned in the shade at least 1.5 For more information on A/C system diagnosis, metres from any wall. refer to the A/C fault symptom chart in this 5. Air conditioning operating on recirc, face, full cold, section. (max.) high blower fan for 5 minutes until A/C system temperatures stable. CAUTION: Never top-up with R134a. If low R134a charge is suspected remove the Test Procedure: remaining charge and re-fill with the recommended R134a quantity. 1. Run with the engine idling and A/C set as per test conditions for 5 minutes until the A/C system temperatures are stable. NOTE: To achieve these settings on automatic climate control vehicles, select manual over-rides. 2. Confirm that the Compressor is engaged.
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01/2003 2003.0 BA Falcon
412-03-19
Air Conditioning
412-03-19
DIAGNOSIS AND TESTING (Continued) Normal centre register Average Air Temperature
NOTE: RECOMMENDED COMPRESSOR CYCLE TIMES: In ambient temperatures below about 25°C, the A/C compressor cycle time will vary. For reference: The compressor should cycle ON for 5 MINIMUM to 30 seconds. The compressor should cycle OFF for 2 — 12 MAXIMUM seconds.
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01/2003 2003.0 BA Falcon
412-03-20
Air Conditioning
412-03-20
DIAGNOSIS AND TESTING (Continued) Normal High side Pressure
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01/2003 2003.0 BA Falcon
412-03-21
Air Conditioning
412-03-21
DIAGNOSIS AND TESTING (Continued) Normal Low side Pressure
Air Conditioning System Performance Test Diagnostics Vent temp High
Disch press High
High
High
High High Normal to high
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Suct press High
Clutch on time Long to continuous
Normal to high Long to continuous Normal to high Normal to low Long to continuous Normal to high Normal Long to continuous Normal to low Normal Long to continuous
Fault Likely cause Low condenser air Blocked condenser or flow. radiator core. One or both cooling fans not working. Non approved parts blocking air flow. Hot air Only one cooling fan recirculating operating. through the Radiator heat shields condenser. missing. Air in the system. Poor evacuation. Low refrigerant to the evaporator. Low refrigerant charge. Partial blockage of the evaporator refrigerant circuit.
Blocked or wrong size orifice. Leaking joint, pipe, or component. Contamination in refrigerant circuit. Damaged, crimped or dented evaporator tubes.
01/2003 2003.0 BA Falcon
412-03-22
Air Conditioning
412-03-22
DIAGNOSIS AND TESTING (Continued) Vent temp High
Disch press Normal
Suct press Normal
Clutch on time Long to continuous
High
Normal
Normal
Normal
High
Low
Normal
Long to continuous
High
Low
High
Long to continuous
Normal to high
Normal to low
High
Long to continuous
Normal
High
Normal to high Normal
Normal
Normal to low
Normal to low
short
Low
Normal to low
Normal to low
continuous
A/C System Leak Test Two options are available for detection of joint leaks. 1. Refrigerant R-134a Leakage detection NOTE: For more information, refer to Electronic leak detection in this section. Refrigerant leakage can be determined by a leak detector. Be sure to remove all oil from the test area before using the leak detector, because the oil may contain refrigerant which would give erroneous readings. Check for leakage at the compressor shaft seal, and at all system fittings and lines as detailed in Joint Locations in this Section. 2. Alternative Leak detection (leak tracer dye) NOTE: For more information, refer to Fluorescent Dye leak detection in this section. G73303 en
Fault Likely cause Heat pick up in air Fresh/recirc door not inlet system. fully in recirc or leaking. Hot engine compartment air drawn into the inlet. Excessive oil in Failure to flush before system. changing compressor. Heat pick up in Temp control not the air delivery achieving full. system. (after the evaporator core) Condenser Damaged or crimped refrigerant flow condenser tube. low. Contaminants blocking refrigerant circuit. Poor compressor Worn or damaged performance. compressor. Compressor drive belt or clutch slipping. Restricted suction Delaminated, crimped line. or block suction line. Insufficient Wrong orifice tube restriction at fitted. orifice. Damaged or missing orifice tube ‘O’ ring. Refrigerant over Topping up instead of charge. full evac and charge. Low evaporator Partially blocked airflow. evaporator fins. Restriction in recirc duct. Clutch not Evaporator air off disengaging. thermistor faulty or not clipped into the correct core location
R-134a fluorescent tracer dye has been added to the A/C system of this vehicle, supplied in the accumulator. The refrigerant dye has a limited life of ~500 hours of air conditioning operation. Leak checking can be performed with an ultra-violet lamp and viewed through U.V. glasses. A/C system pressure must be above 551kPa (80psi) for this operation, and the A/C system must have run for ~15 minutes prior to leak testing, to allow the dye to mix thoroughly. Scan all components, fittings and lines with Rotunda ultra-violet 164-R0721 or equivalent. Leaks can be pin-pointed by bright yellow-green glow of the tracer dye. After the leak is repaired, the traces of dye can be removed from previously leaking areas by using any general purpose oil solvent.
01/2003 2003.0 BA Falcon
412-03-23
Air Conditioning
412-03-23
DIAGNOSIS AND TESTING (Continued) A/C System Noise Test All compressor driven air conditioning systems will emit noise. Careful system tuning has been undertaken to suppress most noise emissions. However, with improvements to cabin quietness, customer complaints for noise, vibration and harshness may need to be addressed. The following chart and proceeding explanations help with these issues. Action Inquire about customer complaint
Validate the customer claim Check air conditioning system Make judgement on type of noise
Make repair and judge affect Explain your findings to customer
Conditions What kind of noise (tone/loudness). When noise occurs (first time etc.). Where is it heard from What conditions it occurs in Reproduce conditions that noise occurs in Detail what, when, where noise occurs Check system layout. Check gas pressures Check belt tension and alignment Use attached notes to judge noise Detail what and where noise occurs Find noise source and transmission path Isolate source to verify Remove source (replace, unbolt) if faulty component Mask noise source if possible Mask transmission path (insulate) Detail your activities If required, request owner to document when noise complaint occurs to help investigation
Test Procedure NOTE: This test is used to identify customer complaints. Vehicle Conditions
1. 2. 3. 4. 5. 6.
Ensure the system is not over charged with refrigerant by conducting an A/C System Performance Test. Inspect to confirm that system is assembled correctly. That is, compressor is fastened to bracket, drive belt is tight, condenser is rubber mounted, A/C pipework is not touching body, retaining clamps are in correct positions, etc. Reproduce the customer complaint noise. (complaint needs to be clearly identified). Gauge if noise is abnormal (it is important to understand the characteristics of the vehicle in its normal state, to judge what is abnormal). Seek additional advice if necessary. Detail what and how noise occurs. Find the noise source and verify it’s transmission path by isolating suspect part from the vehicle. That is, float condenser or A/C piping in space to cut the transmission path, etc. If the noise disappears, this validates the noise source or transmission path. Identify the best method to remove the source. If not possible, mask the source output or isolate the transmission path. Explain you investigations to the owner, as they are attuned to a noise, and it may be difficult for them to accept that the total removal of the noise may not be possible. With noise issues, improvement can often be made but complete removal cannot always be achieved (eg. if the noise complaint is a characteristic of the actual car or a normal A/C system operating characteristic) . Detailing your findings will make your explanation easier.
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01/2003 2003.0 BA Falcon
412-03-24
Air Conditioning
412-03-24
DIAGNOSIS AND TESTING (Continued) A/C Noise Symptom Chart Condition
Source
Action
Internal wear of compressor Mechanical ‘rattling’ noise occurs with compressor engagement
Lack of lubricating oil. In a system with a gas leak, the oil has escaped with the refrigerant. Lack of lubricating oil has caused wear to the compressor internal surfaces.
Check rattling noise from compressor, using a screwdriver to hear compressor internals. Replace compressor and also fix the system leak to prevent recurrence. Likewise, if you detect a leak in the system, estimate and add refrigerant oil to A/C system to ensure future compressor reliability.
Resonant noise with accessory - With A/C on, a ‘cooing’ or ‘woo’ noise can be heard inside the car. Vibration of steering wheel can also occur. Because resonant noise is similar to compressor pulsation noise, you must distinguish by different checking method.
Cause is due to drive accessory resonating at specific engine speed. The vibrations are transmitted to the vehicle body causing the noise.
Check the drive accessories. If accessory can be isolated (press down with a screwdriver) the noise level will be lowered. Repair method can be to stop vibrations of the assembly or modify transmission route to the vehicle body.
Compressor discharge pulsation noise - With A/C on, a rumbling noise is heard inside the vehicle. Vibration of steering can also occur. The noise level rises if the outside temperature is high.
Cause is pressure fluctuation of refrigerant discharged from compressor vibrating the high pressure piping, and abnormal noise occurs by resonating with the car.
Module Configuration Special Tool(s) WDS Diagnostic System (WDS)
To check: Remove the discharge hose mounting clamp and recheck. – Float the condenser without attachments and recheck. To repair: – Put rubber bush between pipe clamps. – If not fixed, decrease refrigerant to minimum specified level. –
For module configurations that effect the air conditioning refrigerant system, refer to: EEC/PCM..........303-14 HIM..................412-04 ICC..................413-08 BEM.................419-10
WDS Parameter Identifier (PID) chart Special Tool(s) The air conditioning refrigerant system does not itself WDS Workshop Diagnostic contain any programmable modules, but the operation System of the climate control system and the output of some A/C Sensors rely on a number of programmable modules. These modules are accessed via the WDS service tool, and the modules may require re-configuring as part of the repair procedure. The WDS is used to select appropriate data for the The following chart lists all PID’s used by the WDS vehicle, and each module configuration must be service tool to access data relevant to the system. relevant for the specific Climate Control system (eg. MCC, ACC, single zone, dual zone, etc.) and for the Acronym Description circumstance where the module has been modified or from ECC/PCM replaced. If this procedure is not followed, the module ACPRES A/C Pressure (PSI) may not function correctly and may set a number of (1 PSI = 6.89kPa) Diagnostic Trouble Codes. HFC High Speed Fan On (Engine Cooling Fan) LFC Low Speed Fan On (Engine Cooling Fan) RPM Engine Speed (RPM) G73303 en
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DIAGNOSIS AND TESTING (Continued) Acronym VS CHT from HIM ACCS A_CT ETSFD EXT_TEMP BLOWVOL BLOWAP BLOWTP LEFTOT RIGHTOT MC_VREF RECIRDS RECIRCDTP CCMODE from ICC AUTO WDS Display from EEC/PCM P0532
Description Vehicle Speed (MPH) Cylinder Head Temperature A/C Compressor Cycling Request Evaporator Temperature External Temperature Sensor Filtered Data (Ambient Temperature) External Temperature From Sensor (unfiltered) (Ambient Temperature) HVAC Blower Voltage Blower Motor Speed - Actual Position Blower Motor Speed - Target Position Passenger’s Display Set Temperature Driver’s Display Set Temperature Vehicle Battery Voltage Recirculation Door Actual Position Recirculation Door Target Position Climate Control Mode AUTO (ACC)
Acronym OFF ACC_POS TMPKNOBP BLWR_FAN AC_SEL_SW RECIRC MODE_SW from BEM AC_SUNSEN INT_TEMP from Instrument VEH_SPD VBATT_VAL
A/C Sunload Sensor Status Interior Temperature Sensor Cluster Vehicle Speed System Battery Voltage Value
WDS Diagnostic Trouble Code (DTC) chart Special Tool(s) WDS Workshop Diagnostic System
The following chart lists all DTC’s relevant to the A/C system that may be set due to operation failures. The codes may be set due to either intermittent or permanent failures.
Fault Description
Possible Cause
A/C Refrigerant Pressure Sensor A Circuit Low Input
Checked at key on, engine off and continuously when A/C on Pressure sensor out of calibration, open-circuit Checked at key on, engine off and continuously when A/C on Pressure sensor out of calibration, short-circuit Slipping compressor clutch Poor compressor performance Low A/C refrigerant charge Low Speed Engine Cooling Fan circuit fault Cooling fan fault High Speed Engine Cooling Fan circuit fault cooling fan fault Checked continuously when A/C on: Low A/C refrigerant charge or A/C System blockage
P0533
A/C Refrigerant Pressure Sensor A Circuit High Input
P1463
A/C Pressure Sensor insufficient pressure change
P1474
Fan Control primary circuit
P1479
High Fan Control primary circuit
P0534
A/C Refrigerant Charge Loss
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Description OFF (ACC) ACC Position Temperature Selector Status Blower Fan Speed Air Conditioning Switch Status Recirculation Status Mode Switch
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DIAGNOSIS AND TESTING (Continued) WDS Display P1465
Fault Description A/C relay circuit
P1270
Engine RPM or Vehicle Speed limiter reached Cylinder Head over-temperature condition, protection active
P1285 P1299 U1900/P1796 from HIM B2014 B1947 B2513 B2006 B2005 B1255 B1257
U2196 U2197 U2199 B2007 B2890 from ICC B1318 B2923 U2201 from BEM B1250 B1251 B1253 B1259 B1261
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CAN communication bus fault
Possible Cause WAC Relay fault relay wiring circuit fault Refer to A/C disable strategy list in this section. Engine overheating fault Refer to A/C disable strategy list in this section. HIM/CAN/BEM/circuit to EEC/PCM fault
Climate Control A/C Post-Evaporator Sensor open circuit
Sensor leads disconnected from HIM sensor failure HIM failure Climate Control A/C Post-Evaporator Sensor leads shorted together Sensor short to ground sensor failure HIM failure Blower (Fan) circuit failure HVAC air flow restriction HIM failure Blower Motor Switch out of range Invalid data code sent by vehicle sub-system Climate Control Temperature Switch out Invalid data code sent by vehicle of range sub-system Air temperature external sensor circuit Sensor lead disconnected from module open Sensor failure Internal module failure (HIM) Air temperature external sensor circuit Sensor leads shorted together short to ground Sensor leads shorted to vehicle body Sensor failure Internal module failure (HIM) Invalid ‘Engine RPM’ data Invalid data code sent by vehicle sub-system Invalid ‘Vehicle Speed’ data Invalid data code sent by vehicle sub-system Invalid ‘Engine Coolant Temperature’ Invalid data code sent by vehicle data sub-system (Driver/Passenger) Solar radiation Sun load sensor faulty, out of calbration Sensor out of range Battery voltage low Climate control button stuck Ambient temperature data invalid
Air temperature internal (cabin) sensor circuit failure Air temperature internal (cabin) sensor circuit open Air temperature internal (cabin) sensor circuit short to ground Solar radiation sensor circuit open Solar radiation sensor circuit short to ground
Low system voltage detected. Battery or alternator fault. Climate control button jammed HIM did not have valid ambient temperature data output Cabin temperature sensor failure Cabin temperature sensor wiring fault, open circuit Cabin temperature sensor wiring fault, short-circuit Sun load sensor wiring fault, open circuit Sun load sensor wiring fault, short-circuit
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DIAGNOSIS AND TESTING (Continued) A/C disable strategy chart The following chart lists the conditions under which the A/C System is disabled to prevent compressor operation, either temporarily or permanently. The A/C System may be disabled temporarily to pretect the compressor until conditions are suitable for operation, on permanently until a fault is rectified. DTC Code N/A - (temporary A/C disengagement only) N/A - (temporary A/C disengagement only) P0532,P0533 P1463
P0534 P0534 P0534 N/A - (temporary A/C disengagement only) P1270 N/A - (temporary A/C disengagement only) U1900 N/A - (temporary A/C disengagement only) P1299
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A/C is Disabled under the following conditions A/C is disabled when the A/C pressure transducer (ACPT) exceeds the maximum allowed pressure, and is re-engaged when the ACPT output drops back down to an acceptable pressure (eg. may occur in extremely high ambient, high vehicle speed conditions) A/C is disabled when the A/C pressure transducer (ACPT) drops below the minimum allowed pressure, and is re-engaged when the ACPT output rises up to an acceptable pressure (eg. may occur in extremely low ambient temperatures) A/C is disabled when the ACPT output is out of range (circuit or calibration fault) A/C is disabled when the ACPT pressure rise after A/C clutch engagement is less than the minimum allowed and is re-engaged when the engine speed drops back down to a lower rpm. ( This may indicate clutch slip, low A/C charge or faulty compressor) A/C is disabled when the A/C performance is not acceptable for given ambient temperature and vehicle operating conditions A/C is disabled when the A/C gas charge level is too low during A/C operation A/C is disabled when the A/C gas charge level drops during A/C operation A/C is disabled when the engine speed is greater than the maximum allowed for a given vehicle speed, and continues to be disabled when the engine speed is greater than the maximum allowed for A/C re-engagement A/C is disabled when the engine speed is more than the maximum allowed for A/C operation (close to red-line rpm), and continues to be disabled when the engine speed is greater than the maximum allowed for A/C re-engagement A/C is disabled when the engine speed is less than the minimum allowed for A/C operation (below idle rpm) A/C is disabled when the HIM CAN link is missing A/C is disabled at the first A/C engagement after a new or reflashed PCM, if the A/C is engaged at too high an engine speed A/C is disabled just before the engine cylinder head temperature exceeds a maximum allowable temperature and the cylinder head protection is activated
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DIAGNOSIS AND TESTING (Continued) Simplified Air Conditioning Electrical Circuit
NOTE: For more information, refer to complete Air Conditioning Control Circuit in Wiring section.
Connector Circuit Reference C-121 (A/C Compressor)
Pin Number(s) 1 2
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Circuit Designation/Description Normal Condition/Measurement Circuit 347A B-Y 12V when A/C on Power Circuit 57A B Earth (less then 5 Ohms to chassis ground) Ground
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DIAGNOSIS AND TESTING (Continued) C-127 (A/C Clutch Diode)
Pin Number(s) 1 2
Circuit Designation/Description Normal Condition/Measurement Circuit 57S B Earth (less then 5 Ohms to chassis ground) Ground Circuit 347B B-Y 12V when A/C on Power
C-122(A/C Pressure Transducer)
Pin Number(s) 1 2 3
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Circuit Designation/Description Normal Condition/Measurement Circuit 359C GR Earth (less then 5 Ohms to chassis ground) Circuit 440 BR Feedback Voltage 0V to 5.0V Circuit 351E BR-W Reference Voltage 5.0V±0.25V
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DIAGNOSIS AND TESTING (Continued) C163 (Power Distribution Board) - WAC Relay
Pin Number(s) 1 2 3 4
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Circuit Designation/Description Circuit 347B B-Y Power Circuit 175A B-Y Circuit 321 GR-W Circuit 361C R
Normal Condition/Measurement 12V supplied when Relay engaged 12V supplied with IG ON condition Earth from ECC for A/C operation 12V supplied with A/C Relay engaged
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DIAGNOSIS AND TESTING (Continued) C-376 Evaporator Thermister NOTE: View from wire entry side (rear).
Pin Number(s) 1 2
Circuit Designation/Description Normal Condition/Measurement Sensor ground Voltage (V) between HIM terminal connection D pin 1 and C376 pin 13 0V (ground) Sensor supply Voltage (V) between HIM terminal connection D pin 2 and C376 pin 13 NOTE: With ignition ON and sensor disconnected, refer to sensor voltage from sensor output table, Pinpoint test G.
Air Conditioning & HVAC Relay and Fuses The air conditioning compressor cut-out relay (WAC relay, R3-black) is located in the Engine Compartment Fuse Box. The A/C compressor clutch is protected with a 30 amp fuse (F11-pink, combined with the engine fuse) located in the Engine Compartment Fuse Box. The A/C condenser fans (engine cooling fans) are controlled with three relays (R8, R9, R10-all white) located in the Engine Compartment Fuse Box. Each fan circuit is protected with a 40 amp fuse (F5, F6-both green) also located in this fuse box. The three relay coils are protected by a single 15A fuse (F2-blue) located in the instrument panel fuse box. The HIM electrical circuits are protected with two fuses, one 15 amp (F4-blue) and one 10 amp, (F27-red), both located in the Instrument Panel Fuse Box. The HVAC blower fan circuit is protected with a 40 amp fuse (F7-green) located in the Engine Compartment Fuse Box.
Pinpoint Tests Special Tool(s) Electrical Multimeter
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DIAGNOSIS AND TESTING (Continued) PINPOINT TEST A : COMPRESSOR OPERATION Test Step A1
Result / Action to Take
CHECK COMPRESSOR OPERATION Turn blower motor to high speed Turn A/C switch on. Set controls to maximum cooling. Inspect magnetic clutch operation.
Yes
Operation is normal.
No
Go to A2.
Does rotor and hub engage and drive the compressor?
A2
CHECK THE A/C COMPRESSOR CIRCUIT 347 (B-Y) FOR POWER Yes
Measure the voltage between the A/C compressor clutch C-121, circuit 347A, harness side and ground.
Go to A3.
Is the voltage greater than 10 volts?
No
Go to A4.
A3
CHECK THE A/C COMPRESSOR CIRCUIT 57 (B) FOR OPEN CIRCUIT Measure the resistance between the A/C compressor clutch, circuit 57A (B) harness side and ground. Is the resistance less than 5 ohms?
Yes
INSTALL a new compressor. Refer to Section 412-03.
No
REPAIR the circuit. TEST the system for normal operation.
A4
CHECK CIRCUIT 347 (B-Y) FOR POWER Measure the voltage between the A/C clutch relay circuit 347, harness Yes side and ground. Repair circuit, Test for normal operation from relay to compressor. Is the voltage greater than 10 volts?
No
Go to A5.
A5
CHECK THE A/C CLUTCH RELAY CIRCUIT 175 (B-Y) FOR POWER Yes
Measure the voltage between A/C clutch relay C163, circuit 175A (B-Y), harness side and ground.
Go to B1. Check relay operation.
Is the voltage greater than 10 volts?
No
Go to A6.
A6
CHECK THE 30A FUSE C163 CIRCUIT 50 (R) FOR POWER Measure the voltage between fuse pin and ground. Is the voltage greater than 10 volts?
Yes
Repair the circuit from the fuse to relay. Test the system for normal operation.
No
Inspect battery and wiring circuit. Repair the circuit, test the system for normal operation.
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DIAGNOSIS AND TESTING (Continued) PINPOINT TEST B : WAC RELAY OPERATION NOTE: Also refer to PCM section 303-14, Air Conditioner Inputs. Test Step B1
CHECK RELAY OPERATION Turn blower motor to high speed Turn A/C switch on at normal idle condition. Does WAC relay engage.
B2
Result / Action to Take
Yes
Relay operation is normal.
No
Go to B2.
CHECK RELAY OPERATION Set circuit as follows: Power (12V) to pin 361 (Pin No.4) on relay Earth (0V) to pin 321 (Pin No.3) on relay Relay should close to give continuity between circuits 175 (Pin No.2) and 347 (Pin No.1).
Yes
Relay operation is normal. Go to B3
No
Replace relay.
Is the resistance less than 5 Ohms across terminals 1 & 2 ?
B3
CHECK RELAY FOR POWER CIRCUIT 361C Operate the A/C system at maximum cooling. Check voltage between ground and 361C (R) wire on wiring harness. Is voltage greater than 10 Volts?
B4
Yes
Go to B4
No
Repair circuit from EEC to relay and test for normal operation. Go to B6.
CHECK EEC OUTPUT 321 GRW Check for resistance between ground and 321 GRW on wiring harness.
Yes
Is resistance less than 5 Ohms?
No
EEC output is normal. Go to B5.
Check A/C disable strategy chart. Confirm correct EEC operation. Repair circuit and test for normal operation.
B5
CHECK WIRING CIRCUIT 347 TO CLUTCH Check for resistance between circuit 347 at wiring harness and 347 at Yes compressor. Circuit 347 is normal. Go to B6. Is resistance less than 5 Ohms?
No
Repair circuit and test for normal operation.
B6
CHECK WIRING CIRCUIT 175A FOR POWER Check voltage between ground and 175A Is voltage greater than 10 Volts?
Yes
Operation is normal.
No
Repair circuit. Test for normal operation.
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DIAGNOSIS AND TESTING (Continued) PINPOINT TEST C : PRESSURE TRANSDUCER OPERATION NOTE: Also refer to PCM section 303-14, Air Conditioner Inputs. Test Step C1
Result / Action to Take
CHECK THE PRESSURE SWITCH REFERENCE VOLTAGE Check voltage between ground and circuit 351 BR-W on wiring harness.
Yes
Is reference voltage correct to spec: V=5±0.25V?
No
Go to C2.
Repair circuit. Test for normal operation.
C2
CHECK EARTH AT SWITCH Check resistance between ground and circuit 359 on wiring harness. Is switch earth present?
Yes
Go to C3.
No
Repair circuit. Test for normal operation.
C3
CHECK SWITCH OUTPUT SIGNAL Apply 5 V to circuit 351 at switch. Apply earth to circuit 359 at switch. Ensure A/C refrigerant pressure is within 200kPa and 3170 kPa. Check voltage between ground and circuit 440 at switch.
Yes
Switch operation is normal.
No
REPLACE switch.
Is voltage within range 0.0 V to 5.25 V ?
PINPOINT TEST D : EVAPORATOR CORE ICE UP CAUTION: Follow all Climate Control system safety precautions when dealing with A/C system refrigerant. Test Step D1
Result / Action to Take
COMPRESSOR CYCLING NOTE: Test can not be conducted in high ambient temperatures, as the compressor may not cycle off, if the ambient temperature is high. Turn blower motor to high speed. Switch A/C ON.
Yes
Go to D2.
No
Go to PinPoint Test G to check evaporator thermistor.
Set to recirculated air. Set controls to maximum cooling. Ensure all vehicle doors and windows are closed. Does the Compressor Cycle OFF and ON?
D2
PRESSURE GAUGE EVALUATION Is the suction pressure constantly at or below approx 150 kPa with the A/C On and Engine speed held at approx 2.000 RPM ?
Yes
Conduct A/C Performance test to diagnose the cause of the Low suction pressure. Refer to Section 412-03.
No
Go to D3.
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DIAGNOSIS AND TESTING (Continued) Test Step D3
Result / Action to Take
SUCTION TUBE INSPECTION Yes Does the Evaporator outlet tube at the Accumulator Frost or Ice-up, with the A/C ON, Blower fan speed 1 (low) and the Engine Check Orifice Tube and recharge A/C system for correct gas charge. Refer to Section 412-03. speed held at 2000 RPM for 3 - 5 Minutes? No
Operation is normal.
Special Tool(s) Evaporator leak test tool
PINPOINT TEST E : EVAPORATOR CORE REFRIGERANT LEAKAGE CAUTION: Follow all Climate Control system safety precautions when dealing with A/C system refrigerant. NOTE: An Evaporator Core Refrigerant leakage will also cause “Smell”. This is due to the PAG Refrigerant Oil being released with the Refrigerant. NOTE: Removal of the Evaporator core should not be undertaken unless all other potential leak sources has been eliminated. Prior to removing Evaporator core from the vehicle conduct Fluorescent Dye Leak test and or Electronic Leak detection (Refer to pg. 412-03-40). Test Step E1
Result / Action to Take
VACUUM HOLDING TEST To attach the Evaporator leak test tool, you must first remove the evaporator core. Refer to procedure in this chapter.
Yes
Go to E2.
Attach the Evaporator leak test tool to the Evaporator tubes.
No Replace the Evaporator core. Refer to this NOTE: Fit new Ford green o’rings onto the Evaporator pipes before section. installing special tool.
Connect the Low side charging station coupling to the special tool charge port. Evacuate the evaporator core until 30 in/hg is reached. Turn off the Low side gauge tap. Allow the vacuum reading to stabilise for 30 minutes minimum.
NOTE: The pressure may rise initially as the refrigerant absorbed in the oil will boil off, and then the vacuum reading will stabilise.
Does the vacuum reading on the Low side gauge hold steady for a minimum of 15 minutes ?
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DIAGNOSIS AND TESTING (Continued) Test Step E2
Result / Action to Take
PRESSURE HOLDING TEST With the special tool still attached to the evaporator inlet / outlet tubes, Yes charge the evaporator with refrigerant through the Low side special The Evaporator core is not the root cause of tool charge port. Refrigerant leakage. Carry out full and accurate leak testing of the remaining A/C system Charge with approx. 100 grams of refrigerant. Turn the Low side components using an Ultra Violet lamp or a pressure gauge tap off. Allow the pressure reading to stabilise. Refrigerant Leak detector. Refer to this section Does the evaporator pressure reading on the Low side pressure (Flurorescent Dye Leak Detection or Electronic Leak Detection). gauge hold steady for a minimum of 15 minutes?
No
Replace the evaporator core. Refer to Section 412-03.
PINPOINT TEST F : CONDENSER FAN OPERATION/PERFORMANCE NOTE: Also refer to PCM section 303-14, Electro Drive Fans. Test Step F1
Result / Action to Take
CHECK FOR AIRFLOW OBSTRUCTION Visually inspect A/C condenser core and radiator core for obstructions Yes such as leaves or bugs. Remove obstruction and clean A/C condenser core and radiator Is there any obstruction ? Retest system.
No
Go to F2.
F2
FAN SELF-TEST The cooling fan motors and circuits are tested during a PCM key On Engine Off Self-Test, using the WDS (Refer to section Section 303-14). Faults detected by the PCM will be recorded as DTC’s.
NOTE: Prior to executing the self-test, any other DTC’s which have been set should be recorded and cleared.
Fan Speed OFF LO HI
Yes
Refer to DTC chart in Section 412-03 and Section 303-14. Repair circuit, replace faulty parts, test for normal operation.
No
Relay 1
Relay 2
Relay 3
Fan 1
Fan 2
OFF ON ON
OFF OFF ON
OFF OFF ON
OFF LOW HIGH
OFF LOW HIGH
The condenser fans are not at fault.
Did the self-test set any DTC’s ?
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DIAGNOSIS AND TESTING (Continued) PINPOINT TEST G : A/C CYCLING SWITCH (EVAPORATOR THERMISTOR) Test Step G1
Result / Action to Take
SYSTEM ON DEMAND SELF TEST Start and run engine until normal operating temperature is reached. Ensure vehicle battery voltage is within normal operating range (12~14volts) before proceeding with test. Using WDS scan tool, record all DTC’s set in the HIM memory. Using WDS scan tool, clear all DTC’s set in the HIM memory.
Yes
Go to G2 if code B2014 is set. Go to G3 if code B1947 is set.
No
System is OK.
Using WDS scan tool, perform HVAC On Demand Self Test (refer section 412-04). Are any DTC codes set?
G2
G3
SENSOR WIRING INSPECTION Disconnect the 2 way Evaporator sensor connector D from the HIM and inspect terminals on the sensor lead assembly for damage or corrosion.
Yes
Do the terminals appear damaged?
Go to G3.
Replace Evaporator sensor
No
SENSOR INSPECTION - RESISTANCE CHARACTERISTIC Yes
Turn off the Air Conditioner, select face outlet, full cold (not A/C Max), (’C’ or ’Low’ for ACC) and operate HVAC blower at full speed to stabilise the Evaporator sensor temperature.
Go to G4.
Disconnect the 2 way Evaporator sensor connector D from the HIM.
Replace Evaporator sensor.
No
Carefully insert the test probes of a resistance meter in to the REAR of the Evaporator sensor connector (wire side). Inserting probes in to front of terminals will damage the sensor assembly and cause intermittent A/C operation. Compare the sensor resistance value overpage with a temperature thermometer located in the face outlet. Is the resistance reading within specification (+/- 5 degC) as per sensor output table?
G4
MODULE FUNCTION CHECK - EVAPORATOR SENSOR TEMPERATURE READING Reconnect the sensor 2 way connector D to the HIM. Connect WDS Scan Tool. Read the A_CT value (Evaporator sensor temperature) from the HIM. Does the value closely match the temperature thermometer located in the face outlet (+/- 5 degC) as per sensor output table overpage?
G5
Yes
System OK.
No
Go to G5.
MODULE FUNCTION CHECK - EVAPORATOR SENSOR SUPPLY VOLTAGE Check the Evaporator sensor supply voltage with a voltmeter.
Yes
With the Evaporator sensor 2 way connector D inserted in to the HIM, attach the positive probe to pin 2 (LHS) and the negative probe to pin 1 (RHS) of the rear of the Evaporator sensor connector. Refer to Evaporative sensor connector diagram for correct pin designations.
No
Go to G6 Replace HIM
Using sensor output table, compare the voltage reading against a temperature probe located in the face outlet with the HVAC Blower fan operating at high speed. Does the voltage value closely match the temperature thermometer located in the face outlet (+/- 5 degC)?
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DIAGNOSIS AND TESTING (Continued) Test Step G6
Result / Action to Take
MODULE OUTPUT CHECK - EVAPORATOR SENSOR SUPPLY VOLTAGE Remove evaporator sensor plug from HIM. Using a voltmeter, attach the probes to the HIM output terminals for the evaporator sensor. Ensure ignition key is ON. Is the voltage reading within 4.5-5.5 Volts?
Yes
System OK. Clear DTC.
No
Replace HIM.
Evaporator Thermister (Temperature Sensor) Output Temperature Sensor Sensor Voltage Degrees Resistance (Volts) (Celsius) (Ohms) -30 25.37k 4.16 -25 18.90k 3.94 -20 14.19k 3.68 -15 10.73k 3.39 -10 8.17k 3.08 -5 6.27k 2.76 0 4.85k 2.44 5 3.78k 2.13 10 2.97k 1.84 15 2.35k 1.56 20 1.87k 1.34 25 1.50k 1.14 30 1.21k 0.96 35 0.98k 0.81 40 0.75k 0.68 45 0.66k 0.57 50 0.55k 0.48 55 0.45k 0.41 NOTE: Use this table as a guide only. Minor variations between actual readings are acceptable.
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GENERAL PROCEDURES
Manifold Gauge Set Connection Special Tool(s)
3. Remove the A/C charging valve cap from the high-pressure service charge port located on the liquid line.
R-134a Manifold Gauge Set or equivalent
1. Turn both valves on the R-134a Manifold Gauge Set all the way to the left to close the low-pressure and high-pressure hoses to the centre manifold and centre hose.
4. Connect the R-134a manifold gauge set low-pressure hose with the R-134a low side quick disconnect to the low-pressure service charge port.
2. Remove the A/C charging valve cap from the low-pressure service charge port located on the suction hose assembly.
5. Connect the R-134a manifold gauge set high-pressure hose with the R-134a high side quick disconnect to the high-pressure service charge port.
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GENERAL PROCEDURES (Continued)
Electronic Leak Detection Special Tool(s) Refrigerant Leak Detector or equivalent
5. If a leak is found, recover the refrigerant and repair the system. For additional information refer to A/C system discharging and recovery in this section.
Fluorescent Dye Leak Detection Special Tool(s) 120 Watt UV Spot Lamp or equivalent
CAUTION: Good ventilation is necessary in the area where electronic A/C leak testing is to be carried out. If the surrounding air is contaminated with refrigerant gas, the leak detector will indicate this gas all the time. Odours from other chemicals such as antifreeze, diesel fuel, disc brake cleaner, or other cleaning solvents can cause the same problem. A fan, even in a well-ventilated area, is very helpful in removing small traces of contamination from the air that might affect the leak detector. 1. Be sure to remove all oil from the test area before using the leak detector, because the oil may contain refrigerant which would give erroneous readings. 2. Remove the Interior Command Centre (ICC). Refer to section 413-08. 3. Detect for leaks inside the HVAC Case assembly by inserting the leak detector probe down the vent opening in the top of the HVAC case. 4. Check for leakage at the compressor shaft seal, and at all system fittings and lines as per Joint Locations in this section. Leak test the refrigerant system using the refrigerant leak detector. Follow instructions included with leak detector for handling and operation techniques. NOTE: System pressure should be between 413 551kPa (60 - 80psi) at 24°C (75°F) with the engine off.
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R-134a Manifold Gauge Set or equivalent
NOTE: Ford Motor Company vehicles are produced with R-134a Leak Tracer Dye incorporated into the A/C system. The location of leaks can be pinpointed by the bright yellow-green glow of the tracer dye. Since more than one leak can exist, always inspect each component. If accumulator is replaced, it is supplied with new dye, which has a limited life of ~500 hours of Air conditioning operation. 1. Run the A/C system for ~15 minutes prior to leak testing, to allow the dye to mix thouroughly. 2. Ensure that the A/C system pressure is between 413 - 551kPa (60 - 80psi) at 24°C (75°F) with the engine off. 3. Check for leaks using a 120-watt UV spot lamp, and viewed through U.V. glasses. 4. Observe for die trace at the drain tube of the HVAC above the transmission. 5. Scan all components, fittings and lines of the A/C system, as per joint locations listed in Electronic Leak Detection in this section. 6. Remove the ICC (Refer to section 413-08) and observe die trace inside the HVAC case assembly. 7. After the leak is repaired, remove any traces of leak dye with a general purpose oil solvent.
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Air Conditioning
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GENERAL PROCEDURES (Continued) Joint Locations
Item 1 2 3 4 5 6 7 8
Description A/C Liquid line to evaporator joint Evaporator to accumulator joint A/C Liquid line, Orifice tube joint High pressure service gauge charge port A/C pressure cut-off switch (pressure tranducer) Compressor pressure relief valve Condenser - A/C liquid line joint Condenser - Discharge hose joint
G73328 en
Item 9 10 11 12 13 14
Description Compressor front seal Suction hose - Compressor joint Discharge hose - Compressor joint Low pressure service gauge charge port Accumulator to suction hose quick connect joint Drain hose for evaporator
NOTE: V8 has extra quick-connect joint between suction hose and suction tube at front of LH side-rail.
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GENERAL PROCEDURES (Continued)
A/C System Discharging and Recovery Special Tool(s) R-134a A/C Service Centre 176-00002 or equivalent
8. Carry out the required repairs, then evacuate and recharge the A/C system. For additional information, refer to the A/C System Evacuation and Charging procedure in this section.
A/C System Evacuation and Charging Special Tool(s) R-134a Refrigerant Centre 176-00002 or equivalent
R-134a A/C Refrigerant Centre 023-00153 or equivalent
R-134a A/C Refrigerant Centre 023-00153 or equivalent R-134a Manifold Gauge Set or equivalent
R-134a Manifold Gauge Set or equivalent 1. Connect the R-134a A/C Refrigerant Centre to the low and high pressure service gauge charge ports. NOTE: Some R-134a service centres require the use of an A/C manifold gauge set. For additional information, refer to the Manifold Gauge Set Connection in this section.
1.2 CFM Vacuum Pump 023-R0162 or equivalent
2. Empty the Refrigerant Recovery Equipment oil drain glass container, so that an accurate measurement can be made of the amount of refrigerant oil removed from the A/C system in the Discharging & recovery process. 4.0 CFM Vacuum Pump 3. Recover the refrigerant from the system following 023-R0163 or equivalent the operating instructions provided by the equipment manufacturer. 4. Once the service centre has recovered the vehicle A/C system refrigerant, close the service centre inlet valve (if so equipped). Then switch off the power supply. 5. Allow the vehicle A/C system to remain closed for 1. Connect the R-134a A/C Refrigerant Centre to the low and high pressure service gauge charge about two minutes. Observe the system vacuum ports. level as shown on the gauge. If the vacuum does NOTE: Ford Motor Company recommends use of not change, disconnect the recovery station a charging station to carry out evacuation and hose(s). charging of the refrigerant system. If a charging 6. If the system pressure rises, repeat Steps 2 station is not available, system charging may be through 4 until the vacuum level remains stable accomplished using a separate vacuum pump, for two minutes. charging cylinder, and manifold gauge set. For 7. Record the amount of refrigerant oil collected in additional information, refer to the Manifold Gauge the Refrigerant Recovery Equipment oil drain Set Connection in this section. glass container, so that this oil can be replaced in the charging process.
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01/2003 2003.0 BA Falcon
412-03-43
Air Conditioning
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GENERAL PROCEDURES (Continued) 2. Evacuate the system until the low-pressure gauge Measure the amount of oil recovered with reads at least 99.4kPa (29.5 in-Hg) (vacuum) and refrigerant (refer to Recovery Machine as close to 101.1kPa (30 in-Hg) as possible. instructions and A/C system Discharging and Continue to operate the vacuum pump for a Recovery). minimum of 45 minutes. This amount of oil must be added to the 3. Turn off the evacuation pump. Observe the system before recharging with refrigerant. low-pressure gauge for five minutes to make sure 2. Compressor Replacement that the system vacuum is held. If vacuum is not Rotate the old A/C compressor shaft six to held for five minutes, leak test the system, service eight revolutions while collecting the oil in a the leaks, and evacuate the system again. clean measuring device. This amount is all 4. To maintain the original total system oil charge, it that is required to be in the replacement is necessary to compensate for the oil lost when service compressor. discharging the refrigerant or after replacement of Drain the oil from the service compressor a system component. For additional information (approx. 200ml) and remove a quantity of this on quantity of oil to be added to the system, refer new oil, so that the amount of oil left in the to the Refrigerant Oil Replacement Quantity in service compressor equals the amount of oil this section. collected from the old compressor. 5. Charge the system with the specified weight of If 140ml was drained from the old compressor refrigerant as determined by A/C label and charge than remove 60ml from replacement with the correct amount of refrigerant oil, using the compressor. (i.e.140 = 200 - 60). Replenishment of Refrigerant Oil procedure in this Pour this revised quantity of new oil back into section. the service compressor. Also add an extra 6. When no more refrigerant is being drawn into the 40ml of new oil to the service compressor, to system, start the engine and select MAX A/C account for oil that was removed from the A/C operation. Adjust the blower motor fan speed to system in replacement of the Accumulator. maximum and allow the remaining refrigerant to If the A/C system has been flushed prior to a be drawn into the system. Continue to add new compressor installation, follow step 7 for refrigerant into the system until the specified refrigerant oil replacement quantity. weight of R-134a has been added. Close the charging cylinder valve and allow the system to 3. Accumulator replacement pull any remaining refrigerant from the hose. Drill two ½ inch holes in the accumulator and When the suction pressure drops to drain the oil into a calibrated container. Add an approximately 207kPa (30psi), close the charging equal amount of oil to the new accumulator plus hose valve. 20 ml for oil not able to be drained from the accumulator. Refrigerant Oil Replacement Quantity 4. Condenser, Evaporator replacement NOTE: During normal A/C operation, oil is circulated Add 40ml of compressor oil for each component through the system with the refrigerant, and a small replaced. As system has been opened the amount is retained in each component. When accumulator must be replaced as described in evacuating or if certain components of the system are step 3. removed for replacement, some of the refrigerant oil 5. Orifice Tube replacement will be lost with the component and with the Additional oil is required for orifice tube refrigerant gas. To maintain the original total system replacement, but as the A/C system has been oil charge, it is necessary to compensate for the oil opened to atmosphere, the suction accumulator lost by adding oil to the system with the new part. must also be replaced . Add additional oil for accumulator as detailed in step 3, and also add NOTE: Service A/C compressors are shipped with 10 ml of oil for orifice tube replacement compressor oil (200cc). 6. Leak Repair (Hose or tube, O-ring, pressure 1. Refrigerant recovery switch, charge port repair / replacement) Each time a system charge is recovered, an Additional oil is required unless you can amount of oil will also be recovered with the determine no evidence of oil loss (No oil stain refrigerant. around joint) As the A/C system has been opened to atmosphere, the suction accumulator must be The amount will differ with type of Recovery replaced . Add additional oil for accumulator as Machine used and time taken to recover detailed in step 3, and also add 20 ml for oil loss refrigerant. at refrigerant leak. The oil balance of the system must be maintained for compressor durability.
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Air Conditioning
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GENERAL PROCEDURES (Continued) 7. System Flushing Effect on Oil Quantity Flushing the system will remove all the refrigerant oil. If a system is flushed prior to a new compressor installation, then the total amount of new oil in the service compressor should be used, to maintain an oil capacity level of 200 ml.
A/C System Flushing
Vehicles that have an inoperative A/C compressor, due to internal causes, should have the refrigerant system cleaned by flushing. This removes any debris or contaminants that may be present to prevent damage to the replacement A/C compressor. Replenishment of Refrigerant Oil System flushing should be performed prior to the installation of the replacement A/C compressor. Flush NOTE: Refrigerant oil should be added to the A/C system with the replacement accumulator before it is only the A/C evaporator core and A/C condenser installed. The correct oil quantity depends upon which core. Note that suction accumulator and A/C A/C part has been repaired or replaced. For correct oil evaporator core orifice cannot be flushed. quantities, refer to Refrigerant Oil Replacement Use Rotunda A/C Refrigerant System Flusher Quantity in this section. 014-00991 or equivalent. Alternative 1: Add oil to inlet tube of the accumulator CAUTION: This system is designed to be (long tube that attaches to evaporator firewall joint). used only with the Ford A/C system flushing Alternative 2: Draw in oil through the low pressure solvent F4AZ-19579- A. Use of other solvents may charge port before evacuation, as detailed in steps result in personal injury and/or damage to the 1-4 below. vehicle and the flusher. 1. Pour the specified amount of refrigerant oil in to a measuring cylinder. CAUTION: Do not let the flushing solvent F4AZ-19579-A come in contact with your eyes or 2. Connect manifold gauge hoses as shown in skin. If eye contamination occurs, flush eyes with illustration. water for 15 to 20 seconds. Remove contaminated Manifold gauge (high pressure side).. air clothing, and wash affected skin with soap and conditioner high pressure charge port. water. Seek medical attention. Manifold gauge (centre).. vacuum port. 1. Before removing any refrigerant system Measuring cylinder (and oil).. air conditioner components, recover the system refrigerant low pressure charge port. following the A/C System Discharging & Recovery procedure outlined in this section. 3. When vacuum pump is run, oil is drawn into air conditioning system from low pressure side. CAUTION: Follow all refrigerant system 4. Switch off vacuum pump after specified amount of safety and service precautions as outlined. oil has been drawn into the system. 2. Disconnect the A/C refrigerant lines from the A/C evaporator core. This will isolate the A/C CAUTION: When handling the oil, please evaporator core orifice and suction wear gloves. accumulator/drier from A/C evaporator core. CAUTION: HFC134a oil is very 3. Disconnect the A/C refrigerant lines from the hygroscopic (absorbs moisture). Keep the oil condenser core. container sealed at all times. 4. Clean all dirt and debris from the fittings on the A/C evaporator core and/or A/C condenser core CAUTION: HFC134a oil reacts with some to be flushed. plastics. Keep it stored in metal container. (Plastic bottle should only be used for o-ring 5. Select the proper Flusher machine fittings, clean lubrication.) and lubricate connections and securely attach fittings to the A/C evaporator core and/or A/C CAUTION: Care should be taken not to condenser core. O-rings must be used with these spill the HFC134a oil on paint work, and fittings to ensure proper leak-free connections. plastic. If this is accidentally done, wipe 6. Follow instructions given on flushing procedure of immediately. the refrigerant system flusher used. CAUTION: Clearly identify the oils when transferred to a different container.
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Air Conditioning
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REMOVAL AND INSTALLATION
A/C Hose/Tube Pad Fitting CAUTION: All refrigerant must be recovered from the A/C system. Removal 1. Recover the refrigerant. Refer to A/C Discharging and Recovery in this section. 2. Remove the bolt from the air conditioning line (pad) fitting.
4. If damaged remove the O-ring seal with a non-metallic tool. CAUTION: Do not use metal tools to remove the O-ring seal. They can cause axial scratches across the O-ring seal groove resulting in refrigerant leaks.
CAUTION: Support the female fitting with a wrench to prevent the tubes from twisting.
Installation 1. Clean all dirt or foreign material from the fittings. 2. If removed, install a new O-ring seal.
3. Pull the air conditioning line (pad) fitting apart.
CAUTION: Use only new genuine Ford black refrigerant O-ring seals which are compatible with refrigerant R-134a and refrigerant oil ND-Oil8. The use of any O-ring seals other than specified may result in intermittent leakage during vehicle operation. Lubricate the O-ring seals with PAG Refrigerant Compressor Oil ND-Oil 8.
3. Lubricate the inside of the fittings with PAG Compressor Oil ND-Oil 8.
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REMOVAL AND INSTALLATION (Continued) 4. Assemble the male and female pad fittings together. NOTE: When correctly assembled, the male and female pad fittings should be flush.
2. Before making any hose and tube connections, apply a few drops of compressor oil to the seat of o-ring to avoid refrigerant leakage.
Air Conditioning (A/C) Compressor — I6 Engine Removal and Installation CAUTION: To prevent refrigerant system contamination, if you are installing a new A/C compressor because the A/C compressor has failed internally, you must use the following procedures:
CAUTION: All refrigerant must be recovered from the A/C system. 1. Recover the refrigerant. For additional information refer to A/C system discharging and recovery in this section. 5. Tighten the pad fitting bolt to the specified torque. NOTE: Installation of a new suction accumulator is NOTE: Once tightened to the specified torque, required when repairing the air conditioning system further tightening of the pad fitting bolt will not except when there is physical evidence of system improve the sealing performance. contamination from a failed A/C compressor damage 6. Charge the system. Refer to Air Conditioning to the suction accumulator, evidence of the A/C System Evacuation and Charging in this section. system being open to the atmosphere/leaking or evidence of moisture absorption.
O-Ring Removal and Lubrication
1. When removing an o-ring from a tube, use a wooden or nylon tool to prevent damaging the tube. NOTE: Always replace the existing o-rings with new genuine Ford O-rings specified for refrigerant HFC-134a, as air conditioning O-rings are made of a material compatible with refrigerant and refrigerant oil. NOTE: The evaporator tube inlet and outlet green/blue refrigerant O-rings are different dimensions to the A/C System black refrigerant O-rings, and should not be mixed. (Refer to Specifications in this section for O-ring details.) The evaporator tube green/blue refrigerant O-rings are also different dimensions from previous models.
NOTE: If an A/C Flusher is available, carry out the air conditioning (A/C) system flushing procedure in this section. 2. Install a new A/C orifice tube assembly. For additional information, refer to Evaporator Core Orifice Tube Assembly in this section. 3. Remove the drive belt. For additional information, refer to Section 303-05. 4. Disconnect the A/C clutch electrical connector.
5. Remove the A/C discharge hose assembly bolt and the suction hose assembly bolt from the side of the A/C compressor and disconnect the A/C hose assemblies. CAUTION: Plug all A/C ports to prevent contamination from dirt or moisture.
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Air Conditioning
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REMOVAL AND INSTALLATION (Continued) CAUTION: All refrigerant must be recovered from the A/C system. 1. Recover the refrigerant. For additional information refer to A/C system discharging and recoveryin this section. NOTE: Installation of a new suction accumulator is required when repairing the air conditioning system when there is physical evidence of system contamination from a failed A/C compressor, damage to the suction accumulator, evidence of the A/C system being open to the atmosphere/leaking or evidence of moisture absorption. 6. Remove the compressor mounting bolts and the A/C compressor.
NOTE: If an A/C Flusher is available, carry out the air conditioning (A/C) system flushing procedure in this section. 2. Install a new A/C orifice tube assembly. For additional information, refer to Evaporator Core Orifice Tube Assembly in this section. 3. Remove the drive belt. For additional information, refer to Section 303-05. 4. Disconnect the A/C clutch electrical connector.
7. To install, reverse the removal procedure. NOTE: Each new compressor is supplied with 200cc of ND-Oil8 for the A/C system lubrication. Refer to Refrigerant Oil Replacement Quantity in this section prior to fitting a new compressor. For installation, black compressor mounting bolt is to be fitted to upper front location (both 5. Remove the A/C discharge hose assembly bolt I6 & V8). Remaining 3 gold compressor and the suction hose assembly bolt from the side mounting bolts to be fitted to other 3 of the A/C compressor and disconnect the A/C locations. hose assemblies. Lubricate the new A/C manifold O-ring seals with PAG Compressor Oil ND-Oil 8. CAUTION: Plug all A/C ports to prevent contamination from dirt or moisture. 8. Recharge the A/C system. For additional information, refer to A/C system evacuation and charging in this section.
Air Conditioning (A/C) Compressor — V8 Engine Removal and Installation CAUTION: To prevent refrigerant system contamination, if you are installing a new A/C compressor because the A/C compressor has failed internally, you must use the following procedures:
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01/2003 2003.0 BA Falcon
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Air Conditioning
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REMOVAL AND INSTALLATION (Continued) 6. Remove the bolts and the two lower compressor mounting spacers and the A/C compressor.
7. To install, reverse the removal procedure. NOTE: Each new compressor is supplied with 200cc of ND-Oil8 for the A/C system lubrication. Refer to Refrigerant Oil Replacement Quantity in this section prior to fitting a new compressor.
2. Disconnect the A/C clutch electrical connector.
3. Remove the compressor mounting bolts and position the A/C compressor aside. 1. For V8, remove the two lower compressor mounting spacers. I6 Compressor
For installation, black compressor mounting bolt to be fitted to upper front location (both I6 & V8). Remaining 3 gold compressor mounting bolts to be fitted to other 3 locations. For V8 only, spacers to be fitted between comp & bracket on two lower comp mounting bolts. Lubricate the new A/C O-ring seals with Compressor Oil ND-Oil 8. 8. Recharge the A/C system. For additional information, refer to A/C system evacuation and charging in this section.
Compressor Clutch, Compressor Pressure Relief Valve and Compressor Shaft Seal
V8 Compressor
Removal and Installation The compressor clutch, compressor pressure relief valve and compressor shaft seal are not serviceable. If any compressor clutch, pressure relief valve or compressor leakage faults occur, replace the complete compressor and clutch assembly.
Air Conditioning (A/C) Compressor Bracket Removal and Installation 1. Remove the drive belt. For additional information, refer to Section 303-05.
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REMOVAL AND INSTALLATION (Continued) 4. Remove the bracket mounting bolts, and the A/C compressor bracket. V8 Bracket
I6 Bracket
5. Remove HVAC Assembly. Refer to Section 412-02. 6. Detach the Foam Insulators from the Heater and Evaporator Tubes.
7. Remove One Screw retaining the Heater Core mounting clamp to the HVAC.
5. To install, reverse the removal procedure.
Evaporator Core
8. Undo One Screw retaining the A/C evaporator tube retaining plate.
CAUTION: All refrigerant must be recovered from the A/C system. NOTE: The evaporator tube inlet & outlet green/blue refrigerant O-rings are different dimensions to the A/C System black refrigerant O-rings, and should not be mixed. The evaporator tube green/blue refrigerant O-rings are also different to previous models. Removal 1. Recover the refrigerant. For additional information, refer to Discharging and Recovery in this section. 2. Drain the water from the engine cooling system (refer to 303-03). 3. Disconnect the evaporator clamp, A/C liquid line, suction accumulator and Heater Hoses, at the Firewall. (refer to details in this section). 4. Remove the Instrument Panel, refer to Section 501-02.
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Air Conditioning
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REMOVAL AND INSTALLATION (Continued) 9. Remove the one screw retaining the HIM Heat sink to the HVAC.
insulator and the core face is parallel to the HVAC opening surface. NOTE: Refer to Refrigerant Oil Replacement Quantity in this section prior to recharging the A/C System. 1. Refit all previously removed Components in reverse order to removal. CAUTION: Care must be taken when installing the Evaporator core as the Aluminium Fins could become damaged and effect air flow over the Evaporator Core. CAUTION: Ensure evaporator seal adequately seals around core to prevent air by pass.
10. Undo the five screws used to retain the Case scroll housing to the HVAC.
CAUTION: Ensure evaporator tube inlet and outlet green/blue refrigerant ‘O’ Rings are present prior to assembling the accumulator and liquid lines. 2. Recharge the A/C System. For additional information, refer to Discharging and Recovery in this section. 3. Refill the engine cooling system (refer to section 303-03).
Orifice Tube Assembly Special Tool(s) Broken Orifice Extractor 412-035 (T83L-19990-B) 11. Gently remove the Case scroll clear of the Evaporator Tubes from the HVAC Main Case. 12. Lift the Evaporator Core clear of the HVAC Main Case.
Fixed Orifice Tube Tool 412-034 (T83L-19990-A)
CAUTION: All refrigerant must be recovered from the A/C system.
Installation CAUTION: Fit the Evaporator core into the HVAC Case opening, ensuring that the lower side of the core rests correctly on the White foam
G34263 en
CAUTION: Ensure liquid line O-ring is present at the nut joint prior to assembly of the A/C liquid line. NOTE: A dirty A/C Orifice tube assembly or A/C liquid line (condenser to evaporator tube) containing black refrigerant oil and particles indicates that the A/C compressor must be inspected.
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REMOVAL AND INSTALLATION (Continued) Removal 5. Hold the special tool T-handle stationary and rotate the special tool body to remove the A/C 1. Recover the refrigerant. For additional information orifice tube assembly. refer to A/C system Discharging and Recovery. NOTE: Adjustment or repair cannot be made to the A/C orifice tube assembly. If damaged or blocked, a new A/C orifice tube assembly must be installed. NOTE: Install a new A/C orifice tube assembly whenever a new A/C compressor is installed. NOTE: The red orifice tube can not be interchanged with different colour orifice tubes from previous models. 2. Remove the screw attaching the liquid line bracket to body adjacent to the charge port, and remove the saddle clamp and nut adjacent to the ABS module. CAUTION: Plug all A/C ports to prevent contamination from dirt or moisture.
3. Undo the nut joint half way along the A/C liquid line. 4. Engage the special tool onto the A/C orifice tube assembly.
6. If the A/C orifice tube assembly is broken, screw the end of the special tool into the broken A/C orifice tube assembly.
7. Hold the special tool T-handle stationary and rotate the special tool body to remove the broken A/C orifice tube.
Installation 1. Lubricate the O-ring seals on the A/C orifice tube. Use PAG Compressor ND Oil-8 or equivalent meeting Ford specification WSH-M1C231-B.
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REMOVAL AND INSTALLATION (Continued) 2. Place the A/C orifice tube into the special tool.
3. Using the special tool, insert the A/C orifice tube into the A/C liquid line (condenser to evaporator line) until seated.
5. Connect the liquid line at the orifice tube and tighten the nut after ensuring the liquid line O-ring is present and undamaged.
6. Refit the screw attaching the liquid line bracket to the body adjacent to the charge port. 7. Refit the saddle clamp and nut adjacent to the ABS module. NOTE: Refer to Refrigerant oil Replacement Quantity in this section prior to recharging to A/C system. 8. Recharge the A/C system. For additional information, refer to A/C system evacuation and charging in this section.
Quick Joint Clamp Special Tool(s) Quick joint clamp removal tool
4. Remove the special tool.
Removal CAUTION: All refrigerant must be recovered from A/C system.
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REMOVAL AND INSTALLATION (Continued) 1. Needles will release quick joint clamp locking tabs. A plate will hold quick joint clamp in to the tool. Stopper lever will locate tool to tube joint.
Item 1 2 3
Description Stopper Lever Needles Plate
2. Recover the refrigerant. For additional information, refer to A/C System Discharging and Recovery in this section.
3. Align the plastic quick joint clamp to suit the quick joint clamp removal tool. NOTE: Guide on quick joint clamp must fit into slot on tool.
Item 1 2 3 4
Description Quick Joint Clamp Stopper Lever Clamp Removal tool Clamp Guide
4. Push tool onto quick joint clamp using thumbs. NOTE: Do not bend the needles inside the tool when inserting.
5. Push with thumbs.
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01/2003 2003.0 BA Falcon
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Air Conditioning
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REMOVAL AND INSTALLATION (Continued) 6. Quick joint clamp will release (spring open). Remove quick joint clamp removal tool by lifting the stopper lever to remove from A/C tube.
Item 1 2
Description Lift Stopper Lever Slide off removal tool and clamp
2. Wrap quick joint clamp about tube joint. 1. Squeeze to close quick joint clamp
3. Clamp must click 1. No gap at (X) joint between both halves of clamp.
Installation 1. Fully insert tube joint, such that: 1. No gap exists. 2. Lubricate O-Ring seals with PAG Compressor oil ND-Oil 8.
Suction Accumulator Special Tool(s) Quick joint clamp removal
Item 1 2 3
Description Female fitting Male fitting O-Ring seals
The BA Falcon suction accumulator from December 2003 (BA-19C808-B, post December 2003) has a different mounting to the earlier version of BA Falcon accumulator (BA-19C808-A, pre December 2003). Both the later level accumulator bracket and the welded body apron brackets have been revised, and the later level accumulator bracket cannot be fitted to the earlier level body bracket. CAUTION: All suction accumulators contain a dessicant which is very hygroscopic (absorbs moisture). It is very important to keep the ports of
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Air Conditioning
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REMOVAL AND INSTALLATION (Continued) the new accumulator sealed until immediately prior to its installation. CAUTION: All refrigerant must be recovered from the A/C system. Removal 1. Recover the refrigerant. For additional information, refer to A/C system discharging and recovery in this section. 2. Disconnect the A/C suction hose assembly from the suction accumulator at the quick connect joint, using the quick joint clamp removal tool. (Refer to section on quick-connect joint removal/assembly.)
4. Disconnect the accumulator inlet tube from the A/C evaporator core by removing the E-clamp and bolt. (Refer to E-Clamp Removal and Installation in this section) CAUTION: Ensure the evaporator outlet tube o-ring (Refer to Specifications in this section for O-ring details) is present and undamaged prior to assembly of the A/C suction accumulator. CAUTION: Plug all A/C ports to prevent contamination from dirt or moisture.
CAUTION: Plug all A/C ports to prevent contamination from dirt or moisture.
5. Remove the suction accumulator. Installation 3. Remove the two suction accumulator mounting nuts.
CAUTION: Refer to Refrigerant Oil Replacement Quantity in this section prior to fitting a new accumulator. 1. To install, reverse the removal procedure. Install the new suction accumulator with the correct amount of PAG Compressor Oil ND-Oil 8. Lubricate the O-ring seals with PAG Compressor Oil ND-Oil 8. 2. Recharge the A/C system. For additional information, refer to A/C system evacuation and charging in this section.
Pressure Cut-off Switch (Pressure Transducer) Removal and Installation CAUTION: All refrigerant must be recovered from the A/C system. 1. Recover the refrigerant. For additional information, refer to A/C system discharging and recovery in this section. 2. Disconnect the A/C pressure cut-off switch electrical connector (pressure transducer).
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REMOVAL AND INSTALLATION (Continued) 3. Remove the A/C pressure cut-off switch (pressure transducer) from the A/C discharge hose assembly.
sideways & forward (refer to Section 303-03) to obtain tool access for the A/C liquid line-condenser joint bolt.
4. To install, reverse the removal procedure. 4. Remove the mounting bolts from the A/C Lubricate the O-ring seals with PAG condenser core brackets. Compressor Oil ND-Oil 8. CAUTION: Prior to removing the NOTE: Refer to Refrigerant Oil Replacement Quantity condenser assembly, insert a sheet of in this section prior to recharging the A/C system. cardboard either side of the core to protect the tubes and fins. 5. Recharge the A/C system. For additional information, refer to A/C system evacuation and NOTE: The condenser assembly can be removed charging in this section. from the top of the vehicle, if the engine cooling fan and shroud has been removed and the Condenser Assembly radiator assembly has been loosened and tilted rearwards. (refer to Section 303-03) Removal and Installation NOTE: The condenser assembly can be removed CAUTION: All refrigerant must be recovered from underneath the vehicle, if the air deflector from the A/C system. has been removed. (refer to Section 501-02) NOTE: Installation of a new suction accumulator is required when repairing the air conditioning system when there is physical evidence of system contamination from a failed A/C compressor, damage to the suction accumulator, evidence of the A/C system being open to the atmosphere/leaking or evidence of moisture absorption. NOTE: If an A/C condenser core leak is suspected, the A/C condenser core should be leak tested before it is removed from the vehicle. For additional information, refer to Electronic Leak Detection and Fluorescent Dye Leak Detection in this section. 1. Recover the refrigerant. For additional information, refer to A/C System Discharging and Recovery in this section. 2. Remove radiator grille sight cover to access front of condenser. 3. Remove the bolts from the two hose assemblies attached to the condenser inlet & outlet tube fittings. Disconnect the two hose assemblies.
5. Remove the A/C condenser core. 6. To install, reverse the removal procedure. Lubricate the new A/C condenser core with the correct amount of PAG Compressor Oil ND-Oil 8 or equivalent meeting Ford specification WSH-M1C231-B. For additional information, refer to Refrigerant and Oil CAUTION: Plug all A/C ports to prevent Adding in this section. contamination from dirt or moisture. Lubricate the O-ring seals with PAG NOTE: If the vehicle is fitted with a turbo Compressor Oil ND-Oil 8 or equivalent intercooler, mounted in front of the condenser, the meeting Ford specification WSH-M1C231-B. intercooler will need to be loosened and slid
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Air Conditioning
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REMOVAL AND INSTALLATION (Continued) NOTE: Refer to Refrigerant Oil Replacement Quantity 8. Disconnect the A/C discharge hose assembly in this section prior to recharging the A/C system. from the compressor. 7. Recharge the A/C system. For additional information, refer to A/C system evacuation and charging in this section.
Condenser Inlet Hose Assembly (Discharge Hose)
CAUTION: Plug all ports to prevent contamination from dirt or moisture. NOTE: Do not insert screwdriver between fittings, as damage can easily occur.
Removal and Installation CAUTION: All refrigerant must be recovered from A/C system. 1. Recover the refrigerant. For additional information, refer to A/C Discharging and Recovery in this section. 2. Remove the bolt from the A/C discharge hose to A/C condenser core inlet tube fitting and disconnect the hose asy from the condenser.
9. To install, reverse the removal procedure. Lubricate the O-ring seals with PAG Compressor Oil ND-Oil 8. NOTE: Refer to Refrigerant Oil Replacement Quantity in this section prior to recharging the A/C system. 10. Recharge the A/C system. For additional information, refer to A/C system evacuation and charging in this section.
CAUTION: Plug all A/C ports to prevent contamination from dirt or moisture. NOTE: Do not insert screwdriver between fittings, as damage can easily occur. 3. Remove the nut from the A/C discharge hose mounting bracket to the radiator support panel. 4. Remove the bolt from the A/C discharge hose to radiator hose guide on the front cross member (V8 only). 5. Disconnect the suction hose assembly from the discharge hose assembly double bracket adjacent to the radiator hose guide on the front cross member (V8 only). 6. Disconnect the A/C discharge hose assembly from the condenser core. 7. Remove the bolt from the A/C discharge hose to compressor fitting.
Compressor Inlet Hose Assembly (I6 & V8 — Suction Hose) and Accumulator Outlet Tube Assembly (V8 — Suction Tube) Special Tool(s) Quick joint clamp removal tool
The BA Falcon 6-cylinder petrol/LPG compressor inlet hoses (suction hoses) from Feb 2004 have been standardised (BA-19997-D) and this is different to the early level of BA Falcon petrol/LPG suction hoses (BA-19997-A ans BA-19997-C), both in hose material and routing. Removal and Installation CAUTION: All refrigerant must be recovered from the A/C system. 1. Recover the refrigerant. For additional information, refer to A/C System Discharging and Recovery in this section.
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Air Conditioning
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REMOVAL AND INSTALLATION (Continued) 2. Disconnect the A/C Suction Hose/Tube assembly 10. Recharge the A/C system. For additional from the suction accumulator at the quick-connect information, refer to A/C system evacuation and joint, using the quick joint clamp removal tool. charging. (Refer to section on Quick Joint Clamp Condenser to Evaporator tube removal/installation.) assembly (A/C liquid line) 3. Disconnect the suction hose/tube from the accumulator (using hands only). 4. Remove the nut from the suction hose bracket to CAUTION: All refrigerant must be recovered shock absorber stud. Disconnect the suction hose from the A/C system. bracket by rotating the bracket on the A/C tube. CAUTION: Ensure the evaporator tube inlet CAUTION: Plug all A/C ports to prevent O-ring (refer to Specifications in this section for contamination from dirt or moisture. O-ring details) is present and undamaged prior to 5. Disconnect the suction hose assembly from the assembly of the A/C liquid line. discharge hose assembly double bracket adjacent Removal and Installation to the radiator hose guide on the front cross 1. Recover the refrigerant. For additional member — (V8). information, refer to A/C System Discharging and 6. Disconnect the suction tube from the suction hose Recovery in this section. at the quick connect joint, using the quick joint 2. Disconnect the A/C liquid line (condenser to clamp removal tool. (Refer to section on Quick evaporator line) at the evaporator by removing the Joint Clamp removal/installation — (V8).) evaporator E-clamp and bolt. (refer to E-Clamp 7. Remove the screw attaching the suction tube removal and installation in this section) bracket to the LH side rail — (V8). 8. Remove the bolt from the A/C suction hose to CAUTION: Plug all A/C ports to prevent compressor fitting. Disconnect the suction hose contamination from dirt and moisture. assembly from the compressor. 3. Remove the bolt from the liquid line condenser outlet tube joint and disconnect the liquid line from CAUTION: Plug all A/C ports to prevent the condenser. contamination from dirt or moisture. NOTE: Do not insert screwdriver between fittings NOTE: Do not insert screwdriver between fittings, as damage can easily occur. as damage can easily occur. NOTE: If the vehicle is fitted with a turbo intercooler mounted in front of the A/C condenser, the intercooler will need to be unbolted and slid sideways and forward in order to obtain tool access for the A/C liquid line condenser joint bolt. (refer to Section 303-03)
9. To install, reverse the removal procedure. Lubricate the O-ring seals with PAG compressor oil ND-Oil8.
CAUTION: Plug all A/C ports to prevent contamination from dirt or moisture. 4. Remove the screw attaching the liquid line bracket to body adjacent to the charge port, and remove the saddle clamp and nut adjacent to the ABS module. 5. To install, reverse the removal procedure. 1. Lubricate O-ring seals with PAG compressor oil ND-Oil8. NOTE: Refer to Refrigerant Oil Replacement Quantity in this section prior to recharging the A/C system.
CAUTION: The SFLPG (Single Fuel LPG) 6. Recharge the A/C system. For additional suction hose is different to the petrol 6-cylinder information, refer to A/C System Evacuation and suction hose, and the SFLPG hose is labelled with Charging. a green stripe. NOTE: Refer to Refrigerant Oil Replacement Quantity in this section prior to recharging the A/C system.
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REMOVAL AND INSTALLATION (Continued)
Evaporator clamp (E-Clamp)
4. Disconnect evaporator sensor plug from HIM connector.
CAUTION: All refrigerant must be recovered from the A/C system. CAUTION: Ensure the evaporator tube genuine Ford green/blue refrigerant O-rings are present and undamaged prior to assembly of the evaporator clamp. Removal and Installation 1. Recover the refrigerant. For additional information, refer to A/C System Discharging and Recovery in this section. 2. Remove the evaporator clamp bolt located between the accumulator inlet tube and the A/C liquid line. 5. Disengage Grommet from heater case. 3. Lift and rotate the evaporator clamp to remove it from both tubes. The swing plate attached to the liquid line will rotate off the accumulator inlet tube. 4. To install, reverse removal procedure, ensuring that the swing plate on the liquid line is swung onto the accumulator inlet tube prior to starting the evaporator clamp bolt. NOTE: Full insertion of both tubes onto the evaporator is critical prior to assembly of the evaporator clamp. NOTE: Refer to Refrigerant Oil Replacement Quantity in this section prior to recharging the A/C system. 5. Recharge the A/C system. For more information, refer to A/C System Evacuation and Charging in this section.
Air Conditioning Cycling Switch (evaporator thermistor)
Item 1 2
Description Grommet Sensor
6. Pull out Sensor. Removal Installation 1. Set A/C controls to face mode. 1. Ensure sleeve on evaporator sensor is straight between sections A and B. 2. Remove ICC display screen, Refer to Section 413-08. 3. Remove glovebox from instrument panel. Refer to Section 501-12.
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REMOVAL AND INSTALLATION (Continued) 2. Insert evaporator sensor into heater case in a similar fashion to removal procedure.
5. Insert evaporator sensor plug into HIM connector.
6. Refit ICC display screen, Refer to Section 413-08. 3. Using a torch and mirror at ICC opening, look into 7. Refit glovebox to instrument panel. Refer to heater case and ensure sensor is correctly section 501-12. directed through the two holes in airmix divider panel. Engine Cooling Fans (Condenser
Fans)
For removal and installation of engine/condenser cooling fans, refer to section 303-03.
4. Securely clip grommet into heater case and ensure that sleeve is still straight and in position as described in 3 above.
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Control Components
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SECTION : 412-04 Control Components VEHICLE APPLICATION : 2003.0 BA Falcon CONTENTS
PAGE
SPECIFICATIONS Specifications ........................................................................................................................412-04-2 DESCRIPTION AND OPERATION Control Components .............................................................................................................412-04-3 HVAC Integrated Module (“HIM” Module) ............................................................................412-04-3 Climate Control Sensors ......................................................................................................412-04-3 Acronyms and Abbreviations ...............................................................................................412-04-3 CAN Bus Information ...........................................................................................................412-04-5 HIM Feature and Benefit Summary ......................................................................................412-04-6 DIAGNOSIS AND TESTING HIM Module ...........................................................................................................................412-04-7 Module Configuration ...........................................................................................................412-04-7 HIM Calibration File Down Load ..........................................................................................412-04-7 Cabin Temperature Sensor Calibration Factor ....................................................................412-04-7 HVAC On-Demand Self Test ...............................................................................................412-04-7 DTC Chart ............................................................................................................................412-04-8 PID Chart ...........................................................................................................................412-04-11 Symptom Chart ..................................................................................................................412-04-12 Connector Circuit Reference ..............................................................................................412-04-12 Air Conditioning & HVAC Relay and Fuses .......................................................................412-03-14 Pinpoint Tests ....................................................................................................................412-04-14 REMOVAL AND INSTALLATION Control Components ...........................................................................................................412-04-30 Cabin Temperature Sensor .................................................................................................412-04-30 Sunload sensor/Twilight sensor ...........................................................................................412-04-30 Ambient Temperature Sensor .............................................................................................412-04-30 Evaporator Temperature Sensor (Evaporator Thermistor) .................................................412-04-30
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SPECIFICATIONS General Specifications Description Lubricants HVAC Lever Cam Grease Engine Coolant
A/C System O-Ring Lubrication A/C System O-Rings
Specification Dow Corning Molykote PG 54 Silicon Grease Do not top up the cooling system with tap water. Use only Ford Specified Coolant at a Ratio of 30 50 % PAG ND-Oil 8 Refrigerant O-Ring, green HNBR, Evaporator Outlet (large) - part no. BA19S710A Evaporator Inlet (small) part no. BA19S710B
Torque Specifications Description HVAC Mounting Upper Bolts (4) HVAC Mounting Lower Nuts (2) Evaporator Tube to A/C Tube Clamping Bolt HVAC Hi / Lo Plastic Self Tapping Screws Heater Tube Clamp Retaining Screw Evaporator Plastic End Plate HIM to HVAC Self Tapping Screws Blower Motor to HVAC Self Tapping Screws
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Nm 6-8 9 - 12 12.7 - 17.3 1.1 - 1.5 1.1 1.1 1.1 1.1 -
1.5 1.5 1.5 1.5
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DESCRIPTION AND OPERATION
Control Components HVAC Integrated Module (“HIM” Module) The introduction of the Ford BA Falcon vehicle brings with it a new concept in Heating, Ventilation and Air Conditioning control. This new technology is known as the HVAC Integrated Module (“HIM”). The HIM is a self-contained electronic control module attached to the passenger side of the HVAC unit. This new generation device contains electric motors, gear drive mechanisms and a PCB Board which electrically and mechanically control the HVAC system. The HIM incorporates air delivery damper control, variable blower fan speed control and high speed serial data communication interconnected to and exchanging data with many other electrical vehicle sub systems. When climate control buttons or knobs are operated, the ICC module sends a CAN message to the HIM. The HIM executes the selected function and sends a message back to the ICC module to update the display screen as required for that function. The HIM is fitted to all three variants of climate control systems available in the FORD BA Falcon vehicle range. The climate control variants are: ACC
Automatic Climate Control with Dual Zone capabilities MCC Standard Heating and Air Conditioning (Manual Climate Control) HTR Heating system only The HIM module is a common component fitted to all three variants, however, in the event of a service replacement, the HIM requires configuration during the installation in to a vehicle. Refer to HIM Module Configuration further in this section. The HIM receives and sends data to various vehicle sub systems via the CAN bus, including the ICC, BEM and PCM. NOTE: The climate system will operate with the ignition key set to RUN position only. Also, the HIM will only respond to diagnostic commands and services from the WDS test tool while the ignition key set to RUN position only.
Climate Control Sensors The climate control system relies on various sensors located in specific positions throughout the vehicle. The sensor data is used to control the various HVAC subsystems such as air distribution, blower fan speed control, air conditioning and heating. Some of the sensor data used by the HVAC system is retrieved through the serial CAN bus data system. The Evaporator temperature sensor is located in the HVAC air conditioning core and is wired directly to the HIM. It is used by the ACC and MCC climate systems only. A12340 en
The Cabin temperature sensor is located in the ICC facia behind a small grille immediately to the right of the ICC display screen and is wired directly to the BEM. It is used by the ACC climate control system only. The CTS takes temperature readings via a DC operated fan motor drawing air from the car interior through the grill and across a thermistor. When there is a change in temperature, the value of resistance changes giving a change in voltage output. This change is read by the BEM where is translated into a CAN message that is read by the HIM. The CTS is not a serviceable item. If the CTS is faulty, the complete ICC should be replaced after prior approval gained. Refer to section 413-08 for ICC replacement. Whenever the ICC or BEM is replaced, the CTS calibration factor needs to be retaught to the BEM. The combined Twilight and Sun Load sensor is located in the top of the instrument panel between the passenger and driver screen air duct. The sensor is wired directly to the BEM. The Sun load sensor is used by the ACC climate control system only, to adjust the ACC for different sun intensity levels. The Twilight Sensor provides information about low light conditions for automatic headlight operation. The Ambient temperature sensor is located in the passenger side external mirror housing and is wired directly to the HIM. It is used by the ACC climate control system only. The Ambient Temperature sensor is not a serviceable item. If the sensor is faulty, the complete LH external mirror assembly should be replaced. The BEM is located within the ICC assembly. Refer to Section 413-08 for ICC functions and specifications, and refer to Section 419-10 for BEM functions and specifications.
Acronyms and Abbreviations The following acronyms will be used throughout this section. A/C ACC ACPT BEM CAN DTC DZ EATC EEC EVT FCSD
Air Conditioning Automatic Climate Control A/C Pressure Transducer Body Electronic Module (GEM) Controller Area Network Diagnostic Trouble Code Dual Zone Electronic Air Temperature Control Electronic Engine Control (part of PCM) Evaporator Vent Temperature Ford Customer Service Division 01/2003 2003.0 BA Falcon
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DESCRIPTION AND OPERATION (Continued) NVM PCM ECU HIM HTR HVAC ICC MAX MCC MIN MSG N/A PID WDS RAM ROM RPM
A12340 en
Electronic Automatic Temperature Control Powertrain Control Module Electronic Control Unit HVAC Integrated Module Heater Heating, Ventilation & Air Conditioning Interior Command Center Maximum Manual Climate Control Minimum Message Not Applicable Parameter Identifier Worldwide Diagnostic System Random Aces Memory (Loss of data when power removed) Read Only Memory Revolutions Per Minute
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DESCRIPTION AND OPERATION (Continued) CAN Bus Information CAN Bus Electrical System Diagram
Data Transmitted by the HIM Information Receiver ACC MCC HTR Description Air Inlet mode (Fresh / ICC YES YES YES Recirc) Air Outlet mode (Face ICC YES YES YES / Floor / Screen) Person display Icon ICC YES YES YES A/C display Icon ICC NO YES NO A/C MAX display Icon ICC NO YES NO A12340 en
Information Description A/C OFF display Icon Blower fan manual speed selection Drivers side temperature selection Passenger side temperature selection Ambient temperature
Receiver ACC MCC HTR ICC ICC
YES YES
NO NO
NO NO
ICC
YES
NO
NO
ICC
YES
NO
NO
ICC
YES
NO
NO
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DESCRIPTION AND OPERATION (Continued) Information Description Climate control mode (AUTO / SEMI / OFF) Blower fan motor operating speed voltage Evaporator core surface temperature A/C Compressor engagement request, (SwitchON)
Receiver ACC MCC HTR ICC
YES
NO
NO
PCM
YES YES YES
PCM
YES YES
NO
PCM
YES YES
NO
Information Received by the HIM Information Description Engine RPM Vehicle road speed DTC Logging Enable A/C Load reduction Engine coolant temperature Engine cylinder count Blower / Temperature knob positions Climate Control push buttons ICC Module type (Auto / Manual climate) Ignition switch accessory position Cabin temperature sensor Sun load sensor
Sender
ACC MCC HTR
PCM PCM PCM PCM PCM
YES YES YES YES YES
YES YES YES YES YES YES YES NO NO NO
PCM ICC
YES NO NO NO YES YES
ICC
YES YES YES
ICC
YES YES YES
BEM
YES YES YES
BEM
YES
NO
NO
BEM
YES
NO
NO
HIM Feature and Benefit Summary The greatest benefit of the new Climate control system is due to the introduction of the serial data CAN bus network. This reduces the wiring required to interconnect sensors and electronic control sub-systems. Sensors are monitored by one electronic sub-system and then the information is shared by any other electronic sub-system that is also connected to the serial CAN bus. This also reduces the total number of possible failures due to poor electrical connection. It also has the greater benefit of a single point connection to monitor and diagnose many vehicle sub-systems via the serial data CAN bus and WDS service tool.
A12340 en
Sharing of Vehicle Sub-Systems Information via Serial CAN data bus Outlet Air Delivery Mode Control Ingress Air Delivery Control Outlet Air Temperature Control HVAC Blower Fan Speed Control
HVAC Blower Fan Over Current Protection Vehicle Battery Voltage Fluctuation Compensation Automatic Climate Control Evaporator Core Temperature Sensor Continuous System Fault Self Diagnosis Calibration Upgrade via WDS service tool Serviceability Benefits
Electric control. Not dependant on engine vacuum like AU. Electric control. Not dependant on engine vacuum. Electric control. Not dependant on engine vacuum. Electric control. Not dependant on engine vacuum. 14 selectable speeds + Off MCC system. 10 selectable speeds + Off + Infinitely variable in Auto mode ACC system Self re-setting thermal overload protection. Minimises HVAC blower fan speed fluctuation due to vehicle system electrical overloads. Dual air temperature control for front seat occupants. Direct connection to HIM. Continuous self diagnosis of HVAC system operation with event capture. System On-Demand Self Test via WDS service tool. HVAC operating system calibration upgrade via WDS service tool. Easy assembly - align levers, fit 3 screws and insert 2 connectors (3 with A/C option.)
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DIAGNOSIS AND TESTING
HIM Module Module Configuration HIM The HIM may be configured to operate in one of three modes. ACC
Automatic Climate Control with Dual Zone capabilities MCC Standard Heating and Air Conditioning (Manual climate control) HTR Heating system only HIM configuration is possible only via WDS service tool. Care must be taken to ensure that the module is correctly configured to match the HVAC assembly type that is installed within the vehicle. Incorrect configuration of the HIM can result in loss of HVAC system functionality and misdiagnosis of the HVAC system. To configure the following: ICC Refer to Section 413-08.
Please refer to FCSD (Ford Customer Service Division) for latest Climate Control system calibration version. Please refer to WDS manual for HIM calibration data upgrade instructions.
Cabin Temperature Sensor Calibration Factor 1. Whenever a cabin Temperature sensor, ICC or BEM is replaced the CTS calibration factor needs to be taught to the BEM. Refer to Section 419-10. 2. The CTS mounted on the ICC has a barcode sticker attached to it. To obtain the calibration factor “Ring the Oasis Hotline” with the Barcode number they will provide a calibration factor to enter into the BEM using the WDS. 3. If a BEM is being replaced, the CTS calibration factor can be read from the original BEM by the WDS using the request read memory block ($21) command ($0E is the relevant memory block for the CTS calibration factor). It can then be downloaded into the new BEM using the request write memory block ($3B) command.
HVAC On-Demand Self Test
The HIM module has the ability to self diagnose most internal circuits and components. Continuous self diagnosis is performed while the ignition key is in the RUN position and sufficient vehicle battery voltage is available. Further to this, the HIM may be PCM commanded to perform additional self diagnosis by Refer to Section 303-14. the WDS service tool. DTC’s will be set as problems HIM Calibration File Down Load arise, where intermittent or permanent circuit failures exist, from continuous self diagnosis or On-Demand The HIM has the provision to accept update HVAC Self Test by WDS service tool. system calibration data. Refer to DTC Chart for individual DTC descriptions. It The calibration data contains many Climate Control is important to note that when performing On-Demand system operating parameters for ACC, MCC and HTR Self Test, the following pre-conditions must be met operating modes. The system calibration data is before starting and during the self test. stored within the HIM’s internal microprocessor The conditions include: memory. Ensure vehicle battery voltage is within 12 ~ 14.5 The Climate Control system calibration version details volts. can be checked using the WDS scan tool to request the data from the HIM via PID “CAL_VER” (EEprom Environment temperature is within 0 ~ +40 Calibration Version.) degrees Celsius. Please refer to Pin Point Test 412-04-I for further Engine temperature is at normal operating instructions in the event of failure to completely down temperature. load the calibration file data from WDS Scan Tool to Record existing DTC’s within the HIM then clear the HIM assembly. before the test. BEM Refer to Section 419-10.
HIM Sub Function: Actuator - Face / Demist Actuator - Floor / Console Actuator - Recirculation Actuator - Air Temperature (Cabin) Actuator - Passenger Air Temperature (Cabin) A12342 en
ACC Yes Yes Yes Yes Yes
Internal Circuit Tests MCC Yes Yes Yes Yes N/A
HTR Yes Yes Yes Yes N/A
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DIAGNOSIS AND TESTING (Continued) HIM Sub Function: Actuator - Driver Air Temperature (Cabin) Sensor - External Air Temperature (Ambient) Sensor - Evaporator Air Temperature Blower fan variable speed controller CAN Bus communication Ignition supply voltage Module configuration Module actuator operating range calibration
DTC Chart The following table lists all DTC’s that may be set by the HIM due to system operation failures. Displayed DTC B1242
B1250
B1255
B1257
B1262
B1266
B1267
B1676
A12342 en
ACC Yes Yes Yes N/A Yes Yes Yes Yes
Internal Circuit Tests MCC N/A N/A Yes N/A Yes Yes Yes Yes
HTR N/A N/A N/A N/A Yes Yes Yes Yes
NOTE: The codes may be logged due to intermittent and/or permanent circuit failures.
Description from MRDB Possible Causes (Recirculation Door Recirc door jammed. Under travel) Recirc lever fouled. Air Flow Recirculation Low battery charge. Door Driver Circuit Internal module failure (HIM). Failure (Cabin Temperature Invalid data code sent by vehicle Sensor) sub-system. Air Temperature Internal Sensor Circuit Failure (Cabin Temperature Sensor) Air Temperature Sensor lead disconnected from External Sensor Circuit module. Open Sensor failure. Internal module failure (HIM). Air Temperature Sensor leads shorted together. External Sensor Circuit Sensor lead shorted to vehicle Short To Ground body. Sensor failure. Internal module failure (HIM). (Screen/Face Actuator Door jammed. under travel) Lever fouled. Servo Motor Defrost Low battery. Circuit Failure Internal module failure (HIM). (Screen/Face Actuator) Servo Motor Air intake Door jammed. Left Circuit Failure Lever fouled. (Passenger Air Low battery. Temperature Actuator) Internal module failure (HIM). (Driver Air Temperature Door jammed. Actuator Under travel) Wiring harness fault. Servo Motor Air intake Actuator fault. Right Circuit Failure Low battery. (Driver Air Temperature Internal module failure (HIM). Actuator) Battery Pack Voltage Poor Battery charge voltage. Out Of Range Battery overcharged. 24 volt jump start. Module internal circuit failure (HIM).
Action Go to section 412-02, Pinpoint test D. Go to PinPoint Test P.
Go to PinPoint Test A. Go to PinPoint Test A.
Go to section 412-02, Pinpoint test E. Go to section 412-02, Pinpoint test G. Go to section 412-02, Pinpoint test H.
Go to PinPoint Test H.
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DIAGNOSIS AND TESTING (Continued) Displayed DTC B1947 B2005
B2006 B2007 B2890
B2010
B2011
B2012
B2013
B2014
Description from MRDB Possible Causes Climate Control A/C Sensor leads shorted together. Post Evaporator Sensor Sensor failure. Circuit Short To Ground Internal module failure (HIM). Climate Control Invalid data code sent by vehicle Temperature Switch sub-system. Out of Range (ICC temperature dial setting) Blower Motor Switch Invalid data code sent by vehicle Out of Range (Blower sub-system. fan dial setting) Solar Radiation Invalid data code sent by vehicle (Driver/Passenger) sub-system. Sensor Out of Range (Floor/Console actuator Under travel) Servo Motor Panel Door Circuit Failure (Floor/Console actuator) (Floor/Console actuator Over travel) Panel Door Actuator Motor Out of Range (Floor/Console actuator) (Driver Air Temp Actuator Over Travel) Driver Air intake Actuator Motor Out of Range (Driver Air Temp Actuator) (Passenger Air Temp Actuator Over travel) Passenger Air intake Actuator Motor Out of Range (Passenger Air Temp Actuator) Climate Control A/C Post Evaporator Sensor Open Circuit
B2141
NVM Configuration Failure.
B2416
(Recirculation Door Over travel) Climate Control Recirculation Actuator Out of Limits
A12342 en
Door jammed. Lever fouled. Low battery. Internal module failure (HIM).
Action Go to PinPoint Test B. Refer to diagnosis in Section 413-08.
Refer to diagnosis in Section 413-08. Refer to BEM diagnosis in Section 419-10 and Sunload sensor pinpoint test in section 417-01. Go to section 412-02, Pinpoint test F.
Linkage disconnected. Linkage failure. Internal module failure (HIM).
Go to section 412-02, Pinpoint test F.
Linkage disconnected. Linkage failure. Wiring harness fault. Actuator fault. Internal module failure (HIM).
Go to section 412-02, Pinpoint test H.
Linkage disconnected. Linkage failure. Internal module failure (HIM).
Go to section 412-02, Pinpoint test G.
Sensor lead disconnected from module. Sensor failure. Internal module failure (HIM). Failure to successfully complete HIM calibration file download. Power interruption to HIM module during file download. Power interruption to WDS scan tool during file download. Linkage disconnected. Linkage failure. Internal module failure (HIM).
Go to PinPoint Test B. Go to PinPoint Test I.
Go to section 412-02, Pinpoint test D.
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DIAGNOSIS AND TESTING (Continued) Displayed DTC B2477 B2513 B2926
C1998
P1796
Description from MRDB Possible Causes Module Configuration Module type not configured. Failure ICC type message data does not match HIM module configuration. Blower (Fan) Circuit HVAC air flow restriction. Failure Internal module failure (HIM). (Screen/Face actuator Over travel) Defrost Actuator Motor Out of Range (Screen/Face actuator) Module Calibration Failure
Linkage disconnected. Linkage failure. Internal module failure (HIM). Actuator calibration not performed. Failure to complete Self Test $02. CAN bus wiring fault.
Invalid data code sent by vehicle sub-system.
U2197
Invalid ‘Vehicle Speed’ data
Invalid data code sent by vehicle sub-system.
U2199
Invalid ‘Engine Coolant Temperature’ data
Invalid data code sent by vehicle sub-system.
U2196
Go to Pinpoint test L & chapter 412-02, Pinpoint test A. Go to section 412-02, Pinpoint test E. Go to PinPoint Test K.
CAN Controller Circuit (Bus Off). CAN Communication Bus Fault - Receive Error Invalid ‘Engine RPM’ data
U1900
Action Go to PinPoint Test J.
Go to PinPoint Test M. Go to PinPoint Test M.
CAN bus wiring fault. Vehicle sub-system failure.
Refer to PCM diagnostics in Section 303-14. Refer to PCM diagnostics in Section 303-14. Refer to PCM diagnostics in Section 303-14.
NOTE: The following table lists all DTC’s that maybe set by the ICC due to climate control related operation failures. Displayed DTC B2923
Description from MRDB Possible Causes Climate control button Climate control button jammed stuck
U2201
Ambient temperature data invalid
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Action Document and clear DTC’s. Carry out Audio Self Test in section 415-00. If the DTC is registered again, replace the ICC. Test the replacement ICC for correct Climate Control System operation. HIM did not have valid data available Clear all DTC’s registered in the HIM. Perform HVAC On-Demand Self Test. Refer to associated Pinpoint test from the DTC chart.
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Control Components
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DIAGNOSIS AND TESTING (Continued) Acronym
PID Chart The following table lists all PID’s utilised by the WDS service tool to access specific functions within the HIM. Acronym CCNT
NTCSDT
A_CT ETSFD
EXT_TEMP
PBDAP PBDTP BLENDDR BLENTP BLOWVOL BLOWAP BLOWTP LEFTOT RIGHTOT MC_VREF HIM_STAT CONPROV
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Description Number of Continuous Trouble Codes Set Number of Trouble Codes Set due to Diagnostic Test Evaporator Temperature External Temperature Sensor Filtered Data External Temperature From Sensor (unfiltered) Passenger Blend Door Actual Position Passenger Blend Door Target Position Driver Blend Door Position Driver Blend Door Target Position HVAC Blower Voltage Blower Motor Speed - Actual Position Blower Motor Speed - Target Position Passenger’s Display Set Temperature Driver’s Display Set Temperature Vehicle Battery Voltage ECU Diagnostic Operating State Configuration and Programming Version
HIM Configuration ACC MCC HTR YES YES YES
CANDSV RECIRDS RECIRDTP
YES YES YES
CCACTM MOD_ID
YES YES
N/A
YES
N/A
N/A
CCMODE BEM_MSG
YES
N/A
N/A ICC_MSG
YES YES YES YES YES YES YES
N/A
N/A
YES
N/A
N/A
YES YES YES
PCM_MSG
ACCS CAL_VER
Description CAN Diagnostic Specification Version Recirculation Door Actual Position Recirculation Door Target Position Climate Control Actuator Modes Module Configuration Check Climate Control Mode GEM - Body Electronics Module CAN Message Receive Status ACM - Interior Control Center Module CAN Message Receive Status PCM - Powertrain Control Module CAN Message Receive Status AC Compressor Cycling Request EEprom Calibration Version Calibration Version Currently Loaded in RAM.
HIM Configuration ACC MCC HTR YES YES YES YES YES YES YES YES YES YES YES YES YES YES YES N/A
YES
N/A
YES YES YES
YES YES YES
YES YES YES
YES YES
N/A
YES YES YES
YES YES YES
CAL_VRAM
YES YES YES
NOTE: The following table lists all PID’s utilised by the WDS service tool to access Climate control functions within the ICC.
YES
N/A
N/A
YES
N/A
N/A
YES YES YES YES YES YES YES YES YES
Acronym TMPKNOBP
Description
Temperature Selector Status BLWR_FAN Blower Fan Speed AC_SEL_SW Air Conditioning Switch Status PANEL_FLR Panel (Face) / Floor
YES YES YES
ICC Configuration ACC MCC HTR N/A YES YES N/A
YES YES
N/A
YES N/A
N/A
YES YES
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DIAGNOSIS AND TESTING (Continued) Acronym
Description
FLR_DEF
Floor / Defrost (mix) FLOOR Floor PANEL_FAC Panel (Face) E DEF_SCRN Defrost (Screen) AUTO Auto OFF Off RECIRC Recirculation Status FAN_MINUS Fan FAN_PLUS Fan + TEMP_DECR Temperature Decrement TEMP_INCR Temperature Increment
ICC Configuration ACC MCC HTR N/A YES YES N/A N/A
YES YES YES YES
YES YES YES YES
YES N/A N/A YES
YES N/A N/A YES
YES N/A YES N/A YES N/A
N/A N/A N/A
YES N/A
N/A
Acronym REAR_DEF
Description
Rear Defrost (heated backlight) PTMP_DECR Passenger Temperature Decrement PTMP_INCR Passenger Temperature Increment MODE_UP Mode UP MODE_DWN Mode DOWN HIM_MSG Missing CANmessage (353) to HIM ACC_POS Ignition key accessory position
ICC Configuration ACC MCC HTR N/A N/A N/A YES N/A
N/A
YES N/A
N/A
YES N/A YES YES N/A N/A YES YES YES YES YES YES
Symptom Chart Refer to 412-02 Symptom Chart.
Connector Circuit Reference HIM Wiring Harness Connectors C376 12 and 2 way NOTE: View from wire entry side (rear).
Pin Number(s) 1 2 5 6 7
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Circuit Designation/Description Normal Condition/Measurement Circuit 38B (B-O) +Battery Voltage ( V ) to vehicle body electrical ground Approximately + Battery ( 12 ~ 14V) while engine running. Circuit 140Z (R-B) Ignition Voltage ( V ) to vehicle body electrical ground Approximately + Battery ( 12 ~ 14V) while engine running. Circuit 914P (BR-Y) Note 1 CAN bus to ICC Circuit 914J (BR-Y) Note 1 CAN bus to PCM Circuit 234 (W-L) Voltage ( V ) between circuit pin 682 and 234 Ambient Sensor 1 ~ 5V ignition key ON, connector attached to HIM. Reading will depend on Ambient sensor temperature.
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DIAGNOSIS AND TESTING (Continued) Pin Number(s) 8 11 12 13
14
Circuit Designation/Description Circuit 682 (R) Sensor GND Circuit 915P (P-L) CAN bus to ICC Circuit 915J (P-L) CAN bus to PCM Circuit 1133 (BR) Blower Motor Circuit 57CB (B) Power GND
Normal Condition/Measurement Resistance (Ohm) between pins 1 and 3 2.7K ~ 3.3K ohms Note 1 Note 1 Voltage ( V ) to vehicle body electrical ground Approximately + Battery ( 12 ~ 14v) while engine running, blower connected and HIM disconnected. Resistance (Ohm) to vehicle body electrical ground 0 ohms approx.
CAUTION: Do not probe terminals with any type of meter as damage to vehicle systems may result. CAUTION: Do not insert probes in to front of terminal, damage may result. Probe only rear (wire entry) of connectors. Dual Zone Actuator Terminal Connections 5 way NOTE: View from wire entry side (rear).
Pin Number(s) 1 2 3 4 5
Circuit Designation/Description Normal Condition/Measurement Potentiometer + Resistance (Ohm) between pins 1 and 3 2.7K ~ 3.3K ohms Potentiometer Resistance (Ohm) between pins 2 and 3 Wiper 0 ~ 3.3K ohms (value dependant on motor output coupling angle) Potentiometer Resistance (Ohm) between pins 1 and 3 2.7K ~ 3.3K ohms Motor Connection Diode (D) Continuity between pins 4 and 5 0.5 ~ 0.7V Motor Connection Diode (D) Continuity between pins 4 and 5 0.5 ~ 0.7V
HIM Input Connection D (Evaporator Temperature Sensor 2 Way) NOTE: View from wire entry side (rear).
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DIAGNOSIS AND TESTING (Continued)
Pin Number(s) 1 2
Circuit Designation/Description Normal Condition/Measurement Sensor ground Voltage ( V ) between HIM terminal connection D pin 1 and C376 pin 13. 0V (ground) Sensor Supply Voltage ( V ) between HIM terminal connection D pin 2 and C376 pin 13 NOTE: With Ignition ON and sensor disconnected, refer to sensor voltage from sensor output table B, Pinpoint test B.
fan circuit is protected with a 40 amp fuse (F5, F6-both green) also located in this fuse box. The three relay coils are protected by a single 15A The air conditioning compressor cut-out relay (WAC fuse (F2-blue) located in the instrument panel fuse relay, R3-black) is located in the Engine Compartment box. Fuse Box. The HIM electrical circuits are protected with two The A/C compressor clutch is protected with a 30 amp fuses, one 15 amp (F4-blue) and one 10 amp, fuse (F11-pink, combined with the engine fuse) (F27-red), both located in the Instrument Panel Fuse located in the Engine Compartment Fuse Box. Box. The A/C condenser fans (engine cooling fans) are The HVAC blower fan circuit is protected with a 40 controlled with three relays (R8, R9, R10-all white) amp fuse (F7-green) located in the Engine located in the Engine Compartment Fuse Box. Each Compartment Fuse Box.
Air Conditioning & HVAC Relay and Fuses
Pinpoint Tests PINPOINT TEST A : TEMPERATURE SENSOR — AMBIENT (ACC) NOTE: REFER to Section 412-02 SYMPTOM CHART BEFORE PROCEEDING Test Step A1
Result / Action to Take
WIRING INSPECTION - SHORT TO VEHICLE BODY Start and run engine until normal operating temperature is reached. Ensure vehicle battery voltage is within normal operating range (12~14volts) before proceeding with test. Using WDS scan tool, record all DTC’s set in the HIM memory. Using WDS scan tool, clear all DTC’s set in the HIM memory.
Yes
Go to A2 if code B1257 is set. Go to A3 if code B1255 is set.
No
System OK
Using WDS scan tool, perform HVAC On Demand Self Test. Are any DTC codes set?
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DIAGNOSIS AND TESTING (Continued) Test Step A2
Result / Action to Take
VEHICLE WIRING INSPECTION - SHORT TO VEHICLE BODY Disconnect the 12 way connector C-376 from the HIM. Using a resistance meter, attach the negative probe to a good metal body earth connection and check the vehicle wiring continuity from HIM connector lead 682 Red wire and lead 234 white-Blue wire for short circuit to vehicle body.
Yes
Go to A4
No
Repair wiring short to vehicle body.
Does the meter read infinite resistance to the vehicle metal body for both leads?
A3
VEHICLE WIRING INSPECTION - CONTINUITY With the 12way connector C-376 removed from the HIM and the 2 Yes way connector removed from the Ambient sensor C-377, use a Go to A4 resistance meter and check the vehicle wiring continuity lead 682 Red No wire and lead 234 White-Blue wire from HIM connector to sensor Repair wiring fault. connector. Does the meter read 0 ohms end to end for each lead?
A4
MODULE FUNCTION CHECK - AMBIENT SENSOR TEMPERATURE Reconnect the 12way connector C-376 to the HIM and the 2way connector C-377 to the Ambient sensor.
Yes
Using the WDS Scan Tool, read the EXT_TEMP value (Ambient sensor temperature) from the HIM.
No
System OK
Go to A5
Compare the value against a temperature probe located near the Ambient sensor.
NOTE: Accurate operation of the sensor relies on air moving
across the sensor. Therefore, while the vehicle is stationary or at low speed or operating for a short period of time only, the display may differ slightly from the true ambient temperature. Do the temperatures closely match?
A5
SENSOR INSPECTION - RESISTANCE CHARACTERISTIC Disconnect the 12way connector C-376 from the HIM. Using a resistance meter, attach probes across lead 682 Red wire and lead 234 White-Blue wire and compare the reading using Table A and a temperature thermometer located near the sensor. Is the resistance reading within specification (+/- 5 degC)?
A6
Yes
Go to A6
No
Replace Ambient sensor
MODULE FUNCTION CHECK - AMBIENT SENSOR SUPPLY VOLTAGE Reconnect the 12way connector C-376 to the HIM and the 2way connector C-377 to the Ambient sensor.
Yes
Using a volt meter, attach the positive probe into rear of connector C-376 lead 682 Red wire and negative probe to lead 234 White-Blue wire.
No
System OK.
Replace HIM.
Ensure Ignition key is ON and HIM responds to ICC controls. Using table A, compare the Ambient sensor voltage reading against a temperature probe located next to the Ambient sensor. Does the voltage value closely match the temperature (+/- 5 degC)?
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DIAGNOSIS AND TESTING (Continued) Table A NOTE: Use this table as a guide only. Minor variations between actual readings are acceptable. Temperature Degrees (Celsius) -30 -25 -20 -15 -10 -5 0 5 10
Sensor Resistance (Ohms) 13.3k 12.2k 11.1k 9.8k 8.6k 7.4k 6.3k 5.3k 4.5k
Sensor Voltage (Volts) 4.20 4.14 4.06 3.97 3.86 3.72 3.56 3.38 3.18
Temperature Degrees (Celsius) 15 20 25 30 35 40 45 50 55
Sensor Resistance (Ohms) 3.7k 3.1k 2.5k 2.1k 1.8k 1.5k 1.2k 1.0k 0.8k
Sensor Voltage (Volts) 2.97 2.74 2.51 2.28 2.05 1.83 1.62 1.43 1.28
NOTE: The Ambient sensor is an integral part of the Left Hand Side external rear view mirror assembly. Refer to section 501-19 for mirror assembly replacement instructions.
PINPOINT TEST B : TEMPERATURE SENSOR — EVAPORATOR (ACC/MCC) NOTE: REFER to Section 412-02 SYMPTOM CHART BEFORE PROCEEDING Test Step B1
Result / Action to Take
SYSTEM ON DEMAND SELF TEST Start and run engine until normal operating temperature is reached. Ensure vehicle battery voltage is within normal operating range (12~14volts) before proceeding with test. Using WDS scan tool, record all DTC’s set in the HIM memory. Using WDS scan tool, clear all DTC’s set in the HIM memory.
Yes
Go to B2 if code B2014 is set. Go to B3 if code B1947 is set.
No
System OK
Using WDS scan tool, perform HVAC On Demand Self Test. Are any DTC codes set?
B2
B3
SENSOR WIRING INSPECTION Disconnect the 2 way Evaporator sensor connector D from the HIM and inspect terminals on the sensor lead assembly for damage or corrosion.
Yes
Do the terminals appear damaged?
Go to B3
Replace Evaporator sensor
No
SENSOR INSPECTION - RESISTANCE CHARACTERISTIC Yes
Turn off the Air Conditioner, select face outlet, full cold (not A/C Max), (‘C’ or ‘Low’ for ACC) and operate HVAC blower at full speed to stabilise the Evaporator sensor temperature.
Go to B4
Disconnect the 2 way Evaporator sensor connector D from the HIM.
Replace Evaporator sensor
No
Carefully insert the test probes of a resistance meter in to the REAR of the Evaporator sensor connector (wire side). Inserting probes in to front of terminals will damage the sensor assembly and cause intermittent A/C operation. Compare the sensor resistance value from Table B with a temperature thermometer located in the face outlet. Is the resistance reading within specification (+/- 5 degC) as per table B?
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DIAGNOSIS AND TESTING (Continued) Test Step B4
Result / Action to Take
MODULE FUNCTION CHECK - EVAPORATOR SENSOR TEMPERATURE Yes
Reconnect the sensor 2 way connector D to the HIM.
System OK.
Connect WDS Scan Tool. Read the A_CT value (Evaporator sensor temperature) from the HIM. Does the value closely match the temperature thermometer located in the face outlet (+/- 5 degC) as per table B?
B5
No
Go to B5
MODULE FUNCTION CHECK - EVAPORATOR SENSOR SUPPLY VOLTAGE Check the Evaporator sensor supply voltage with a voltmeter. With the Evaporator sensor 2 way connector D inserted in to the HIM, attach the positive probe to pin 2 (LHS) and the negative probe to pin 1 (RHS) of the rear of the Evaporator sensor connector. Refer to Evaporative sensor connector diagram for correct pin designations.
Yes
Go to B6
No
Replace HIM.
Using table B, compare the voltage reading against a temperature probe located in the face outlet with the HVAC Blower fan operating at high speed. Does the voltage value closely match the temperature thermometer located in the face outlet (+/- 5 degC)?
B6
MODULE OUTPUT CHECK - EVAPORATOR SENSOR SUPPLY VOLTAGE Yes
Remove evaporator sensor plug from HIM. Using a voltmeter, attach the probes to the HIM output terminals for the evaporator sensor.
No
Ensure ignition key is ON. Is the voltage reading within 4.5-5.5 Volts?
Table B NOTE: Use this table as a guide only. Minor variations between actual readings are acceptable. Temperature Degrees (Celsius) -30 -25 -20 -15 -10 -5 0 5 10 15 20 25
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Sensor Resistance (Ohms) 25.37k 18.90k 14.19k 10.73k 8.17k 6.27k 4.85k 3.78k 2.97k 2.35k 1.87k 1.50k
System OK. Clear DTC.
Sensor Voltage (Volts) 4.16 3.94 3.68 3.39 3.08 2.76 2.44 2.13 1.84 1.56 1.34 1.14
Replace HIM.
Temperature Degrees (Celsius) 30 35 40 45 50 55
Sensor Resistance (Ohms) 1.21k 0.98k 0.75k 0.66k 0.55k 0.45k
Sensor Voltage (Volts) 0.96 0.81 0.68 0.57 0.48 0.41
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DIAGNOSIS AND TESTING (Continued) PINPOINT TEST C : ACTUATOR — RECIRCULATION DOOR (ACC / MCC / HTR) NOTE: REFER to Section 412-02 SYMPTOM CHART BEFORE PROCEEDING Test Step C1
Result / Action to Take
SYSTEM ON DEMAND SELF TEST Start and run engine until normal operating temperature is reached. Ensure vehicle battery voltage is within normal operating range (12~14volts) before proceeding with test. Using WDS scan tool, clear all DTC’s set in the HIM memory.
Yes
Go to C3
No
Go to C2
Using WDS scan tool, perform HVAC On Demand Self Test. Is code B1242 set?
C2
SYSTEM ON DEMAND SELF TEST - DTC CHECK Is code B2416 set?
Yes
Go to C3
No
System OK
C3
VISUAL INSPECTION - RECIRC DOOR LEVER ENGAGEMENT Check Recirc door HVAC/HIM coupling levers for correct engagement. Are the levers disengaged?
Yes
Reconnect levers. Go to C1
No
Go to C4
C4
WDS FUNCTIONAL TEST - FRESH / RECIRC Turn Ignition ON and and run engine. Connect WDS Scan Tool. Remove glove compartment and visually check operation of the Recirc door while selecting Recirc then Fresh using RECIRDTP.
Yes
System OK
No
Go to C5
Does the Recirc door fully seal at open and closed positions?
C5
VISUAL INSPECTION - RECIRC DOOR OBSTRUCTION Check Recirc door and Recirc door coupling levers for interference from external objects. Are there any obstructions?
Yes
Remove obstructions. Go to C1
No
Go to C6
C6
SYSTEM ON DEMAND SELF TEST - FAULT RECONFIRMATION Start and run engine until normal operating temperature is reached. Ensure vehicle battery voltage is within normal operating range (12~14volts) before proceeding with test. Using WDS scan tool, record all DTC’s set in the HIM memory.
Yes
Replace HIM
No
System OK
Using WDS scan tool, clear all DTC’s set in the HIM memory. Using WDS scan tool, perform HVAC On Demand Self Test. Is code B1242 set again?
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DIAGNOSIS AND TESTING (Continued)
PINPOINT TEST D : ACTUATOR — SCREEN / FACE DOOR (ACC / MCC / HTR) NOTE: REFER to Section 412-02 SYMPTOM CHART BEFORE PROCEEDING Test Step D1
Result / Action to Take
SYSTEM ON DEMAND SELF TEST Start and run engine until normal operating temperature is reached. Ensure vehicle battery voltage is within normal operating range (12~14volts) before proceeding with test. Using WDS scan tool, record all DTC’s set in the HIM memory. Using WDS scan tool, clear all DTC’s set in the HIM memory.
Yes
Go to D2 if code B1262 is set. Go to D2 if code B2926 is set.
No
System OK Refer to Section 413-08.
Using WDS scan tool, perform HVAC On Demand Self Test. Are any DTC codes set?
D2
WDS FUNCTIONAL TEST - SCREEN Turn Ignition ON and and run engine. Connect WDS Scan Tool. Select Screen using CCACTM. Does the air flow from the Screen outlet?
D3
Yes
Go to D3
No
Replace HIM
WDS FUNCTIONAL TEST - FACE Select Face using CCACTM. Does the air flow from the Face outlet?
Yes
System OK
No
Replace HIM
PINPOINT TEST E : ACTUATOR — PASSENGER AIR TEMPERATURE MIX. (ACC / MCC / HTR) NOTE: This actuator is utilized to control air temperature to both passenger and driver by the single zone manual climate control system. It is used to control only the passenger side air temperature for dual zone automatic climate control system. NOTE: REFER to Section 412-02 SYMPTOM CHART BEFORE PROCEEDING Test Step E1
Result / Action to Take
SYSTEM ON DEMAND SELF TEST Start and run engine until normal operating temperature is reached. Ensure vehicle battery voltage is within normal operating range (12~14volts) before proceeding with test. Using WDS scan tool, record all DTC’s set in the HIM memory. Using WDS scan tool, clear all DTC’s set in the HIM memory.
Yes
Go to E2 if code B1266 is set. Go to E2 if code B2013 is set.
No
System OK Refer to Section 413-08.
Using WDS scan tool, perform HVAC On Demand Self Test. Are any DTC codes set?
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DIAGNOSIS AND TESTING (Continued) Test Step E2
Result / Action to Take
WDS FUNCTIONAL TEST - PASSENGER AIR MIX FULL HOT Yes
Connect WDS Scan Tool.
Go to E3
Turn Ignition ON and and run engine. Ensure engine is running and at normal operating temperature. Select Passenger Full Hot using PBDTP. Is the airflow from the HVAC hot (LHS for ACC system, Both sides for MCC / HTR)?
E3
No
Ensure engine cooling system is operating correctly. Go to E3
WDS FUNCTIONAL TEST - PASSENGER AIR MIX FULL COLD Yes
Select Passenger Full Cold using PBDTP. Is the airflow from the HVAC cool (LHS for ACC system, Both sides for MCC / HTR)?
System OK
No
Replace HIM if DTC code B1266 or B2013 is set.
NOTE: The temperature test is a subjective check only and careful assessment must be performed to correctly diagnose Full cooling and Full heating operation from the HVAC. The temperature can vary depending on factors such as A/C ON/OFF (where fitted), environment air temperature drawn in to HVAC unit and engine coolant system level and temperature.
Incorrect temperature performance without the setting of either DTC after performing the HVAC On Demand Self Test does not necessitate replacement of the HIM.
PINPOINT TEST F : ACTUATOR — FLOOR / CONSOLE DOOR NOTE: REFER to Section 412-02 SYMPTOM CHART BEFORE PROCEEDING Test Step F1
Result / Action to Take
SYSTEM ON DEMAND SELF TEST Start and run engine until normal operating temperature is reached. Ensure vehicle battery voltage is within normal operating range (12~14volts) before proceeding with test. Using WDS scan tool, record all DTC’s set in the HIM memory. Using WDS scan tool, clear all DTC’s set in the HIM memory.
Yes
Go to F2 if code B2010 is set. Go to F2 if code B2011 is set.
No
System OK Refer to Section 413-08.
Using WDS scan tool, perform HVAC On Demand Self Test. Are any DTC codes set?
F2
WDS FUNCTIONAL TEST - FLOOR OPEN Turn Ignition ON and and run engine. Connect WDS Scan Tool. Select Floor using CCACTM. Does the air flow from the Floor outlet?
F3
Yes
Go to F3
No
Replace HIM
WDS FUNCTIONAL TEST - FLOOR CLOSED Select Face using CCACTM. Does the air flow from the Floor outlet?
Yes
System OK
No
Replace HIM
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DIAGNOSIS AND TESTING (Continued) NOTE: Very minor bleed of air from Floor outlets is acceptable. PINPOINT TEST G : ACTUATOR — DRIVER AIR TEMPERATUR MIX. (ACC) CAUTION: Use extreme care when probing the harness terminals. Forcing the Multimeter probes into the terminals will cause damage and intermittent operation of the Actuator. NOTE: This actuator is utilized to control air temperature to the driver side only for the Dual Zone automatic climate control system. NOTE: The temperature test is a subjective check only and careful assessment must be performed to correctly diagnose Full cooling and Full heating operation from the HVAC. The temperature can vary depending on factors such as A/C ON/OFF (where fitted), environment air temperature drawn in to HVAC unit and engine coolant system level and temperature. Incorrect temperature performance without the setting of either DTC after performing the HVAC On Demand Self Test does not necessitate replacement of the HIM. NOTE: REFER to Section 412-02 SYMPTOM CHART BEFORE PROCEEDING Test Step G1
Result / Action to Take
SYSTEM ON DEMAND SELF TEST Start and run engine until normal operating temperature is reached. Ensure vehicle battery voltage is within normal operating range (12~14volts) before proceeding with test. Using WDS scan tool, record all DTC’s set in the HIM memory. Using WDS scan tool, clear all DTC’s set in the HIM memory.
Yes
Go to G2 if code B1267 is set. Go to G2 if code B2012 is set.
No
System OK Refer to Section 413-08.
Using WDS scan tool, perform HVAC On Demand Self Test. Are any DTC codes set?
G2
WDS FUNCTIONAL TEST - DRIVER AIR MIX FULL HOT Connect WDS Scan Tool. Ensure engine is running and at normal operating temperature. Select Driver Full Hot using BLENTP. Is the airflow from the HVAC Right Hand side (Driver) hot?
G3
Go to G3
No
Ensure engine cooling system is operating correctly. Go to G3
WDS FUNCTIONAL TEST - DRIVER AIR MIX FULL COLD Connect WDS Scan Tool. Ensure engine is running and at normal operating temperature. Select Driver Full Cold using BLENTP. Is the airflow from the HVAC Right Hand side (Driver) cool?
G4
Yes
Yes
System OK
No
Ensure Air Conditioning system is operating correctly. Go to G4
ELECTRICAL CHECK - DRIVER AIR MIX ACTUATOR
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Yes
Check dual zone actuator as per “Dual Zone Actuator Terminal Connections” in “Connector Diagrams” earlier in this section with the wiring harness disconnected from the dual zone actuator.
Go to G5
Are all checks correct?
Replace dual zone actuator.
No
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DIAGNOSIS AND TESTING (Continued) Test Step G5
Result / Action to Take
ELECTRICAL CHECK - DRIVER AIR MIX ACTUATOR Remove the Glove box. Refer to Section 501-12. Disconnect the dual zone actuator wiring harness connector C from the HIM. Disconnect the dual zone wiring harness from Drivers side actuator.
Yes
Go to G6
No
Replace wiring harness
Using a resistance meter, check the continuity of all wiring between both electrical connectors. Did all wires have Continuity in each corresponding position?
G6
SYSTEM ON DEMAND SELF TEST Start and run engine until normal operating temperature is reached. Ensure vehicle battery voltage is within normal operating range (12~14volts) before proceeding with test. Using WDS scan tool, clear all DTC’s set in the HIM memory.
Yes
Replace HIM.
No
System OK
Using WDS scan tool, perform HVAC On Demand Self Test. Are codes B1267 or B2012 set?
PINPOINT TEST H : INPUT FUNCTION — BATTERY VOLTAGE (ACC / MCC / HTR) NOTE: This DTC may be accidentally triggered due to a vehicle jump start from a 24 volt battery system. NOTE: REFER to Section 412-02 SYMPTOM CHART BEFORE PROCEEDING Test Step H1
Result / Action to Take
SYSTEM ON DEMAND SELF TEST Start and run engine until normal operating temperature is reached. Ensure vehicle battery voltage is within normal operating range (12~14volts) before proceeding with test. Using WDS scan tool, record all DTC’s set in the HIM memory.
Yes
Go to H2
No
System OK
Using WDS scan tool, clear all DTC’s set in the HIM memory. Using WDS scan tool, perform HVAC On Demand Self Test. Is DTC code B1676 set?
H2
MODULE FUNCTION CHECK - BATTERY VOLTAGE READING Connect WDS Scan Tool. Start and run engine. Ensure charging system is within normal vehicle specifications. Read Battery voltage from HIM using MC_VREF.
Yes
System OK
No
Replace HIM
Using a digital voltmeter, attach positive probe to lead 38B and negative probe to lead 57CB of 12 way connector C-376 and compare readings. Is the MC_VREF value within +/-0.5 volt of the digital voltmeter reading?
PINPOINT TEST I : INPUT FUNCTION — MODULE INTERVAL EEPROM MEMORY (ACC / MCC / HTR) NOTE: The setting of this DTC is due to incomplete calibration file download from WDS scan tool to HIM. Care must be taken to ensure that the HIM calibration file is successfully completed before replacing the HIM. Disturbances to vehicle battery power or the serial CAN bus can interfere with the process. In the event of A12342 en
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DIAGNOSIS AND TESTING (Continued) repeated unsuccessful file download, the HIM has a basic backup of all data stored in the HIM microprocessor Read Only Memory (ROM). The HIM microprocessor will use the back up data to provide full HVAC system functionality but may have some degree of noticeable changes to the Climate Control system operating performance. Both the ROM backup and EEprom calibration data is utilised by all three HIM variants, namely ACC, MCC and HTR. A PID “CAL_VRAM” is provided to perform a check to determine which calibration data is loaded to RAM and being used by the HIM microprocessor. For Example: The Basic backup calibration data stored in the HIM ROM version is = 1. The HIM Calibration file data stored in the HIM EEprom version is = 5, or the same number as your current calibration file version. Using WDS scan tool, request the data for PID “CAL_VRAM” from the HIM. If the data returned is = 1 Then the HIM microprocessor has load the Basic backup calibration data to RAM due to a fault in the EEprom calibration data area. NOTE: The version number for ROM calibration data is always =1. It is safe to operate the vehicle in the event of EEprom Calibration file download failure. If the data returned for PID “CAL_VRAM” is = 5 (or the same number as your current calibration file version) Then the HIM microprocessor has load the update EEprom calibration data to RAM and there is no problem. (IE. DTC B2141 will not be set.) NOTE: REFER to Section 412-02 SYMPTOM CHART BEFORE PROCEEDING Test Step I1
Result / Action to Take
MODULE CHECK - HIM SYSTEM CALIBRATION FILE DOWNLOAD Run engine and ensure vehicle battery condition is of normal charge state.
Yes
Connect WDS tester.
No
Clear DTC’s in HIM.
Replace HIM
System OK.
Proceed with HIM calibration file download. Wait until file download process has successfully completed before proceeding any further. Wait until file download process has successfully completed before proceeding any further. Reset the HIM using the WDS scan tool HIM reset button. Or, switch OFF the ignition and disconnect the HIM 12 and 2way connectors C-376 from the HIM for 5 minutes and then reconnect both connectors. Turn on the ignition and request DTC status from the HIM. Is DTC B2141 set?
PINPOINT TEST J : INPUT FUNCTION — MODULE CONFIGURATION (ACC / MCC / HTR) NOTE: The HIM may be configured to operate in any one of three types of modes. Namely, Dual zone Automatic climate control (ACC), Single zone with A/C (MCC) or Single zone without A/C (HTR). Firstly, to ensure trouble free operation, the HIM configuration must match the HVAC system type. Secondly, the ICC must be the correct type to operate the HVAC system. The DTC will be set while the ICC system does not match the HVAC system type and all climate functions will be inoperable. Thirdly, the DTC may also be set while the HIM is not configured. This may be the case for a new spare part HIM only. The DTC code can not be cleared by the WDS test tool. Setting and Clearing of the DTC is automatically controlled by the HIM. NOTE: REFER to Section 412-02 SYMPTOM CHART BEFORE PROCEEDING
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Control Components
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DIAGNOSIS AND TESTING (Continued) Test Step J1
Result / Action to Take
VISUAL INSPECTION - ICC TYPE MATCH Is ICC the correct type for HVAC system?
Yes
Go to J3
No
Go to J2
J2
ICC TYPE INSPECTION Install the correct ICC system type. Check DTC’s stored in HIM using WDS scan tool. Is the HIM DTC B2477 is set?
J3
Yes
Go to J3
No
System OK
MODULE FUNCTION CHECK - HIM MODULE CONFIGURATION CHECK Using WDS scan tool, check that the HIM configuration is set correctly Yes and matches the HVAC system type. System OK DTC will be self Cleared Is the HIM configured correctly?
No
Set the correct HIM configuration using WDS scan tool. Refer to “HIM Module Configuration” earlier in this section. Check that HIM DTC B2477 is cleared.
PINPOINT TEST K : INPUT FUNCTION — MODULE SERVO ACTUATOR CALIBRATION (ACC/MCC/HTR) NOTE: This DTC is only set due to the HIM servo Actuators never completing a full calibration process. This would normally only be the case for a new spare part HIM. NOTE: REFER to Section 412-02 SYMPTOM CHART BEFORE PROCEEDING Test Step K1
Result / Action to Take
MODULE CALIBRATION CHECK - HIM SERVO ACTUATORS Is DTC C1991 set?
Yes
Perform HVAC On Demand Self Test.
No
System OK.
PINPOINT TEST L : INPUT FUNCTION — HVAC BLOWER (ACC / MCC / HTR) NOTE: It is normal for the HVAC Blower to stop operating during excessively high vehicle battery voltage conditions such as jump starting from a 24 volt power source. The HVAC blower fan will automatically restart when the vehicle battery voltage returns to normal operating range. The HIM also employs internal HVAC blower fan speed controller thermal protection. The HVAC blower fan will be disabled when the fan speed controller heatsink (located within the HIM assembly) has exceeded safe operating temperatures. Some reasons for fan speed controller heatsink overheat can include, High temperatures may be artificially produced for reasons such as restricted HVAC air filter by dust or plastic bag. Excessive heat drawn in to the HVAC air inlet from the engine bay with the bonnet open. Face mode selected and all air outlet registers are closed. The HVAC blower fan should restart after the fan speed controller heat sink has cooled sufficiently and the Ignition key is then turned OFF and ON. A12342 en
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Control Components
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DIAGNOSIS AND TESTING (Continued) NOTE: Ensure that there are no restrictions to HVAC airflow or excessive heat pick-up in to HVAC air intake before replacement of HIM. NOTE: REFER to Section 412-02 SYMPTOM CHART BEFORE PROCEEDING Test Step L1
Result / Action to Take
WDS FUNCTIONAL TEST - HVAC BLOWER FAN OPERATION Run engine and ensure vehicle battery is at normal charge state. Select Face / Floor outlet mode. Select Recirc inlet mode. Select full cold.
Yes
System OK
No
Go to L2
Set the HVAC blower fan speed to maximum using WDS scan tool with PID “BLOWTP. Is the HVAC Blower fan operating at full speed?
L2
VISUAL INSPECTION - HVAC BLOWER MOTOR POWER FUSE Check HVAC blower motor power supply fuse. Is the fuse blown?
Yes
Replace the fuse
No
Go to L3
L3
ELECTRICAL INSPECTION - HVAC BLOWER MOTOR POWER SUPPLY Yes
Using a voltmeter, check that battery power is available at the HVAC blower motor 2way connector C-221 Pin 1 lead 118B.
Go to L4
Is approx battery voltage present?
No
Repair wiring fault
L4
L5
VISUAL INSPECTION - HVAC BLOWER MOTOR Yes
Check HVAC blower motor current draw with a clamp type ammeter attached on to the HVAC blower fan battery supply lead. Pin 1 of 2way connector C-221 lead 118B.
Replace HVAC blower motor.
Is the reading greater than 25 Amps?
Go to L5
No
VISUAL INSPECTION - HVAC BLOWER MOTOR Remove HVAC blower and inspect for lose or damaged impeller. Is impeller damaged or lose fit on motor shaft?
Yes
Replace HVAC blower motor.
No
Go to L6
L6
WDS FUNCTIONAL TEST - HVAC BLOWER FAN OPERATION Reinstall the HVAC blower fan motor and operate at mid and full speeds for 10 minutes each using WDS scan tool with PID “BLOWTP”.
Yes
NOTE: More time may be required to run the blower at each speed
System OK
Go to L7
No
during low ambient temperature conditions (cold weather). Does the blower stop operating?
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Control Components
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DIAGNOSIS AND TESTING (Continued) Test Step L7
Result / Action to Take
WDS DTC CHECK - HVAC BLOWER FAN SPEED CONTROLLER Using WDS scan tool check DTC’s in HIM.
Yes
Replace HIM fi this DTC is consistently set.
Is DTC B2513 set?
No
System OK
PINPOINT TEST M : INPUT FUNCTION — CAN BUS. (ACC / MCC / HTR) NOTE: REFER to Section 412-02 SYMPTOM CHART BEFORE PROCEEDING Test Step M1
WDS FUNCTION TEST - REQUEST DIAGNOSTIC SESSION Turn ON ignition. Connect WDS Scan Tool. Request Diagnostic session from HIM. Does HIM acknowledge command?
M2
Result / Action to Take
Yes
Clear DTC in HIM System OK
No
Go to M2
ELECTRICAL INSPECTION - HIM POWER SUPPLY Using a voltmeter, check that Battery and Ignition power is available Yes to the HIM with ignition ON. Connect negative probe to vehicle Go to M3 electrical ground point. Connect positive probe to each Pin 1 and then No Pin 2 of HIM 12 way connector C-376. Repair power / wiring fault. Is approx battery power available at both Pins?
M3
WDS FUNCTION TEST - REQUEST DIAGNOSTIC SESSION Check CAN bus wiring. Refer to section 418-00.
NOTE: Care should be taken to ensure CAN bus wiring fault is not intermittent.
Is there a CAN bus wiring fault?
M4
Yes
Refer to section 418-00 for CAN bus wiring fault repair instructions.
No
Go to M4
WDS FUNCTION TEST - REQUEST DIAGNOSTIC SESSION Turn ON ignition. Connect WDS Scan Tool. Request Diagnostic session from HIM. Does HIM acknowledge command?
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Yes
Clear DTC in HIM System OK
No
Replace HIM
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Control Components
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DIAGNOSIS AND TESTING (Continued) PINPOINT TEST N : INPUT FUNCTION — CAN BUS MESSAGE RECEPTION (ACC / MCC / HTR) NOTE: REFER to Section 412-02 SYMPTOM CHART BEFORE PROCEEDING Test Step N1
WDS FUNCTION TEST - REQUEST HIM DTC’s Turn ON ignition. Connect WDS Scan Tool. Request DTC’s from the HIM. Is DTC code U1900 set?
N2
Result / Action to Take
Yes
Go to N2
No
System OK
WDS FUNCTION TEST - REQUEST CAN BUS COMMUNICATION FAULT PID DATA FOR ICC SYSTEM Using WDS scan tool, request data from the HIM for PID B902. Is ICC_MSG set?
Yes
Refer to ICC section 413-08.
No
Go to N3
N3
WDS FUNCTION TEST - REQUEST CAN BUS COMMUNICATION FAULT PID DATA FOR BEM SYSTEM Is BEM_MSG set?
Yes
Refer to BEM section 419-10.
No
Go to N4
N4
WDS FUNCTION TEST - REQUEST CAN BUS COMMUNICATION FAULT PID DATA FOR PCM SYSTEM Is PCM_MSG set?
Yes
Refer to ICC section 303-14.
No
System OK
PINPOINT TEST O : INPUT FUNCTION — HIM MODULE INTERNAL RAM MEMORY (ACC / MCC / HTR) NOTE: The HVAC Climate Control system operation may be unpredictable in the event of this type of failure condition. Operate the vehicle with great care until the fault is rectified by an authorised service dealer. NOTE: The setting of this DTC is due to an internal failure of the HIM microprocessor RAM memory. NOTE: Complete the test below before replacing the HIM. NOTE: REFER to Section 412-02 SYMPTOM CHART BEFORE PROCEEDING
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DIAGNOSIS AND TESTING (Continued)
Test Step O1
Result / Action to Take
MODULE CHECK - HIM MICROPROCESSOR INTERNAL RAM CHECK Run engine and ensure vehicle battery condition is of normal charge state.
Yes
Connect WDS tester.
No
Replace HIM.
System OK.
Clear DTC’s in HIM. Switch OFF the ignition and disconnect the HIM 12 and 2way connectors C-376 from the HIM for 5 minutes and then reconnect both connectors. Turn the ignition ON and request DTC status from the HIM. Is DTC code C2784 set?
PINPOINT TEST P : CABIN TEMPERATURE SENSOR OPERATION (HIGH SERIES/ACC) NOTE: With the ignition key in the ignition or start position, the BEM provides power to the fan motor of the cabin temperature module. With the ignition switch in the ignition position the BEM reads the analogue temperature signal from the module and converts the analogue data into degrees Centigrade and transmits this data on the CAN bus to the climate control system. DTC’s will not be logged for invalid data when the ignition switch is in the off or accessories position. The WDS service tool is to be used to program and check the calibration factor loaded into the BEM. This calibration factor should be the same as the calibration factor identified on the CTS ID label. NOTE: REFER to Section 412-02 SYMPTOM CHART BEFORE PROCEEDING Test Step P1
CABIN TEMPERATURE SENSOR AIRFLOW Start the engine and switch on the automatic climate control. Place a small piece of tissue paper over the cabin temperature grille. Ensure that the grille is completely covered. Does the tissue paper stick to the grille to indicate air being drawn into the cabin temperature sensor?
P2
Result / Action to Take
Yes
Go to P2
No
Check for blockage of the cabin temperature sensor grille and remove any restrictions and retest. If result is still No replace the ICC. Section 413-08
CABIN TEMPERATURE SENSOR READING Using the WDS tester activate and monitor Pid INT_TEMP. Place a thermometer/temperature probe in front of the CTS grille and check that the reading matches the INT_TEMP information on the WDS tester.
Yes
CTS is operating correctly.
No
CTS is faulty. Replace the ICC. Section 413-08
Using a hair dryer or similar blow warm air across the thermometer/temperature probe and into the CTS grille. Check that the temperature changes on the thermometer/temperature probe match the INT_TEMP information on the WDS tester. Does the temperature change on the thermometer/temperature probe match the INT_TEMP information on the WDS?
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DIAGNOSIS AND TESTING (Continued) NOTE: The cabin temperature sensor is an integral part of the ICC, and is not a separately serviceable item. It the sensor is faulty, the complete ICC must be replaced. Section 413-08 PINPOINT TEST Q : SUNLOAD SENSOR/TWILIGHT SENSOR OPERATION (HIGH SERIES/ACC) NOTE: REFER to Section 412-02 SYMPTOM CHART BEFORE PROCEEDING Test Step
Result / Action to Take
Q1 Refer to Section 417-01, for Sun Load Sensor Pinpoint Test.
NOTE: Activation of the battery saver supply (J3/3, refer Section
419-10) provides power to the sunload.twilight sensor module. With the ignition on and the battery saver supply active, the BEM reads the signals from the sensor. The BEM transmits the sunload data over the CAN bus to the climate control module. This sensor also controls the Auto Headlight on function. Refer to Auto Headlight section.
NOTE: DTC’s will not be available for invalid data signalled with the ignition switch in either the accessories or the start position. The output voltage from the sunload sensor is available at pin (J2/1. refer section 419-10), it is in the range of five to zero volts.
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REMOVAL AND INSTALLATION
Control Components For HVAC Integrated Module (HIM), refer to Section 412-02. For Interior Command Centre, refer to Section 413-08. For Body Electronic Module, refer to Section 419-10. For Powertrain Control Module, refer to Section 303-14.
Cabin Temperature Sensor The cabin temperature sensor is an integral part of the ICC module, and is not a separately serviceable item. If the sensor is faulty, the complete ICC must be replaced (refer to section 413-08)
Sunload sensor/Twilight sensor Removal and Installation 1. Remove trim panel from sensor from rearward facing edge. 2. Using two screwdrivers carefully pry sensor out of instrument panel. 3. Lift sensor out until wiring prevents further movement. 4. Tie length of string around wiring below connector. Disconnect sensor from wiring. N.B. If wiring returns through access hole, instrument panel may have to be removed. 5. Assemble in reverse order.
Ambient Temperature Sensor The ambient temperature sensor is an integral part of the passenger side external mirror assembly, and is not a separately serviceable item. If the sensor is faulty, the complete mirror assembly must be replaced (Refer to section 501-09).
Evaporator Temperature Sensor (Evaporator Thermistor) Refer to Section 412-03 for Removal and Installation.
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Instrument Cluster
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SECTION : 413-01 Instrument Cluster VEHICLE APPLICATION : 2003.0 BA Falcon CONTENTS
PAGE
DESCRIPTION AND OPERATION Instrument Cluster .................................................................................................................413-01-2 Principles of Operation .........................................................................................................413-01-4 Instrument Cluster Gauges ..................................................................................................413-01-5 Warning Indicators ...............................................................................................................413-01-5 General Operation ................................................................................................................413-01-7 Audible Warnings .................................................................................................................413-01-7 DIAGNOSIS AND TESTING Instrument Cluster .................................................................................................................413-01-9 Inspection and Verification ...................................................................................................413-01-9 Self Tests .............................................................................................................................413-01-9 Functional Tests .................................................................................................................413-01-10 DTC Chart ..........................................................................................................................413-01-11 Pid Chart ............................................................................................................................413-01-12 CAN Data Information ........................................................................................................413-01-13 Symptom Chart ..................................................................................................................413-01-14 Connector Circuit Reference ..............................................................................................413-01-16 Pinpoint Tests ....................................................................................................................413-01-19 REMOVAL AND INSTALLATION Instrument Cluster ...............................................................................................................413-01-26
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Instrument Cluster
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DESCRIPTION AND OPERATION
Instrument Cluster Low Series
Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21
Description Hazard Switch ABS Multifunction Indicator Security Indicator Tachometer Gauge Low Oil Warning Indicator Brake Fail Warning Indicator Park Brake Warning Indicator High Beam Indicator Alternator Indicator Seatbelt Warning Indicator Low Fuel Indicator Speedometer Gauge Fuel Cut Off Indicator Door Ajar Indicator High Temperature Warning Indicator Multifunction Dimming Switch Trip Computer Switch Throttle Fault Indicator Traction Control Indicator (If fitted) Odometer/Tripmeter display Temperature Gauge
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Item 22 23 24 25
Description Fuel Gauge Average speed/Transmission display Airbag Warning Indicator Foglamps Indicator (If fitted)
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Instrument Cluster
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DESCRIPTION AND OPERATION (Continued) XR Series
Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22
Description Hazard Switch ABS Multifunction Indicator Security Indicator Tachometer Gauge Low Oil Warning Indicator Brake Fail Warning Indicator Park Brake Warning Indicator High Beam Indicator Alternator Indicator Seatbelt Warning Indicator Low Fuel Indicator Speedometer Gauge Fuel Cut Off Indicator Door Ajar Indicator High Temperature Warning Indicator Multifunction Dimming Switch Trip Computer Switch Throttle Fault Indicator Traction Control Indicator (If fitted) Odometer/Tripmeter display Temperature Gauge Fuel Gauge
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Item 23 24 25
Description Average speed/Transmission display Airbag Warning Indicator Foglamps Indicator (If fitted)
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Instrument Cluster
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DESCRIPTION AND OPERATION (Continued) High Series
Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22
Description Hazard Switch ABS Multifunction Indicator Security Indicator Tachometer Gauge Low Oil Warning Indicator Brake Fail Warning Indicator Park Brake Warning Indicator High Beam Indicator Alternator Indicator Seatbelt Warning Indicator Low Fuel Indicator Speedometer Gauge Fuel Cut Off Indicator High Temperature Warning Indicator Dim up Switch Dim down Switch Throttle Fault Indicator Traction Control Indicator (If fitted) Odometer/Tripmeter display Temperature Gauge Fuel Gauge Average speed/Transmission display
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Item Description 23 Airbag Warning Indicator 24 Foglamps Indicator (If fitted) There are three basic levels of instrument cluster, low series, XR series and high series. Vehicle options can dictate the operation of warning indicators, and some warnings may be fitted, but will not be illuminated. Instrument clusters is not a serviceable part and should be replaced in the event of a fault. Refer to Wiring Diagram Section 413-01 for schematic and connector information.
Principles of Operation The instrument cluster provides information to the driver in the form of gauges, warnings and indicators and LCD displays. The instrument cluster uses both hard-wired interfaces and a CAN communication link to other electronic modules in the vehicle. When the ignition switch is in the ON position with the engine off the instrument cluster carries out a display test to verify that the warning/indicator lamps and monitored systems are functioning correctly. The warning indicators that illuminate during this display test are: Anti-lock brake system (ABS) — If fitted Air bag system 01/2003 2003.0 BA Falcon
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Instrument Cluster
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DESCRIPTION AND OPERATION (Continued) Charging system Brake warning indicator Low fuel indicator Low oil pressure High temperature indicator Throttle fault indicator Security indicator (3 seconds only)
Instrument Cluster Gauges Engine Temperature Gauge The instrument cluster receives engine temperature information from the PCM to display on the temperature gauge. If the data is missing or invalid for more than 1 minute, the instrument cluster will move the temperature gauge pointer to the cold position and the high temperature warning light will be activated. A DTC will also be set to indicate this occurrence.
Fuel Gauge The instrument cluster receives the fuel level signal from the fuel sender unit. This is a variable resistor. When the fuel level is low, the resistance is low, when the fuel level is high the resistance is high. If a faulty input signal is received, the fuel gauge will then default to the empty position and the low fuel warning indicator will flash after one minute. A DTC will also be set to indicate this occurrence. The fuel level input signal is heavily dampened to allow for movement of fuel in the tank when the ignition is in the ON position. The fuel gauge pointer will be moved to zero when the ignition is turned off.
Speedometer Vehicle speed data is received from the PCM. The PCM compensates for tyre size and axle ratio, and then outputs vehicle speed information to the instrument cluster, which is then indicated in km/h on the gauge. If there is no valid speed data received by the instrument cluster for 5 seconds, the speedometer is set to zero and a failure mode DTC is set.
Tachometer The instrument cluster receives tachometer data from the PCM. If there is no valid tachometer data received by the instrument cluster for 5 seconds, the tachometer is set to zero and a failure mode DTC is set.
To change between the odometer, trip A of trip B display modes, the odometer button is pressed. To reset the trip A and trip B functions, the odometer button is pressed continually for 1 second with the respective trip (A or B) odometer display active is reset.
Warning Indicators Air Bag Warning Indicators The air bag warning indicator is hardwired to the air bag module. The airbag warning indicator is activated if the input is connected to ground. Refer to Section Section 502-20b.
ABS Warning Indicator The anti-lock brake system (ABS) warning indicator is hardwired directly to the ABS module where fitted. The ABS warning indicator is activated if the input is connected to ground. Refer to Section Section 206-09.
Brake System Warning Indicator The brake system warning indicator is hardwired directly to the master cylinder. The brake fail warning will be activated if the input is connected to ground. Refer to Section Section 206-00.
Alternator Warning Indicator The PCM controls the charging system and the alternator warning indicator. The PCM turns the lamp off once the system is running, and illuminates it under fault conditions (including stall conditions). REFER to Section 414-00. The alternator warning indicator is activated if the input is connected to ground.
The High Beam Indicator The high beam indicator is hardwired directly to the light / Lever Combination switch. The high beam indicator is activated if the input is is switched to supply.
Hazard Switch, Left and Right Turn Signal Indicators
The instrument cluster controls the front, rear and side external indicators as well as the indicator warning in the instrument cluster. The inputs for the left and right turn signal indicators are hardwired directly to the Lever Combination switch. The input is switched to Odometer supply to activate the signal. The instrument cluster Distance traveled data is received from the PCM. The will then pulse both the external lamps and the indicator warning in the instrument cluster at a normal PCM compensates for tyre size and axle ratio and rate. If a bulb out failure is detected, the flash rate will then outputs the distance traveled to the instrument cluster which calculats, and electronically displays this increase approx. three times and a DTC will be set to indicate this condition. information in the LCD display. The hazard button on the instrument cluster will In addition, there are 2 trip odometer functions activate the hazard warning, pulsing both the left and displayable on the LCD. right indicators simultaneously. G86736 en
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Instrument Cluster
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DESCRIPTION AND OPERATION (Continued) Lights Indicator
High Temperature Indicator
For high series instrument cluster variants, lights on indicator is displayed on the LCD to indicate that auto-headlights are have been activated. This information is controlled by the BEM. The park lights switch input is hardwired directly to the instrument cluster. The park lights symbol will be activated, along with an audible warning, if the ignition is turned off whildt the lights are still on. This warning will not occur when lamps are on with switch in auto position (where fitted).
The high temperature indicator is activated by the PCM. When the indicator is first illuminated, an audible warning is also activated. This audible warning is repeated every 60 seconds whilst the high temperature condition remains.
Park Brake Indicator
Transmission Fail Indicator
The park brake switch is hardwired directly to the instrument cluster. The park brake indicator is activated when the park brake input is connected to ground (Park Brake engaged). The park brake indicator will flash and an audible warning will sound if the park brake is on and the vehicle is moving at a speed of greater than 10km/hr. The audible warning will last for 20 seconds.
Transmission fault is indicated with the flashing of the PRND display on the LCD. It is activated by the PCM.
Transmission Overheat Indicator The transmission overheat indicator consists of the high temperature indicator flashing in conjunction with the PRND display flashing. It is activated by the PCM.
Low Wash Indicator (where fitted) The low wash indicator is located on the instrument cluster LCD. It is activated by the BEM.
Seatbelt Indicator
The seatbelt indicator uses information hardwired from the Airbag module using Seatbelt/Airbag Audible The throttle fault warning indicator is controlled by the input. Refer to Section 501-20a. PCM module. There are 2 modes for the seatbelt indicator: 1. Basic Mode: The seatbelt indicator will be Traction Control Indicator activated when the ignition is turned on. The The traction control indicator is controlled by the warning light will remain on for the first 3 seconds traction control module. The traction control indicator regardless of seatbelt status. If the seatbelt is is illuminated when the traction control is disabled. In unbuckled, the seatbelt warning light is turned on the event of a TCS failure the traction control indicator for 8 seconds or until the seatbelt buckled input is be also illuminated. The traction control indicator will activated, whichever occurs first. flash to indicate a traction control event is currently in 2. Audible Warning Mode: The seatbelt indicator will progress REFER to Section 206-09. be activated when the ignition is turned on. The warning light will remain on for the first 3 seconds Low Oil Pressure Warning Indicator regardless of seatbelt status. If the seatbelt is The oil pressure warning is controlled by the PCM. In unbuckled, the seatbelt warning light will stay on the event of a low oil pressure event, an audible until the seatbelt is buckled. An audible seatbelt warning will also be sounded. warning and synchronous flashing of the seatbelt warning light every 30 seconds will be activated if Low Fuel Warning Indicator the vehicle speed is detected to be more than The fuel cut offindicator will illuminate when a fuel cut 5km/hr. It will continue until the seatbelt is buckled out event has occured. It is a hard wired input, or until 5 minutes has elapsed, at which the activated when switched to ground. warning will be disabled. The Audible Warning Mode can be enabled or Fuel Cut off Indicator disabled using the diagnostics command ’see The low fuel warning indicator is controlled by the programmable options-variant information’ or with the instrument cluster based on the information from the following procedure: resistive fuel sender. If the damped value of the fuel Buckle the seatbelt sender input is less than approx. 10 litres, the fuel Set the ignition to the on position without the warning indicator will be illuminated. vehicle running (RPM < 400) Door ajar indicator Press and hold the hazard switch The high series variant has individual door ajar and Unbuckle, then buckle the seatbelt boot ajar information displayed on the LCD. Other Release the hazard switch variants have one warning lamp that is activated if any of the doors/boot are ajar. Activation of the door ajar indicators is controlled by the BEM.
Throttle Fault Indicator
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DESCRIPTION AND OPERATION (Continued) Security Indicator
to hold that TRIP button for an additional second, all resettable functions will be reset and the cluster will The security indicator is activated for 3 seconds when emit 2 beeps. the ignition is first turned to the ON position. The security indicator is continually flashed when the HI Series ignition is turned to the OFF position. This warning is HI Series clusters send this trip data information to the attached by either PCM or BEM in the occurrence of a ICC unit, control of displayed data is conducted with security event. the use of ICC mounted trip buttons.
Fog Lights Indication (where fitted) The fog lamp indicator is activated by a hard-wired connection to the fog lamp switch. The fog lamp indicator is activated if the input is connected to supply.
Cruise Indication (where fitted)
Average Speed The average speed display indicates the average speed since the last time that the average speed function was reset. It is calculated based on distance information received from the PCM via the CAN communication interface and time calculated internally in the instrument cluster.
The cruise control information is displayed on the LCD Travel Time when requested by the PCM. If the cruise control is on, CRUISE is displayed. If the cruise control is active The travel time is the time in minutes since the last CRUISE SET is displayed. travel time function was reset. It is calculated internal to the instrument cluster. PRND + 1234 Indication The PRND information is displayed in the LCD. In addition, Adaptive and Performance modes are indicated. For the high series vehicles, PERF is continually displayed when performance mode is activated, with no display when in adaptive mode. For other variants, the numbers of the board trip computer display on the LCD are replaced with AdP or PEF to indicate adaptive and performance mode respectively.
General Operation
Range The range displays the estimated distance before the vehicle runs out of fuel. This estimation is based on the resistive fuel tank sender input, fuel usage received from the PCM and the calculated fuel consumption based on recent driving style. When the range reaches 80, 40, 20 or 0, an audible warning is sounded.
Average Economy The average economy, uses data since the last average economy function was reset. The calculation The dimming for the vehicle interior is controlled is based on fuel usage and distance information, both through the switches on the instrument cluster. For the high series variants, there are dim up and dim received from the PCM. down button, for LOW/XR variants, there is a single When car is stationary L/hr is displayed. When car is dimming button that cycles through 4 fixed dimming detected to be moving, L/100km is displayed. levels. NOTE: Trip Computer functions are only updated The instrument cluster has 2 dimming outputs to whilst engine is running. control the illumination levels in other parts of the vehicle. These outputs are switched to ground with a Audible Warnings pulsed signal. The pulse width modulation for the Buzzer Sounds signal determines the illumination level.
Dimming Operation
On Board Trip Computer LOW/XR Series
Function
Mode The on board computer supplies the driver with Overspeed information for average speed, travel time, range, average economy and instantaneous economy trip Airbag data. The information is displayed on the LH cluster LCD. The trip computer display mode is cycled by pressing Seatbelt the TRIP button on the instrument cluster. Single beep is also emitted. It is possible to reset the average speed, travel time and average economy functions by pressing and holding the TRIP button for 1 second while in the appropriate mode. By continuing G86736 en
Tone sequence One beep Three running tones 1 beep per pulse train detection 6 beeps, repeated at 30s intervals
Duration 50 ms 300ms for each frequency 500ms on, 200ms off time @ 5Hz air bag signal 250ms on, pause for 750ms between beeps
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Instrument Cluster
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DESCRIPTION AND OPERATION (Continued) Function Door ajar
Tone sequence Three beeps
Duration
400ms on, pause for 300ms between beeps Park brake Continuous for 500 ms on, 1 second 20 seconds off High Five beeps at 300ms on, pause for temperature 30 second 100ms between intervals beeps Low oil Four beeps 300ms on, pause for after 5 second 100ms between delay beeps Low fuel Three beeps 300 ms on, pause for Range repeated at 1s 100 ms between intervals Park lights Three beeps 300ms on, pause for on repeated at 2s 200ms between intervals beeps Indicator / One beep 5 ms for the relay on hazard sound and 5 ms for the relay off sound
Buzzer Activation Function Indicator / hazard Mode Overspeed Airbag Seatbelt Door ajar Park brake High temperature Low oil Low fuel Park lights on
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Activation Indicator light is turned on Increase or decrease of overspeed threshold, change of overspeed function status Vehicle indicated speed becomes greater than the Overspeed threshold with the overspeed function activated Airbag audible request activated Refer Seatbelt and Airbag Audible section Door ajar flags set when the car is started (Revs over 350RPM) Park brake input is active and vehicle speed is more than 10 km/hr High temperature request flag on CAN is set the first time and every 1 minute 5 seconds after low oil LED warning is first activated Range decreases to 80, 40, 20 or 0 Park lights are on when the ignition is being switched off for 20 seconds. Headlights fail flag set with ignition on
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Instrument Cluster
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DIAGNOSIS AND TESTING activated and that all buttons on the cluster (Dim Up, Dim Down (or Trip computer Mode switch - if fitted), Hazard and Trip reset) are not pressed. Prior to Inspection and Verification executing the self test, set continuous DTC’s should A visual inspection of the vehicle cluster unit and be checked for and cleared. See DTC list for various electrical connections should be made prior to explanation on codes that the cluster may return. any detailed tests are performed. 1. To enter the instrument cluster self diagnostic 1. Verify the customer concern by operating the mode, Place the ignition and Parklights in the ON system. position and select the Self test option on the WDS. 2. Visually inspect for obvious signs of mechanical or electrical damage. 2. The self-test is deactivated after 5 seconds has elapsed. During the self test, the ignition should Ensure that battery terminal connection is well be held in the ON position. made. If loose / corroded, clean and re-tighten. Any returned trouble codes should then be checked for using the WDS unit. Refer to the DTC list for Check general condition of cluster. Look for further actions. any physical signs of damage, that might be cause of cluster problem. Tests performed during the self test (Duration 5 seconds). Check condition of cluster related fuses. Visual Inspection Chart Test Performed On: Test Description Mechanical Electrical Cluster LCD, dial, All Illumination Initiates to Off. External switch and Illumination values are then Damaged engine oil Fuse(s) LCD Illumination progressively raised until the filter Central junction box maximum value is reached. Low engine oil level (CJB) fuse F30 (7.5A) Engine coolant level CJB fuse F34 (7.5A) NOTE: May not be noticeable Damaged coolant Circuit in daylight conditions. thermostat LED(s) Speedometer, All Gauges initiate to minimum Door adjustment Wiring harness Tachometer, values. They are then swept Loose or corroded Temperature and to their full scale deflection connector(s) Fuel gauge and back to minimum again. Damaged instrument Warning LEDs All warning LEDs are initiated cluster to be Off. Each warning LED 3. If an obvious cause for an observed or reported is then activated one at a concern is found, correct the cause (if possible) time, in a clockwise fashion. before proceeding to the next step. Buzzer Buzzer sweep cycle is 4. Verify the following systems are working correctly sounded. by operating the system. See DTC List for further details and information Charging regarding DTC’s. Fuel Module Configuration Cooling All new instrument clusters are defaulted with the Turn signals following information: Headlamps Odometer set to 0km The continuous trouble codes should then be checked Sedan petrol fuel map for using the WDS unit. See DTC list for explanation on codes that the cluster may return. Upon checking Police mode disabled for previously set codes, the Self-diagnostic Mode Traction control fitted should be entered. Seatbelt audible reminder enabled Self Tests The instrument cluster is a programmable module, which must be configured via the WDS. The WDS is Diagnostic Self Test Mode used to select appropriate data for the vehicle i.e., if The Diagnostics self test provides an automated the cluster is replaced or any cluster options are to be means of testing the cluster functionality, allowing the modified. operator to check for correct operation in one easy Data Extraction from existing Cluster: sequence. Faults detected by the cluster will be recorded in the form of DTC’s, as detailed in the DTC If a cluster is to be replaced with a new unit, section. It is important that for the duration of the test, depending on the condition of the existing cluster, the the ignition is in the ON position, the Park Lamps are
Instrument Cluster
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Instrument Cluster
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DIAGNOSIS AND TESTING (Continued) configuration data is read from the existing cluster and written to the new replacement cluster. Place key in the ‘ON’ position and select ‘Programmable Module Installation’ on the WDS Follow the text screens until successful Place key in OFF position and install the replacement instrument cluster - See ‘Removal and Installation’ for details Key in the ON position. Follow text screens until successful. Once complete, verify correct operation. Programmable Options: Odometer: The odometer can be programmed using the WDS unit by selecting ‘Update Odometer Value’ The Odometer value can be programmed to any value between 0km and 999,999km, providing the following conditions have been met: The replacement cluster odometer value is less than 100km The replacement cluster has had its odometer set less than three times Once programmed, the replacement clusters odometer will immediately be updated (+0/-1) and a permanent (unerasable) DTC will be set if the odometer was set to a value greater than 100km.
the gauge fails, the input (e.g. fuel sender) is checked for validity and user prompted with further tests / pinpoint tests.
Button Test This test will check for mechanical button problems within the cluster 1. User will be prompted to press each button, with confirmation upon each press. (Stuck / non operational buttons detected). The cluster buttons tested are: 1. Hazard Button 2. Trip Reset Button 3. Dim Up Button 4. Dim Down / Trip Computer Button
Illumination Test This test will check for illumination problems within the cluster 1. Each Illumination channel driven to set levels with user confirmation.
Multifunction Output Test — LCD / Warning LED / Buzzer
This test will check the following: 1. Working LCD segments within the cluster 1. All segments (PRND, Odometer, Cruise, Trip Data, Overspeed and Low wash symbols) enabled, then disabled, with user Fuel Table: confirmation. The fuel table map can be programmed using the 2. Software controllable LEDs within the cluster WDS unit by selecting ‘Update Fuel’ options. Upon 1. All software controllable warning LED’s selection, the technician will be prompted with enabled, then disabled, with user questions to determine the fuel table required. The confirmation. If a LED fails, the user will be appropriate map is then uploaded to the cluster. guided through test to pinpoint the failure. The LEDs controlled are: Variant Information: Security Warning The Variant Information can be programmed using the Park Brake Reminder WDS unit by selecting ‘Update Variant Information’ Seatbelt Reminder option. Upon selection, the technician will be Low Fuel Warning prompted with a list of available options for the High Temp Warning replacement cluster. The technician should then Throttle Warning select the appropriate options and upload the data. Traction Control Warning The options for the cluster include: Door Ajar Warning Traction Control Fitted - Only selected if the 2. Cluster hardwired LED’s NOT tested during vehicle has a traction control unit fitted. this test include: Seatbelt Audible Reminder Enabled - Set if user Fog Lights Reminder requests the seatbelt audible reminder to be High Beam Reminder enabled by default. Alternator Reminder Brake Fail Warning Functional Tests ABS Warning Fuel Cut Off Warning Gauge Test 3. Buzzer operation within the cluster This test will check for mechanical gauge problems 1. Buzzer sweep cycle engaged, with user within the cluster confirmation of operation. 1. Each gauge is swept / pointed to a particular value, with user confirmation on gauge position. If G86737 en
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Instrument Cluster
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DIAGNOSIS AND TESTING (Continued) Input and Data Test This test will check for hard wired inputs to the cluster 1. User will be prompted with items to check and data to verify 1. Park Lights 2. Park Brake 3. Left Turn / Right Turn Switch 4. Autolamps 2. Tests on input status will be conducted, with user confirmation. Upon failure detected user will be guided through further tests for that particular failure. This test will also check for data errors (Odometer, Trip data, etc.) 3. User will be prompted with item to check, verification of data and further tests to conduct will be provided as required.
DTC Chart Instrument Cluster Diagnostic Trouble Code (DTC) Index Display B1201 B1342
B1499
B1503
B1579 B1583 B1875 B2675 B2680 B2681 B2895
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Description Fuel Sender Circuit Failure
Action Conduct Functional Test: Gauge Test Conduct Pinpoint Test: ‘Fuel Gauge Circuit Test’ ECU is faulted / EE checksum Internal data failure, disconnect power, wait 10 failure seconds and re-apply power. Run self test. If DTC is still present, Conduct Functional Test: Data Test. Lamp Turn Signal Left Circuit Bulb out detected on Left Turn Circuit. Check Failure bulbs, then conduct Functional Test: Input and Data Test. Conduct Pinpoint Test: ‘Turn Signal Input Test’ Lamp Turn Signal Right Circuit Bulb out detected on Left Turn Circuit. Check Failure bulbs, then conduct Functional Test: Input and Data Test. Conduct Pinpoint Test: ‘Turn Signal Input Test’ Dim Panel Increase Input Circuit Dim Increase circuit failure or button stuck. Failure Conduct Functional Test: Button Test. Dim Panel Decrease Input Circuit Dim Increase circuit failure or button stuck. Failure Conduct Functional Test: Button Test. Turn Signal / Hazard Switch Signal Hazard circuit failure or button stuck. Conduct Circuit Failure Functional Test: Button Test. Trip reset button stuck Trip reset Conduct Functional Test: Button Test. circuit failure or button stuck. Odometer Changed Permanent DTC indicating that Odometer has been manually reset. - No Action Required PRND Sender Failure Invalid PRND data detected, Conduct Functional Test: Multifunction Output Test. Check PCM PRND data Trip Computer Mode Switch Circuit Trip computer circuit failure or button stuck. Failure Conduct Functional Test: Button Test.
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Instrument Cluster
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DIAGNOSIS AND TESTING (Continued) Display B2896
Description Odometer Data Failure
U1900
CAN Communication Bus Fault Receive Error
U2196
Invalid ‘Engine RPM’ data
U2197
Invalid ‘Vehicle Speed’ data
U2198
Invalid ‘Fuel Pulse’ data
U2199
Invalid ‘Engine Coolant Temperature’ data Invalid ‘ODO Count’ data
U2200
Action Internal odometer data failure, disconnect power, wait 10 seconds and re-apply power. Run self test. If DTC is still present, Conduct Functional Test: Voltage Supply Test. Missing message from external module detected. Use WDS to diagnose module and check module indicated for correct operation. PCM output data failure. Check PCM module. Conduct Functional Test: Gauge Test PCM output data failure. Check PCM module. Conduct Functional Test: Gauge Test PCM output data failure. Check PCM module. Conduct Functional Test: Gauge Test PCM output data failure. Check PCM module. Conduct Functional Test: Gauge Test PCM output data failure. Check PCM module. Conduct Functional Test: Input & Data Test.
Pid Chart Parameter Name CCNT NTCSDT VBATT_VAL LCD_ILLUM PWM_ILLUM PWM_DUTY1 PWM_DUTY2 ODO_M TRIP_MET TRIPB_MET TRIP_TIME FUEL_ECON AVG_FUEL VEH_SPD TRIP_CMP FUEL_LEVEL SPD_IND TACH_IND TEMP_IND FUEL_SNDR TEMP_GA CLU_STAT
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Description Number of Continuous Trouble Codes Set Number of Trouble Codes Set due to Diagnostic Test System Battery Voltage Value LCD Illumination Level Illumination PWM value PWM Duty Cycle #1 PWM Duty Cycle #2 Odometer Vehicle Trip Odometer - Metric Vehicle Trip Odometer - B - Metric Trip Instantaneous Fuel Economy - Metric Average Fuel Economy - Metric Vehicle Speed Trip Computer Fuel Level Input Speedometer Gauge Indicator Control Tachometer Gauge Indicator Control Engine Temperature Gauge Pointer Place Degrees C. Fuel Sender Temperature Gauge ECU Operating States
Data Type DTC(s) DTC(s) Volts % duty cycle on time % duty cycle on time % duty cycle on time % duty cycle on time Kilometers Kilometers Kilometers Minutes l/100km or l/hr l/100km or l/hr Kilometers / hour Kilometers % FULL KPH RPM Degrees Celsius Ohms % MAX Default / Std. Diag Mode
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Instrument Cluster
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DIAGNOSIS AND TESTING (Continued) Parameter Name TRANSGEAR
Description Gear selected
DIMMER_S3
Dimmer Switch Input Status
FUEL_MODE
Fuel Economy Display Mode
LCD_DSPL
LCD Segment Display
BEM_MSG CDU_MSG ABS_MSG PCM_MSG PARKBRAK TONE_REQ RESETSW P_LMP_SW HAZ_SW RT_SWITCH LT_SWITCH AUTOLMPSW SBLTMP MENU_SW HAZ_WARN LMPONWRN AUD_WARN LHS_CURNT
BEM Missing Message ACM Missing Message ABS / TCS / IVD Missing Message Powertrain Control Module Missing Message Park Brake Applied Warning Lamp Tone request - Airbag fault warning Reset Switch Park Lamps Switch Hazard switch Right Turn Switch Left Turn Switch Autolamp ON Switch Seat Belt Lamp Driver Output State Menu Switch Hazard Warning Lamp ON Audible warning ON * Left Hand Side Indicator Current Draw *RHS_CURNT Right Hand Side Indicator Current Draw
* Output current value only valid whilst globes are being driven.
CAN Data Information The CAN interface facilitates the information transfer between the electronic modules in the vehicle and provides a means for diagnostics interrogation. In normal operating conditions, with ignition activated, the cluster will receive and transmit the following information.
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Data Type Unknown Reverse Forward Drive Forward Drive 2 Forward Drive 3 Forward Drive 4 Forward Drive 5 Park Drive "D" Neutral Invalid Data NO Keypress Dimmer Switch Illumination UP / Dimmer Switch Illumination DOWN Illumination UP + DOWN Litres per 100km Litres per hr On Off — — — — ON/OFF ACTIVE/NON ACTIVE ACTIVE/NON ACTIVE ACTIVE/NON ACTIVE ACTIVE/NON ACTIVE ACTIVE/NON ACTIVE ACTIVE/NON ACTIVE ACTIVE/NON ACTIVE ACTIVE/NON ACTIVE ACTIVE/NON ACTIVE ACTIVE/NON ACTIVE ACTIVE/NON ACTIVE ACTIVE/NON ACTIVE Amps. Amps.
Cluster CAN Transmission Data Damped fuel level Instantaneous fuel input Fuel empty Fuel sender fail Park lamps on Park brake on Auto headlamps input Battery voltage level 01/2003 2003.0 BA Falcon
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Instrument Cluster
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DIAGNOSIS AND TESTING (Continued) Switches illumination level LCD illumination level Average Speed Average Economy Mode Average Economy Travel Time Range Instantaneous Economy mode Instantaneous Economy Display DTE Odometer Odometer overflow
Tx Module Central Display Unit (CDU)
Body Electrics Module (BEM)
Cluster CAN Receive Data Tx Module Powertrain Control Module (PCM)
Engine RPM Vehicle speed Coolant temperature Odometer count Fuel pulse Oil pressure warning Cruise warning ETC warning Flash security warning Manual Transmission Transmission mode PRND Transmission overheat Transmission fail
Traction Control System (TCS)
Overspeed active Overspeed mode switch Overspeed up switch Overspeed down switch Reset average speed Reset average economy Reset trip time External LCD illumination on Front right door Front left door Rear right door Rear left door Boot lid door Rear demist Low wash warning Headlamp fail Hazard flash request Security warning on TCS warning
Symptom Chart Condition
Source
Action
ABS Warning Indicator always activated / inoperative
Circuit. ABS module Instrument cluster.
Conduct Pinpoint Test ‘ABS warning Test’.
Airbag warning always on.
Circuit. Airbag module Instrument cluster.
Conduct Pinpoint Test ‘Airbag Warning Test’.
Alternator Warning Indicator always activated / inoperative
Circuit. Instrument cluster.
Conduct Pinpoint Test ‘Alternator Warning Test’.
Autolamps always activated / inoperative
Circuit. Switch. Instrument cluster.
Conduct Functional Test: Input & Data Test. Conduct Pinpoint Test ‘Autolamps Indicator Test’.
Audio Illumination inoperative with ignition OFF
Circuit - CAN wakeup. CDU. Instrument cluster.
Conduct Pinpoint Test ‘CAN wakeup Test’.
Brake Fail Warning Indicator always activated / inoperative
Circuit. Switch. Instrument cluster.
Conduct Pinpoint Test ‘Brake Fail Warning Test’.
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Instrument Cluster
413-01-15
DIAGNOSIS AND TESTING (Continued) Condition
Source
Action
Cruise Control Indication always on / inoperative
Circuit / CAN. PCM. Instrument cluster.
Conduct Functional Test: Multifunction Output Test.
Dimming Functionality inoperative
Circuit. Instrument cluster Switch Instrument cluster.
Conduct Functional Test: Button test
Door Ajar Indicator always on / inoperative
Circuit / CAN. PCM. Instrument cluster.
Conduct Functional Test: Multifunction Output Test.
Fog Lights Indicator always on / inoperative
Circuit. Switch. Instrument cluster.
Conduct Pinpoint Test ‘Fog Lights Input Test’
Fuel gauge indication incorrect
Circuit / CAN - fuel used. Fuel pump module. Instrument cluster.
Conduct Functional Test: Gauge Test. Conduct Pinpoint Test ‘Fuel Gauge Circuit Test’.
Fuel Cut Off Warning Always Activated
Circuit. Fuel Cut Off Unit. Instrument cluster.
Conduct Pinpoint Test ‘Fuel Cut Off Test’.
Hazards always activated / inoperative
Circuit / CAN. Instrument cluster.
Conduct Functional Test: Button Test. Conduct Pinpoint Test ‘Turn Signal Indicator Test’.
High Temperature Warning always on / inoperative
Circuit / CAN. PCM. Instrument cluster.
Conduct Functional Test: Multifunction Output Test.
Illumination always on / inoperative (Park Lights Input)
Circuit. Switch. Instrument cluster.
Conduct Functional Test: Input & Data Test. Conduct Pinpoint Test ‘ParkLamps Input Test’.
Fuel gauge inoperative/indication incorrect
Circuit / CAN - fuel used. Fuel pump module. Instrument cluster.
Conduct Functional Test: Gauge Test. Conduct Pinpoint Test ‘Fuel Gauge Circuit Test’.
Temperature gauge inoperative/indication incorrect
Circuit / CAN. Cylinder head temperature sensor (CHT) or engine coolant temperature sensor (ECT). PCM. Instrument cluster.
Conduct Functional Test: Gauge Test
Indicator Left / Right Turn Signal always activated / inoperative
Circuit. Switch. Instrument cluster.
Conduct Functional Test: Input and Data Test. Conduct Pinpoint Test ‘Turn Signal Indicator Test’.
Low Fuel Warning always on / inoperative
Circuit. Fuel pump module. Instrument cluster.
Conduct Functional Test: Multifunction Output Test. Conduct Pinpoint Test ‘Fuel Gauge Circuit Test.
Low Oil Pressure Warning always on / inoperative
Circuit / CAN. PCM. Instrument cluster.
Conduct Functional Test: Multifunction Output Test.
Low Wash Indicator always on / inoperative
Circuit / CAN. BEM. Instrument cluster.
Conduct Functional Test: Multifunction Output Test.
Odometer / Trip Odometer not incrementing
Circuit / CAN. Instrument cluster.
Conduct Functional Test Input & Data Test.
Odometer / Trip Odometer Reset Switch inoperative
Circuit. Instrument cluster Switch Instrument cluster.
Conduct Functional Test: Button Test.
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Instrument Cluster
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DIAGNOSIS AND TESTING (Continued) Condition
Source
Action
Odometer Error (OdOErr is displayed on odometer
Circuit. Instrument cluster.
Conduct Functional Test: Input & Data Test.
On Board Computer inoperative
Circuit. Instrument cluster Switch Instrument cluster.
Conduct Functional Test: Button Test.
Park Brake Warning always on / inoperative
Circuit. Switch. Instrument cluster.
Conduct Functional Test: Multifunction Output Test. Conduct Pinpoint Test ‘Park Brake Test’.
Seatbelt Indicator Warning always on / inoperative
Circuit / CAN. Instrument cluster.
Conduct Functional Test: Multifunction Output Test. Conduct Pinpoint Test ‘Seatbelt Input Test’.
Security Indicator always on / inoperative
Circuit / CAN. PCM / BEM. Instrument cluster.
Conduct Functional Test: Multifunction Output Test.
The high beam indicator is inoperative
Circuit. Switch. Instrument cluster.
Conduct Pinpoint Test ‘High Beam Indicator Test’.
Speedometer is inoperative/indication incorrect
Circuit / CAN. Vehicle speed sensor. PCM Instrument cluster.
Conduct Functional Test: Gauge Test.
Tachometer is inoperative/indication incorrect
Circuit / CAN. PCM. Instrument cluster.
Conduct Functional Test: Gauge Test
Throttle Fault Warning always on / inoperative
Circuit / CAN. PCM. Instrument cluster.
Conduct Functional Test: Multifunction Output Test.
Traction Control Warning always on / inoperative
Circuit / CAN. TCS. Cluster Configuration. Instrument cluster.
Conduct Functional Test: Multifunction Output Test.
Transmission Fail Warning always on
Circuit / CAN. PCM. Instrument cluster.
Conduct Functional Test: Multifunction Output Test.
Transmission Overheat Warning always on
Circuit / CAN. PCM. Instrument cluster.
Conduct Functional Test: Multifunction Output Test.
PRND Indication inoperative
Circuit / CAN. PCM. Instrument cluster.
Conduct Functional Test: Multifunction Output Test.
Connector Circuit Reference Connector A - C171
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Instrument Cluster
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DIAGNOSIS AND TESTING (Continued) Pin Number(s) 1A
2A 3A 4A
6A 7A
8A
9A
10A
11A
12A
13A
14A
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Circuit Designation/Description Normal Condition/Measurement Illumination 5W output Pulse width modulated signal switched to ground (from cluster) corresponding to the selected illumination level. Less than 5 ohms between the instrument cluster and illumination destination. CAN low Serial CAN Communications. Less than 5 ohms between the instrument cluster and diagnostic connector / surrounding CAN controlled modules. CAN high Serial CAN Communications. Less than 5 ohms between the instrument cluster and diagnostic connector / surrounding CAN controlled modules. Fog Lights 0 Voltage with the Fog Lights switch in the OFF position, Greater than 10 volts with the Fog Lights switch in the ON position. Less than 5 ohms between the instrument cluster and the Fog Lamps switch. Greater than 10,000 ohms between the instrument cluster and ground. Ground 0 Voltage, Less than 5 ohms to chassis Ground Seatbelt/Airbag audible 0 Voltage, Less than 5 ohms between the Instrument Cluster and Airbag Module. Greater than 10,000 ohms between the Airbag Module and ground. Fuel Cut Off 0 Voltage, Less than 5 ohms between the Instrument Cluster and Fuel Cut Off Switch. Greater than 10,000 ohms between the Fuel Cut Off Switch and ground. High beam 0 Voltage with High Beam Multifunction Switch in the OFF position and greater than 10 volts in the ON turn position. Less than 5 ohms between the instrument cluster and the multifunction switch. Greater than 10,000 ohms between the instrument cluster and ground. Park lights on 0 Voltage with Park Lamps Multifunction Switch in the OFF position and greater than 10 volts in the ON turn position. Less than 5 ohms between the instrument cluster and the multifunction switch. Greater than 10,000 ohms between the instrument cluster and ground. Auto headlamps 0 Voltage with Auto Headlamps Multifunction Switch in the OFF position and greater than 10 volts in the ON turn position. Less than 5 ohms between the instrument cluster and the multifunction switch. Greater than 10,000 ohms between the instrument cluster and ground. Park brake 0 Voltage, Less than 5 ohms between the Instrument Cluster and Park Brake. Greater than 10,000 ohms between the Park Brake and ground. Petrol input 0 voltage, Variable resistance between the instrument cluster and fuel ground return pin, from 40 to 280 ohms, depending on the fuel tank and fuel level. Less than 5 ohms between the instrument cluster and fuel sender connector pin. Fuel ground return 0 voltage, Less than 5 ohms between the Instrument Cluster and fuel sender connector pin.
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Instrument Cluster
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DIAGNOSIS AND TESTING (Continued) Pin Number(s) 15A 16A 17A
18A
19A
Circuit Designation/Description Normal Condition/Measurement Ignition 0 Voltage with key OFF, Greater than 10 volts with key ON. Greater than 10,000 ohms between instrument cluster and ground. Battery Greater than 10 volts with key ON or OFF. Greater than 10,000 ohms between the instrument cluster and ground. Left indicator switch 0 Voltage with turn indicator in the OFF position and greater than 10 volts in the LH turn position. Less than 5 ohms between the instrument cluster and the multifunction switch. Greater than 10,000 ohms between the instrument cluster and ground. Right indicator switch 0 Voltage with turn indicator in the OFF position and greater than 10 volts in the RH turn position. Less than 5 ohms between the instrument cluster and the multifunction switch. Greater than 10,000 ohms between the instrument cluster and ground. Illumination 25W output Pulse width modulated signal switched to ground (from cluster) corresponding to the selected illumination level . Less than 5 ohms between the instrument cluster and illumination destination.
Connector B - C171
Pin Number(s) 1B 2B 3B 4B
5B 6B
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Circuit Designation/Description Normal Condition/Measurement Airbag 0 voltage, Less than 5 ohms between the Instrument Cluster and Airbag module. Brake fail 0 voltage, Less than 5 ohms between the Instrument Cluster and ABS module. Indicators supply Greater than 10 volts with key ON or OFF. Greater than 10,000 ohms between the instrument cluster and ground. Right indicator output 0 Voltage with turn indicator in the OFF position. Alternating between 0 and 10+ volts (from cluster) in the RH turn position. Less than 5 ohms between the instrument cluster and external indicator globes. Greater than 10,000 ohms between the instrument cluster and ground. CAN wakeup 0 voltage, Less than 5 ohms between the Instrument Cluster and CDU - CAN wakeup modules. ABS 0 voltage, Less than 5 ohms between the Instrument Cluster and ABS module. 01/2003 2003.0 BA Falcon
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Instrument Cluster
413-01-19
DIAGNOSIS AND TESTING (Continued) Pin Number(s) 7B 8B
Circuit Designation/Description Normal Condition/Measurement Alternator fail 0 voltage, Less than 5 ohms between the Instrument Cluster and Alternator module. Left indicator output 0 Voltage with turn indicator in the OFF position. Alternating between 0 and 10+ volts (from cluster) in the LH turn position. Less than 5 ohms between the instrument cluster and external indicator globes. Greater than 10,000 ohms between the instrument cluster and ground.
Pinpoint Tests PINPOINT TEST A : VOLTAGE SUPPLY TEST Test Step A1
Result / Action to Take
TEST BATTERY VOLTAGE Key in OFF position. Use the Multimeter in the MDS, measure the voltage between the Battery (+) pole and ground. Is the voltage result obtained within a valid range (11.5 - 13v) ?
Yes
Go to A2 TEST BATTERY VOLTAGE SUPPLY TO THE CLUSTER.
No
Check battery / charging circuit. Continue once valid voltage is obtained.
A2
TEST BATTERY VOLTAGE SUPPLY TO THE CLUSTER Key in OFF position.
Go to A3 TEST IGNITION VOLTAGE AT CLUSTER.
Using a digital Multimeter, measure the voltage between Pin 16 of connector B (harness side)and ground.
No
Is the voltage within a valid range (11.5 - 14.5v)?
A3
Yes
Disconnect Instrument cluster Connector A.
Check fuse / power HARNESS to cluster.
TEST IGNITION VOLTAGE AT CLUSTER Key in ON position (Engine not running). Using a digital Multimeter, measure the voltage between connector A, pin 15 (harness side) and ground. Is the voltage within a valid range (11.5 - 13v)?
Yes
Disconnect, Check and Re-connect both cluster connectors. If fault is found repair and re-test instrument cluster. If still non-operational, contact service center for cluster replacement authorization. If granted, install a new Instrument Cluster. See Removal and Installation and Module Configuration for details. TEST the system for normal operation. If problem still exists, place the original cluster back to the vehicle.
No
Check fuse / power HARNESS to cluster.
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Instrument Cluster
413-01-20
DIAGNOSIS AND TESTING (Continued) PINPOINT TEST B : FUEL GAUGE CIRCUIT TEST Test Step B1
Result / Action to Take
CHECK FUEL GAUGE CIRCUIT Key in OFF position. Disconnect Fuel Pump Module (Refer to section Section 310-00). Key in ON position. Enter the Instrument cluster Fuel Sender Input Value (ohms) menu in the MDS. With Fuel Sender input in an open circuit state, Check that the fuel sender resistance indicated by the WDS is greater than 250 ohms. If it is less than 250 ohms, go to EDS section and check harness. On the harness side, short Fuel Sender pin to its ground pin. Is the resistance indicated by the WDS less than 10 ohms? If it is not less than 10 ohms, go to EDS section and check harness. Check fuel sender (Refer to section Section 310-00), Investigate fuel sender module for normal operation.
PINPOINT TEST C : AIRBAG WARNING TEST Test Step C1
Result / Action to Take
CHECK AIRBAG INPUT RESISTANCE Yes
Key in OFF position. Disconnect Instrument cluster Connector B. Key in ON Position. Start Car. Wait 5 seconds for modules to initialize. Using a digital Multimeter, measure the resistance between Instrument cluster Connector B pin 1 (harness side) and ground.
Check Airbag Module.
No
Execute ‘Voltage Supply’ pinpoint test and re-test the system for normal operation.
Is the resistance less than 5 ohms?
PINPOINT TEST D : ABS WARNING TEST Test Step D1
Result / Action to Take
CHECK ABS INPUT RESISTANCE Key in OFF position. Disconnect Instrument cluster Connector B (070). Key in ON Position. Start Car. Wait 5 seconds for modules to initialize. Using a digital Multimeter, measure the resistance between Instrument cluster Connector B pin 6 (harness side) and ground. Is the resistance less than 5 ohms?
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Yes
Check ABS Module.
No
Key in Off Position. Check and Re-connect Connector, Place Key in ON position. Start Car. Wait 5 seconds for modules to initialize. Check ABS Warning. If still active, Execute ‘Voltage Supply’ pinpoint test and re-test the system for normal operation.
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Instrument Cluster
413-01-21
DIAGNOSIS AND TESTING (Continued) PINPOINT TEST E : BRAKE FAIL WARNING TEST Test Step E1
Result / Action to Take
CHECK BRAKE FAIL INPUT RESISTANCE Yes
Key in OFF position. Disconnect Instrument cluster Connector B (070). Key in ON Position. Start Car. Wait 5 seconds for modules to initialize. Using a digital Multimeter, measure the resistance between Instrument cluster Connector B pin 2 (harness side) and ground. Is the resistance less than 5 ohms?
Check ABS Module.
No
Key in Off Position. Check and Re-connect Connector, Place Key in ON position. Start Car. Wait 5 seconds for modules to initialize. Check Brake Fail Warning. If still active, Execute ‘Voltage Supply’ pinpoint test and re-test the system for normal operation.
PINPOINT TEST F : ALTERNATOR WARNING TEST Test Step F1
Result / Action to Take
CHECK ALTERNATOR INPUT RESISTANCE Yes
Key in OFF position. Disconnect Instrument cluster Connector B (070). Key in ON Position. Start Car. Wait 5 seconds for modules to initialize. Using a digital Multimeter, measure the resistance between Instrument cluster Connector B pin 7 (harness side) and ground. Is the resistance less than 5 ohms?
Check Charging system.
No
Key in Off Position. Check and Re-connect Connector, Place Key in ON position. Start Car. Wait 5 seconds for modules to initialize. Check Alternator Warning. If still active, Execute ‘Voltage Supply’ pinpoint test and re-test the system for normal operation.
PINPOINT TEST G : HIGH BEAM INDICATOR TEST Test Step G1
Result / Action to Take
CHECK FOR HIGH BEAM VOLTAGE Key in OFF position.
Turn the Headlamp switch to HIGH beam position.
Key in Off Position. Check and Re-connect Connector, Place Key in ON position. Place the headlamp switch to HIGH beam position. If still inoperative, Execute ‘Voltage Supply’ pinpoint test and re-test the system for normal operation.
Using a digital Multimeter, measure the voltage between the Instrument cluster Connector A, Pin 9 (harness side) and ground.
No
Disconnect Instrument cluster Connector A. Key in ON position.
Is the voltage greater than 10 volts?
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Yes
REPAIR the circuit. TEST the system for normal operation.
01/2003 2003.0 BA Falcon
413-01-22
Instrument Cluster
413-01-22
DIAGNOSIS AND TESTING (Continued) PINPOINT TEST H : PARK BRAKE TEST Test Step H1
Result / Action to Take
CHECK PARK BRAKE INPUT RESISTANCE Yes
Key in OFF position.
Using a digital Multimeter, measure the resistance between Instrument cluster Connector A pin 12 (harness side) and ground. Take note of the resistance.
Engage Park Brake. If the resistance less than 5 ohms, Key in OFF Position. Check and Re-connect Connector, Place Key in ON position. Check Park Brake Warning. If still not functioning, Execute ‘Voltage Supply’ pinpoint test and re-test the system for normal operation. Otherwise, Check harness connection in EDS section.
Is there an open circuit?
No
Disconnect Instrument cluster Connector A. Key in ON Position. Disengage Park Brake.
Check harness connection in EDS section.
PINPOINT TEST I : THE TURN SIGNAL INDICATOR TEST Test Step I1
Result / Action to Take
TEST FOR VOLTAGE AT INSTRUMENT CLUSTER INDICATOR INPUT NOTE: Prior to executing test, Visually check individual globes for operation. If non operational globe is found, replace and re-test. Key in OFF position. Disconnect Instrument cluster Connector B. Key in ON position. Using a digital Multimeter, measure the voltage between the Instrument cluster Connector B pin 3 (harness side) and ground.
Yes
For Left Indicator, Go to I2. CHECK LEFT HAND TURN SIGNAL INPUT. For Right Indicator, Go to I4. CHECK RIGHT HAND TURN SIGNAL INPUT. (Note: Conduct both tests if required.)
No
Check Indicator supply fuse and HARNESS.
Is the voltage greater than 10 volts?
I2
CHECK LEFT HAND TURN SIGNAL INPUT Key in OFF position. Disconnect Instrument cluster Connector A. Key in ON position. Using a digital Multimeter, measure the voltage between the Instrument cluster Connector A pin 17 (harness side) and ground.
Yes
Go to I3. TEST FOR VOLTAGE AT INSTRUMENT CLUSTER INDICATOR OUTPUT.
No
Check Indicator lever and harness.
Place the turn signal switch in the Left hand Indicator position, then the Off Position. Is the voltage greater than 10 volts when in Left Position and 0v when in Off?
I3
TEST FOR VOLTAGE AT INSTRUMENT CLUSTER INDICATOR OUTPUT Ensure all cluster connectors are securely fastened and place key in ON position. Using a digital Multimeter, measure the voltage output to the left indicator bulbs harness. (Refer to EDS manual for details). Place the turn signal switch in the Left hand Indicator position. Does the voltage pulse to greater than 10 volts and then to 0v, In time with the flash indicator?
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Yes
No fault found in the LEFT HAND TURN SIGNAL indicator circuit.
No
Check harnesses, if error remains, execute ‘Voltage Supply’ pinpoint test and re-test the system for normal operation.
01/2003 2003.0 BA Falcon
413-01-23
Instrument Cluster
413-01-23
DIAGNOSIS AND TESTING (Continued) Test Step I4
Result / Action to Take
CHECK RIGHT HAND TURN SIGNAL INPUT NOTE: Prior to executing test, Visually check individual globes for
Yes
Key in OFF position.
Go to I5. TEST FOR VOLTAGE AT INSTRUMENT CLUSTER INDICATOR OUTPUT.
Disconnect Instrument cluster Connector A.
No
operation. If non operational globe is found, replace and re-test.
Check Indicator lever and harness.
Key in ON position. Using a digital Multimeter, measure the voltage between the Instrument cluster Connector A pin 18 (harness side) and ground. Place the turn signal switch in the Left hand Indicator position and then the Off position. Is the voltage greater than 10 volts when in Right Position and 0v when in Off?
I5
TEST FOR VOLTAGE AT INSTRUMENT CLUSTER INDICATOR OUTPUT Ensure all cluster connectors are securely connected and place key in Yes ON position. No fault found in the RIGHT HAND TURN SIGNAL indicator circuit. Using a digital Multimeter, measure the voltage output to the right indicator bulbs harness. (Refer to EDS manual for details). No Check harnesses, if error remains, execute Place the turn signal switch in the Right hand Indicator position. ‘Voltage Supply’ pinpoint test and re-test the Does the voltage pulse to greater than 10 volts and then to 0v, In system for normal operation. time with the flash indicator?
PINPOINT TEST J : AUTOLAMPS INDICATOR TEST Test Step J1
Result / Action to Take
TEST OPERATION OF AUTOLAMPS Key in OFF position. Disconnect Instrument cluster Connector A. Cover up the photo (light) sensor, see EDS section for details. Key in ON position. Using a digital Multimeter, measure the resistance between the Instrument cluster Connector A pin 11(harness side) and ground, Whilst activating and de-activating the Autolamps switch.
Yes
With Autolamps activated, Is there an open circuit? if yes, Execute ‘Voltage Supply’ pinpoint test and re-test the system for normal operation. Otherwise, Check HARNESS and Autolamps switch.
No
Check HARNESS and Autolamps switch.
With Autolamps de-activated, Is the resistance less than 5 ohms?
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01/2003 2003.0 BA Falcon
413-01-24
Instrument Cluster
413-01-24
DIAGNOSIS AND TESTING (Continued) PINPOINT TEST K : PARKLAMPS INPUT TEST Test Step K1
Result / Action to Take
TEST OPERATION OF PARKLAMPS HARNESS Yes
Key in OFF position. Disconnect Instrument cluster Connector A. Key in ON position. Activate the Park Lamps switch. Using a digital Multimeter, measure the voltage between the Instrument cluster Connector A, Pin 10 (harness side) and ground. Take note of this voltage.
Execute ‘Voltage Supply’ pinpoint test and re-test the system for normal operation.
No
Check HARNESS and Autolamps switch.
De-activate the Park Lamps switch. Using a digital Multimeter, measure the voltage between the Instrument cluster Connector A, Pin 10 (harness side) and ground. Take note of this voltage. With Park Lamps activated, Was the voltage greater than 10 volts and less than 1 volt with Park Lamps de-activated?
PINPOINT TEST L : SEATBELT INPUT TEST Test Step L1
Result / Action to Take
CHECK SEATBELT RESISTANCE Yes
Key in OFF position.
Insert Seatbelt.
Remove seatbelt. If the resistance greater than 5 ohms, Key in OFF Position. Check and Re-connect Connector, Place Key in ON position. Start Car. Wait 5 seconds for modules to initialize. Check Seatbelt warning. If still not functioning, Execute ‘Voltage Supply’ pinpoint test and re-test the system for normal operation. Otherwise, Check seatbelt harness and Module.
Is the resistance less than 5 ohms?
No
Disconnect Instrument cluster Connector A. Key in ON Position. Start Car. Wait 5 seconds for modules to initialize. Using a digital Multimeter, measure the resistance between Instrument cluster Connector A pin 7 (harness side) and ground.
Check seatbelt harness and Module.
PINPOINT TEST M : FOG LIGHTS INPUT TEST Test Step M1
Result / Action to Take
CHECK FOR FOG LIGHTS INPUT VOLTAGE Key in OFF position.
Yes
If the voltage less than 1 volt when the Fog Lamps are de-activated, Key in Off Position. Check and Re-connect Connector, Place Key in Key in ON position. ON position. Check for Fog Lamp Functionality. Activate the Fog Lights switch. Using a digital Multimeter, measure If still inoperative, Execute ‘Voltage Supply’ the voltage between the Instrument cluster Connector A, Pin 4 pinpoint test and re-test the system for normal (harness side) and ground. Take note of this voltage. operation. Otherwise, REPAIR the circuit. TEST De-activate the Fog Lights switch. Using a digital Multimeter, measure the system for normal operation. the voltage between the Instrument cluster Connector A, Pin 4 No (harness side) and ground. Take note of this voltage. REPAIR the circuit / Fog Light switch. TEST the system for normal operation. Is the voltage greater than 10 volts when the Fog Lamps are activated? Disconnect Instrument cluster Connector A.
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01/2003 2003.0 BA Falcon
413-01-25
Instrument Cluster
413-01-25
DIAGNOSIS AND TESTING (Continued) PINPOINT TEST N : ILLUMINATION OUTPUT TEST Test Step N1
Result / Action to Take
TEST OPERATION OF CLUSTER ILLUMINATION OUTPUTS Yes
NOTE: Prior to executing test, Check fuses relating to the illumination circuit under test. If non operational fuse is found, replace and re-test.
Check illumination section of the CDU.
NOTE: The access points for testing the illumination outputs of the
No
Cluster is assessable at the connector end of the CDU unit. Please refer to Check harness (Refer EDS section). If harness connectivity correct, Execute ‘Voltage Supply’ the Pin Point test section of the CDU for details. pinpoint test and re-test the system for normal operation. NOTE: The signal from the Cluster for the illumination is by means of Pulse Width Modulation (PWM) and to instigate this signal for the CDU, follows the steps below: Key in ON position. Activate the Park Lights switch. Use WDS oscilloscope section to measure the PWM output from the Cluster at the CDU / Switch side of the harness. See EDS section for details. Change the brightness and observe the PWM waveform on the WDS. Is there any changes on the PWM output ?
PINPOINT TEST O : FUEL CUT OFF TEST Test Step O1
OPEN CIRCUIT TEST Yes
Key in OFF position. Disconnect harness from the Fuel Cutoff sender.
Go to O2
No
Key in ON position. Is the Fuel Cutoff LED switched off?
O2
Result / Action to Take
Check harness of the EDS section.
TEST CONT. Short the Fuel Cutoff pin at the sender end of the connector to ground. Is the Fuel Cutoff LED switched on when the pin is shorted to ground?
Yes
Circuit is working correctly.
No
Check harness of the EDS section and the Fuel Cutoff circuit.
PINPOINT TEST P : CAN WAKEUP TEST Test Step P1
Result / Action to Take
CHECK CAN WAKEUP INPUT Key in OFF position. Disconnect connector B. Using a Multimeter to measure the voltage at pin 5 of connect B (Cluster Side). Is the voltage reading greater than 10Volts?
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Yes
Check harness and CDU.
No
Execute ‘Voltage Supply’ pinpoint test and re-test the system for normal operation.
01/2003 2003.0 BA Falcon
413-01-26
Instrument Cluster
413-01-26
REMOVAL AND INSTALLATION
Instrument Cluster
4. Remove the two lower screws.
Removal 1. Drop leaver and move steering column down.
5. Disconnect the two wiring connectors and carefully remove cluster unit. 2. Pull rubber back to expose the two screw locations.
Installation 1. Reverse the Removal procedure. 3. Remove the three upper screws.
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01/2003 2003.0 BA Falcon
413-06-1
Horn
413-06-1
SECTION : 413-06 Horn VEHICLE APPLICATION : 2003.0 BA Falcon CONTENTS
PAGE
SPECIFICATIONS Specifications ........................................................................................................................413-06-2 DESCRIPTION AND OPERATION Horn ......................................................................................................................................413-06-3 DIAGNOSIS AND TESTING Horn ......................................................................................................................................413-06-4 Inspection and Verification ...................................................................................................413-06-4 Symptom Chart ....................................................................................................................413-06-4 Pinpoint Tests ......................................................................................................................413-06-4 REMOVAL AND INSTALLATION Horn ......................................................................................................................................413-06-8
01/2003 2003.0 BA Falcon
413-06-2
Horn
413-06-2
SPECIFICATIONS Torque Specifications Description Screw M6X18 Taptite
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Nm 8
01/2003 2003.0 BA Falcon
413-06-3
Horn
413-06-3
DESCRIPTION AND OPERATION
Horn Low series vehicles are fitted with one low note horn, whilst high series vehicles are fitted with a pair of tuned horns. One has a high pitch tone and the other has a low pitched tone. The horn mylar switch pad is incorporated in the steering wheel pad providing a large contact area.When pressed the horn switch pad completes the circuit to the horns. The horn system consists of the following components: steering wheel pad horn switch horns horn relay The steering wheel pad horn switch is part of the driver side air bag module. For additional information, refer to Section 501-20b.
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01/2003 2003.0 BA Falcon
413-06-4
Horn
413-06-4
DIAGNOSIS AND TESTING Inspection and Verification
Horn
Refer to Wiring Diagram Section 413-06 for schematic 1. Verify the customer concern. 2. Visually inspect for the following obvious signs of and connector information. mechanical and electrical damage: Special Tool(s) Visual Inspection Chart 73III Automotive Meter Mechanical Electrical 105-R0057 or equivalent Horn(s) Central junction box Horn relay (CJB) fuse. Steering wheel pad Circuitry horn switch 3. If the fault is not visually evident, verify the symptom and proceed to the Symptom Chart.
Symptom Chart Condition
Source
Action
The horn does not sound
Loose connections at horn button contact. Open wire from horn to horn button. Open wire from fuse box to horn button. Horns defective or out of adjustment. Fuse burned out.
Go to PinPoint Test A.
The horn sounds continuously
Horn button defective.
Go to PinPoint Test B.
One horn fails to operate (if dual horm is fitted).
Broken or loose wire to the horn. Horn defective or out of adjustment
Go to PinPoint Test C.
Pinpoint Tests PINPOINT TEST A : THE HORN DOES NOT SOUND Test Step A1
CHECK POWER SUPPLY TO HORN RELAY Disconnect Horn Relay. Measure the voltage between horn relay [Circuit 1], harness side and ground; and between the horn relay [Circuit 385], harness side and ground. Are the voltages greater than 10 volts?
A2
Result / Action to Take
Yes
Go to A2.
No
REPAIR the circuit. TEST the system for normal operation.
CHECK HORN RELAY Test the horn relay. Is the horn relay OK?
Yes
Go to A3.
No
INSTALL a new horn relay. TEST the system for normal operation.
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01/2003 2003.0 BA Falcon
413-06-5
Horn
413-06-5
DIAGNOSIS AND TESTING (Continued) Test Step A3
Result / Action to Take
CHECK STEERING WHEEL PAD HORN SWITCH SIGNAL TO HORN RELAY Measure the resistance between the horn relay [Circuit 1], harness side and ground under the following conditions:
Steering Wheel Pad Horn Switch Position Pressed Released
Resistance
Yes
Go to A4.
No
Go to A5.
Less than 5 ohms Greater than 10,000 ohms
Are the resistances correct?
A4
CHECK CIRCUIT BETWEEN HORN RELAY AND HORN Yes
Disconnect Horn(s). Measure the resistance between the horn relay [Circuit 1A], harness side and the LH horn, circuit 1B, harness side or the RH horn , circuit 1C, harness side; and between the horn relay [Circuit 1A], harness side and ground. Is the resistance less than 5 ohms between the horn relay and the horns and greater than 10,000 ohms between the horn relay and ground?
A5
No
REPAIR the circuit. TEST the system for normal operation.
CHECK CIRCUIT BETWEEN HORN RELAY AND AIR BAG SLIDING CONTACT Disconnect the clockspring. For removal instructions for closkspring, Section 211-04. Measure the resistance between the clockspring, circuit 1B, harness side and the horn relay [Circuit 4], harness side. Is the resistance less than 5 ohms?
A6
INSTALL a new horn, REFER to Horn in this section. TEST the system for normal operation.
Yes
Go to A6.
No
REPAIR the circuit. TEST the system for normal operation.
CHECK THE STEERING WHEEL PAD HORN SWITCH Deactivate the air bag system. Refer to Section 501-20b . Disconnect Steering Wheel Pad Horn Switch Harness. Measure the resistance between the between the steering wheel pad horn switch harness, circuit 57CH, harness side and ground under the following conditions:
Steering Wheel Pad Horn Switch Position Pressed Released
Resistance
Yes
INSTALL a new air bag sliding contact, REFER to Section 501-20b. TEST the system for normal operation.
No
INSTALL a new driver side air bag module, REFER to Section 501-20b. TEST the system for normal operation.
Less than 5 ohms Greater than 10,000 ohms
Are the resistances correct?
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01/2003 2003.0 BA Falcon
413-06-6
Horn
413-06-6
DIAGNOSIS AND TESTING (Continued) PINPOINT TEST B : THE HORN SOUNDS CONTINUOUSLY Test Step B1
Result / Action to Take
CHECK HORN CIRCUIT Yes
Key in OFF position.
REPAIR circuit 1A. TEST the system for normal operation.
Disconnect Horn Relay. Does the horn continue to sound?
No
Go to B2.
B2
CHECK HORN RELAY Yes
Test the Horn Relay.
REINSTALL the horn relay. Go to B3.
Is the horn relay OK?
No
INSTALL a new horn relay. TEST the system for normal operation.
B3
CHECK CIRCUIT Yes
Disconnect the clockspring.
If equipped with anti-theft, Go to B4. Otherwise, REPAIR the circuit. TEST the system for normal operation.
Does the horn continue to sound?
No
Go to B5.
B4
CHECK BEM INPUT Yes
Disconnect BEM.
REPAIR circuit 1A. TEST the system for normal operation.
Does the horn continue to sound?
No
REFER to Section 419-10. TEST the system for normal operation.
B5
CHECK STEERING WHEEL PAD HORN SWITCH Deactivate the air bag system. Refer to Section 501-20b . Disconnect Steering Wheel Pad Horn Switch Harness. Measure the resistance between the steering wheel pad horn switch harness, circuit 57CH, harness side and ground under the following conditions:
Steering Wheel Pad Horn Switch Position Pressed Released
Resistance
Yes
INSTALL a new air bag sliding contact, REFER to Section 501-20b . TEST the system for normal operation.
No
INSTALL a new driver side air bag module, REFER to Section 501-20b . TEST the system for normal operation.
Less than 5 ohms Greater than 10,000 ohms
Are the resistances correct?
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01/2003 2003.0 BA Falcon
413-06-7
Horn
413-06-7
DIAGNOSIS AND TESTING (Continued) PINPOINT TEST C : ONE HORN FAILS TO OPERATE Test Step C1
CHECK HORN 1 FOR OPERATION Disconnect Horn 2 from wiring harness Depress horn pad on sterring wheel Does horn 1 sound?
C2
Yes
Go to C4
No
Go to C2
CHECK POWER WIRE ON HORN 1 Remove horn relay Measure resistance of circuit 1A-1B Is resistance <5 ohms?
C3
Result / Action to Take
Yes
Go to C3
No
There is a break in the wire. Repair harness and retest for correct operation.
CHECK EARTH WIRE FROM HORN 1 Remove Horn 1 Measure resistance of circuit 57AF to ground Is resistance <5 ohms?
Yes
Horn must be faulty. Replace horn and retest for correct operation.
No
There is a break in the wire. Repair harness and retest for correct operation.
C4
CHECK HORN 2 FOR OPERATION Disconnect Horn 1 from wiring harness Reconnect Horn 2 to wiring harness Depress horn pad on sterring wheel Does horn 2 sound
C5
Horn is operating correctly.
No
Go to C5
CHECK POWER WIRE TO HORN 2 Remove horn relay Measure resistance of circuit 1A-1C Is resistance <5 ohms?
C6
Yes
Yes
Go to C6
No
There is a break in the wire. Repair harness and retest for correct operation.
CHECK EARTH WIRE FROM HORN 2 Remove Horn 2 Measure resistance of circuit 57AG to ground Is resistance <5 ohms?
Yes
Horn must be faulty. Replace horn and retest for correct operation.
No
There is a break in the wire. Repair harness and retest for correct operation.
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01/2003 2003.0 BA Falcon
413-06-8
Horn
413-06-8
REMOVAL AND INSTALLATION
Horn Removal 1. Remove the grille from between the headlamps. 2. Disconnect the electrical connector(s) . 3. Remove the horn and bracket assembly(s). 1. Disconnect the electrical connector. 2. Remove the nut. 3. Remove the horn.
4. To install, reverse the removal procedure.
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01/2003 2003.0 BA Falcon
413-07-1
Clock
413-07-1
SECTION : 413-07 Clock VEHICLE APPLICATION : 2003.0 BA Falcon CONTENTS
PAGE
SPECIFICATIONS Specifications ........................................................................................................................413-07-2 DESCRIPTION AND OPERATION Clock .....................................................................................................................................413-07-3 DIAGNOSIS AND TESTING Clock .....................................................................................................................................413-07-4 Inspection and Verification ...................................................................................................413-07-4 Symptom Chart ....................................................................................................................413-07-4 Pinpoint Tests ......................................................................................................................413-07-4 REMOVAL AND INSTALLATION Clock .....................................................................................................................................413-07-6
01/2003 2003.0 BA Falcon
413-07-2
Clock
413-07-2
SPECIFICATIONS General Specifications Description Time keeping accuracy Fixings
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Specification Better than 5 seconds variation per day Inter-locking tabs plus two clips
01/2003 2003.0 BA Falcon
413-07-3
Clock
413-07-3
DESCRIPTION AND OPERATION
Clock To adjust the time displayed, press and hold the left button (to turn the clock backwards) or the right button (to turn the clock forwards).
Press momentarily for fine adjustment, or press and hold for fast adjustment.
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01/2003 2003.0 BA Falcon
413-07-4
Clock
413-07-4
DIAGNOSIS AND TESTING
Clock Inspection and Verification Visual Inspection Chart Mechanical Two clips fully engaged Interlocking fingers properly engaged Margins are consistant Electrical connector connected
Symptom Chart Condition
Source
Action
Illumination not working
Wiring fault Cluster fault Clock fault
Go to PinPoint Test A
Clock not working at all
Wiring fault Clock fault
Go to PinPoint Test B
Clock gains / looses time
Clock fault
Go to PinPoint Test C
Clock minute hand turns at seconds speed
Clock fault - loss of calibration
Replace Clock
Clock set buttons not working.
Wiring fault Clock fault
Go to PinPoint Test B
Pinpoint Tests PINPOINT TEST A : ILLUMINATION TEST Test Step A1
CONTROLS CHECK Turn ignition on. Turn Park Lamps on. Vary the illumination controls on the IC. Does the illumination change?
A2
Result / Action to Take
Yes
Functioning correctly
No
Go to A2
CONTROLS CHECK CONT. Yes
Does the IC display illumination vary.
Go to A3
No
Refer to IC diagnostics.
A3
CORRECT CONNECTION CHECK Remove Clock from Instrument panel. Is the connector fully engaged?
Yes
Go to A4
No
Engage connector and check functionality. Go to A1 if necessary.
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01/2003 2003.0 BA Falcon
413-07-5
Clock
413-07-5
DIAGNOSIS AND TESTING (Continued) Test Step A4
Result / Action to Take
VOLTAGE CHECK Yes
Disconnect Clock. Connect multimeter to pin ?? of Clock wiring connector and measure voltage while varying IC illumination control switches. Does the voltage vary?
Replace Clock.
No
Go to B1
PINPOINT TEST B : CLOCK NOT WORKING Test Step B1
Result / Action to Take
CORRECT CONNECTION Remove Clock from Instrument panel. Is the connector fully engaged ?
Yes
Continue.
No
Engage connector and check functionality. Go to B2 if still not functioning.
B2
VOLTAGE CHECK Yes
Disconnect Clock. Set multi meter to measure 12 volts and connect multimeter across pins. For (Y-B) and (B-LG) wires of Clock wiring connector and measure voltage.
Replace clock.
No
Check wire integrity.
Is 12 volts present.
PINPOINT TEST C : CLOCK LOSING / GAINING TIME Test Step C1
Result / Action to Take
VOLTAGE CHECK Yes
Is battery voltage above 12 volts?
Continue.
No
Refer batter service.
C2
CLOCK CONDITION Yes
Does clock loose / gain more than five seconds every 24 hours?
Replace clock.
No
Clock functioning correctly.
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01/2003 2003.0 BA Falcon
413-07-6
Clock
413-07-6
REMOVAL AND INSTALLATION
Clock Removal 1. To remove the analogue clock, gently slide a flat blade item ( eg. large screw driver) into the rear margin, closest to the windscreen, and pry the clock panel upwards to disengage the two clips.
2. Rotate this end up to disengage the interlocking fingers attaching the clock panel to the air register panel. 3. Disconnect the electrical connector. Installation 1. To install the clock, first make the electrical connection. 2. Ensure clock functions and illumination varies. 3. Ensure all interlocking fingers are aligned and rotate the clock panel down wards to drive the panel home and engage the two clips.
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01/2003 2003.0 BA Falcon
413-08-1
Interior Command Centre
413-08-1
SECTION : 413-08 Interior Command Centre VEHICLE APPLICATION : 2003.0 BA Falcon CONTENTS
PAGE
DESCRIPTION AND OPERATION Interior Command Centre .....................................................................................................413-08-2 ICC Handling and Storage ....................................................................................................413-08-2 DIAGNOSIS AND TESTING Interior Command Centre .....................................................................................................413-08-4 Principles Operation .............................................................................................................413-08-4 Inspection and Verification ...................................................................................................413-08-6 Symptom Chart ....................................................................................................................413-08-9 Service Procedures ............................................................................................................413-08-11 REMOVAL AND INSTALLATION Interior Command Centre (ICC) ...........................................................................................413-08-19 Service Body Computer (BEM) ...........................................................................................413-08-23 Service Remote Key Receiver (RKR) .................................................................................413-08-25 Service Air Register ............................................................................................................413-08-25 Cabin Temperature Sensor ..................................................................................................413-08-26
01/2003 2003.0 BA Falcon
413-08-2
Interior Command Centre
413-08-2
DESCRIPTION AND OPERATION
Interior Command Centre The Interior Command Centre includes audio, climate control and auxiliary controls (i.e.. Door locks, courtesy lamps, interior lamps) displayed in a centralised area. System status is displayed on a screen built into the instrument panel. The Interior Command Centre screen is monochromatic for low series screens. High series vehicles receive a colour screen. Vehicles with Sat-Nav optioned also receive a colour screen. Features of each screen are highlighted below: 1. LCD for low series: Monochromatic Uses preset symbols to display information 2. TFT for high series: Full colour Reconfigurable screen settings Video input for Sat-Nav, as well as preset screens The Interior Command Centre consists of the following base components: Audio features: LCD screen Loud button Tuning/Track select Auto store CD eject button CD mode button Mode select button Audio On/Off/Volume button FM/AM select buttons HVAC features: A/C on/off Automatic Climate Control On/Off Driver/Passenger temp settings Front windscreen demist Air distribution modes Fresh/Recirc air inlet Blower fan speed Ambient temperature display Rear demist (heated backlight) Door lock Dome lamp For further information regarding the function of each button, please refer to the Owners Guide.
ICC Handling and Storage 1. ICC must be handled appropriately. Grab points are shown in illustrations.
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2. Warranty is void if ICC is dropped, handled roughly or treated outside of these guidelines. 3. The ICC must not to be tilted beyond 90 degrees from upright. At no stage can the ICC be shocked or excessively vibrated. Such action may damage the Audio mechanism. Warranty will be void if these conditions are not met. 4. The ICC contains many delicate mechanical and electrical components. Special care must be taken. The following are important : 1. DO NOT scratch the Class A appearance surfaces. 2. DO NOT apply excess pressure to the screen surface at any time. 3. DO NOT apply force in excess of 10 kg to any appearance surface of the ICC. 4. DO NOT touch the pins of the Self-aligning connector at the rear of the Audio Module. 5. DO NOT touch the Cabin Temperature Sensor (refer illustration). 6. DO NOT apply pressure to any of the switches, knobs or buttons exceeding 5 kg. 7. AVOID all contact with dirt, dust, metal flakes, metal shavings. 5. The ICC is sensitive to Electro Static Discharge. Avoid all contact with static electricity and all precautions must be undertaken to ensure adequate grounding of the repair technician and the ICC Module outside of the vehicle environment to avoid ESD damage. 6. Avoid all contact with any liquids : soft drinks, water, hot drinks, alcohol, etc. ICC electronic components will be damaged by any contact with liquids. 7. ICC is not to be disassembled except for recognised service items. The only recognised service items are the Body Computer (BEM), Air Register and Remote Key Receiver. These individual components are to be removed in tact as required, according to the Service Manual requirements. Components are not to be tampered with or else component warranty is voided. 8. ICC storage temperature is never to exceed the range -30°C to +85°C. 9. Adhesive labels cannot be used on CD’s as they can peel off and damage internal mechanisms. The use of a disc that deviates from above industrial standards, use of soiled, scratched, dented, cracked, or warped discs and use of pirated discs, etc. will void a warranty claim. Sumitomo will not accept a warranty claim if any part of the audio unit or ICC has been damaged by the use of an "unsupported" disc.
01/2003 2003.0 BA Falcon
413-08-3
Interior Command Centre
413-08-3
DESCRIPTION AND OPERATION (Continued) CD-DA
CDTEXT
CD-ROM
CD-I
CDCD-R Recordable CDRecordable
CDRW
RED BOOK
This format is used for Music data and Text data (title etc). GREEN This format is used BOOK for games and educational software. It may contain Music, Pictures, Graphics, Text and application software. ORANGE This format is BOOK one-time Recordable Compact Disc. ORANGE This format is BOOK multi-write Rewritable Compact Disc
10. When refitted to the car, only approved mounting screws may be used to the specified torques. 11. All mating connectors are to be appropriately aligned prior to fitment back into the vehicle. Check that white housing of the main Audio Self-aligning connector (vehicle-side) is reset outwards (by pulling the white connector block rearwards in the car) prior to loading of the ICC into the Instrument Panel. Failure to do so may result in permanent damage to both the vehicle-side connector and the Audio Module.
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Interior Command Centre
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DIAGNOSIS AND TESTING
Interior Command Centre Principles Operation The ICC (Interior Command Centre) functions are handled internally by the audio module microprocessor or externally by sending data on the CAN bus to another module. All the buttons and knobs on the ICC are inputs to the Audio microprocessor. Audio functions are executed internally by the audio microprocessor and any screen information is updated directly by this micro. Climate control buttons and knobs are also inputs to the audio micro and can also be checked at the audio module using WDS. When Climate control buttons or knobs are operated, the audio module send a CAN message to the HIM. The HIM executes a function and sends a message back to the audio module to update the screen as required for that function. A similar control flow exists for Trip Computer functions. The Trip button and reset button are inputs to the audio module that sends a message to the instrument Cluster. The instrument Cluster does the calculations and sends a CAN message to the audio module which then displays the value on the screen. The Dome Lamp Button, Door lock button and heated backlight button are also inputs to the audio module. The audio module sends a CAN message to the BEM. In this case it is only the Heated Backlight function that returns a CAN message to the Audio module as it is the only one requiring a Screen status update. The traction control button also is an input to the Audio module that sends a message to the traction control module. In this case the traction control
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module sends the status to the Instrument Cluster that displays the relevant jewel. This flow of control needs to be understood to correctly diagnose faults with the system. The correct operation of the button or knob should be checked using WDS, transmission of the CAN message can be checked using DTCs as can the validity of the message content (invalid data DTCs). The functionality of receiving module can be checked by following the relevant modules diagnostics. This checking process usually needs to be done twice for the ICC as a message sent out from the ICC to another module triggers a message sent out from that module to the ICC. The ICC can be thought of as a big radio that controls more than usual number of buttons and a larger than normal screen. The actual climate control functions, Sat Nav, and auxiliary button control are done in other modules. The ICC sends CAN Messages to and receives CAN messages from modules as listed in the following table; ICC CAN Messages Transmitted to; Received from; Instrument Cluster PCM HIM Instrument Cluster BEM HIM Traction Control BEM The physical layout of this CAN bus is shown below:
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Interior Command Centre
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DIAGNOSIS AND TESTING (Continued) Daisy CAN Wiring Layout
Satellite Navigation control is via the infrared receiver above the colour screen. It is wired directly to the Sat Nav module and does not have any interface to the audio module. The video signal also goes directly to the colour screen. When the Sat Nav module display is switched on, a video select line is grounded between the Sat Nav Module and the Screen module. This then runs the Sat Nav Video as the back ground display on the screen and the ICC function become pop up overlays. The Cabin Temperature Sensor and remote key receiver antenna are also directly wired to the BEM and have no connection to the Audio Module. If the ICC is replaced, the CTS calibration factor needs to be retaught to the BEM (refer to section 419-10). The ICC/Audio Security Module Reconfiguration will be required. WDS must be used for this operation.
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Interior Command Centre
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DIAGNOSIS AND TESTING (Continued) Normal Condition
Inspection and Verification Visual Inspection Chart Normal Condition
Possible cause of abnormality All margins even and ICC not fully docked surfaces flush indicating Not all hardware secured the interior command Four yellow clips not centre is fully seated and engaged self-aligning connector is Self Aligning connector correctly docked. not reset when ICC installed Object obstructing ICC fitment BEM connector not made / causing obstruction Air registers and Physical damage, foreign thumbwheel control body obstruction or operate through full damaged movement range of movement Screen, switches and Physical damage - refer knobs are free of marks to diagnostics to check and are secure correct operation CD Slot clear of Foreign matter present obstruction CTS slots free of Foreign matter present obstructions
CDs load and unload correctly Colour screen switches on and off using 5 second press of volume knob Screen updates when pressing buttons CTS draws air through slots in facia (Cabin Temperature Sensor CTS) No rattles or abnormal sounds
Possible cause of abnormality Foreign matter present or CD mechanism failure refer to Audio diagnostics Faulty button / Screen see ICC diagnostics Faulty button / Screen see ICC diagnostics Faulty CTS or obstructed slots/air way Unit not secure Four clips not fitted CTS is obstructed loose components Damaged/Loose air registers
CAN Information Refer CAN Message List. NOTE: If the ICC is replaced, the CTS calibration factor needs to be retaught to the BEM (refer to section 419-10). The ICC/Audio Security Module Reconfiguration will be required. WDS must be used for this operation.
DTC Chart DTC B1342
Description ECU is faulty
Possible Causes Faulty Audio unit
B1318
Battery voltage low
Low system voltage detected
B2103
Antenna not connected
Antenna connection not made/damaged
B2203
CD error
CD inserted incorrectly, data CD inserted
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Action Document and clear the DTC’s. Carry out the self test. If the DTC is registered again replace ICC. Test the system for correct operation. Document and clear the DTC’s. Run vehicle for 2 minutes. If the DTC is registered again check / correct battery. Document and clear the DTC’s. Carry out the self test. If the DTC is registered again refer to Poor radio reception symptom in the symptom chart of Audio diagnostics in Section 415-00. Document and clear the DTC’s. Remove all CD’s then reload CD’s and read CM (continuously monitored) DTC’s. If the DTC is registered again refer to CD does not play symptom in the symptom chart of Audio diagnostics in Section 415-00.
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Interior Command Centre
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DIAGNOSIS AND TESTING (Continued) DTC 2403
Description Multi CD mechanical error
B2404
Audio steering wheel switches faulty
B2406
Single CD mechanical error
B2408
Speaker line short
B2409
AM tuner fault
B2410
FM tuner fault
B2924
Audio button stuck
B2922
Auxiliary button stuck
B2923
Climate control button stuck
B2925
Subwoofer speaker short
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Possible Causes BCD stuck etc.
Action Document and clear the DTC’s. Remove all CD’s then reload 6 CD’s and play each momentarily. Read CM DTC’s. If the DTC is registered again refer to Unable to load / eject CD’s (multi player ) symptom in the symptom chart of Audio diagnostics in Section 415-00. Audio steering wheel Document and clear the DTC’s. Read switch jammed CM DTC’s If the DTC is registered again refer to Steering wheel audio switch not operating symptom in the symptom chart of Audio diagnostics in Section 415-00. CD stuck etc. Document and clear the DTC’s. Remove and then reload CD. Read CM DTC’s. If the DTC is registered again refer to Unable to load / eject CD’s (single player ) symptom in the symptom chart of Audio diagnostics in Section 415-00. Detects speaker line Document and clear the DTC’s. Carry shorted to ground or B+ out the self test. If the DTC is registered again refer to One or more speakers not operating symptom in the symptom chart of Audio diagnostics in Section 415-00. No AM signal (Antenna Document and clear the DTC’s. Carry test) out the self test. If the DTC is registered again refer to Poor radio reception symptom in the symptom chart of Audio diagnostics in Section 415-00. No FM signal (antenna Document and clear the DTC’s. Carry test) out the self test. If the DTC is registered again refer to Poor or no radio reception symptom in the symptom chart of Audio diagnostics in Section 415-00. Audio button jammed Document and clear the DTC’s. Read CM DTC’s. If the DTC is registered again refer to Audio button not working symptom in the symptom chart of Audio diagnostics in Section 415-00. Auxiliary button jammed Document and clear the DTC’s. Read CM DTC’s. If the DTC is registered again refer to the following symptoms in the symptom chart. Traction button not working. Trip / Reset button no working. Interior lamp button not working. Lock/Unlock button not working. Climate control button Document and clear the DTC’s. Read jammed CM DTC’s. If the DTC is registered again refer to Climate control button not working symptom in the symptom chart. Subwoofer line shorted Document and clear the DTC’s. Read to ground or B+ CM DTC’s. If the DTC is registered again refer to Subwoofer not working symptom in the symptom chart of Audio diagnostics in Section 415-00.
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Interior Command Centre
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DIAGNOSIS AND TESTING (Continued) DTC U2014
Description Audio subwoofer not connected
Possible Causes Subwoofer disconnected/not fitted
B2911
Trip computer data invalid
U1900
CAN communication fault
Instrument Cluster did not have valid data available CAN messages not received
U2201
Ambient temperature data invalid
HIM did not have valid data available
PID Chart Command CCNT NTCSDT AUD_VOL AUSTCRES AUTO_VCG ATNN_RSS AUDIO_SI TMPKNOBP BLWR_FAN LCD_SEG SEC_STAT ACM_STAT MOD_ID CONPROV CANDSV TCSW VOL_UP VOL_DN SEEK_BTN MODE_SW TRIP_SW TRIP_SW DOME_SW NAV_PRES REVRS_INP MENU_SW CLK_DSPL PHONE_AT G86737 en
Description Number of Continuous Trouble Codes Set Number of Trouble Codes Set due to Diagnostic Test Audio Volume Audio Steering Switch Circuit Resistance Automatic Volume Control Gain Antenna Reception Signal Strength Audio Security Identification Temperature Selector Status Blower Fan Speed LCD Segment Display Security Status ECU Operating State Module ID Check Configuration and Programming Version CAN Diagnostic Specification Version Traction Control Switch Status (+) Volume button (-) Volume button (+) Seek button Mode Switch Trip Trip Reset Switch Dome Lamp Switch Navigation Reverse Menu switch Clock Display Enable Status Phone Transceiver Active
Action Document and clear the DTC’s. Carry out the self test. If the DTC is registered again refer to Subwoofer not working symptom in the symptom chart of Audio diagnostics in Section 415-00. Document and clear the DTC’s. Read DTC’s. If the DTC is registered again refer to Section 413-01. Document and clear the DTC’s. Read DTC’s. If the DTC is registered again refer to CAN bus diagnostics Section 303-14. Document and clear the DTC’s. Read DTC’s. If the DTC is registered again refer to Section 412-04.
Command AC_SEL_SW VOLI_SW VOLD_SW TUNE_UP TUNE_DN SEEK_UP DEF_SCRN PLUS_SW AM_SWT FM_SWT CD_SWT AUTO_SW EJECT_SW PRE1_SW PRE2_SW PRE3_SW PRE4_SW PRE5_SW PRE6_SW POWER_SW SUB_AMP VID_SRC AUD_SR CLK_ODV LOAD_SW LOUD_SW CD_SLOT6 CD_SLOT5 CD_SLOT4 CD_SLOT3 CD_SLOT2 CD_SLOT1 PANEL_FLR
Description Air Conditioning Switch Status Volume Increase Switch Volume Decrease Switch Tune Increase Switch Tune Decrease Switch Seek Increase Switch Defrost (Screen) (+) Switch AM Switch FM Switch CD Switch Autoset Eject Preset 1 Switch Preset 2 Switch Preset 3 Switch Preset 4 Switch Preset 5 Switch Preset 6 Switch Power Switch Subwoofer Amplifier Video Source CAudio Source Clock Overlay Display on Video Load Switch pressed Loudness Switch pressed CD in slot 6 CD in slot 5 CD_SLOT4 CD in slot 3 CD in slot 2 CD in slot 1 Panel (Face) / Floor 01/2003 2003.0 BA Falcon
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Interior Command Centre
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DIAGNOSIS AND TESTING (Continued) Command FLR_DEF FLOOR PANEL_FACE DEF_SCRN AUTO OFF RECIRC FAN_MINUS FAN_PLUS TEMP_DECR TEMP_INCR REAR_DEF
Description Floor / Defrost (mix) Floor Panel (Face) Defrost (Screen) Auto Off Recirculation Status Fan Fan + Temperature Decrement Temperature Increment Rear Defrost (heated backlight)
Command PTMP_DECR PTMP_INCR MODE_UP MODE_DWN C_LOCK_SW RUN_POS ACC_POS EATC_HIM BEM_MSG CLUST_MSG PCM_MSG
Description Passenger Temperature Decrement Passenger Temperature Increment Mode UP Mode DOWN Central Lock/Unlock Switch Status Run ACC Position EATC (HIM) GEM Instrument Cluster (IC) Powertrain Control Module
Symptom Chart Condition
Source
Action
Illumination not working
Wiring fault Cluster fault ICC fault
Refer to service procedure Illumination fault. (Test A).
Climate control button not working
Internal fault CAN fault HIM fault
Refer to service procedure Climate control button not working. (Test B) Refer to CAN Diagnostics. Refer to HIM Diagnostics.
Traction button not working
Internal fault Wiring fault Traction module fault BEM fault
Refer to service procedure Auxiliary switch fault (Test C) Refer to Traction diagnostics. Refer to BEM diagnostics.
Trip/Reset button not working
Internal fault Wiring fault BEM fault
Refer to service procedure Auxiliary switch fault (Test C). Refer to BEM diagnostics.
Interior Lamp (Courtesy button) not working
Internal fault Wiring fault BEM fault
Refer to service procedure Auxiliary switch fault (Test C). Refer to BEM diagnostics.
Lock/Unlock button not working
Internal fault Wiring fault BEM fault
Refer to service procedure Auxiliary switch fault (Test C). Refer to BEM diagnostics.
Visual Damage
Internal fault
Refer to service procedure ICC visual damage (Test D)
Display not working
Internal fault Wiring fault Cluster fault
Refer to service procedure ICC display fault (Test E). Refer to Cluster diagnostics.
Automatic Climate Control Temperature setting higher or lower than is expected
Obstruction in CTS BEM Fault CTS Fault HIM fault
Check that CTS slots are clear. Refer to HIM diagnostics. Refer to BEM diagnostics.
Noisy
Not fitted/installed correctly CTS obstructed/faulty Internal fault
Refer to Inspection and Verification in this section. Refer to BEM diagnostics. Refer to service procedure Unusual noise from ICC (Test F)
Air registers not working
Internal fault
Refer to Inspection and Verification in this section. Refer to service procedure Faulty air register (Test G).
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Interior Command Centre
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DIAGNOSIS AND TESTING (Continued) Condition
Source
Action
Climate control shows flashing "recirc air" symbol or continious "recirc air" symbol with no other climate control symbol displayed.
Wiring Fault HIM Fault
Refer to CAN diagnostics. Refer to Climate Control diagnostics.
Outside Temperature not working
Wiring Fault HIM Fault
Refer to CAN diagnostics. Refer to Climate Control diagnostics.
Navigation not working
Internal fault Remote control fault Navi module fault Wiring fault
Refer to symptom navigation not working in Audio Section 415-00. Refer to Navigation diagnostics.
Audio button not working
Low system voltage Internal fault
Check for low battery voltage. Refer to symptom audio button not working in Audio Section 415-00.
ICC does not turn on.
No Accessory line power. No Ignition line power. Internal fault. BEM fault.
Refer to symptom ICC does not turn on in Audio Section 415-00. Refer to ignition diagnostics section. Refer to BEM diagnostics.
Telephone input not working.
Internal fault Wiring fault
Refer to symptom Telephone input not working in Audio Section 415-00.
Auxiliary input not working
Internal fault Wiring fault
Sonar not operating.
Internal fault. Wiring fault. ICC not correctly configured. Sonar module fault.
Refer to symptom Sonar not operating in Audio Section 415-00. Refer to Sonar diagnostics.
Unable to load / eject CD’s (single CD)
Internal fault. Faulty CD.
Refer to symptom Unable to load / eject CD’s (single CD) in Audio Section 415-00.
Unable to load / eject CD’s (multi CD)
Internal fault. Faulty CD.
Refer to symptom Unable to load / eject CD’s (multi CD) in Audio Section 415-00.
CD does not play.
Internal fault. Faulty CD.
Refer to symptom CD does not play in Audio Section 415-00.
Poor or no radio reception.
Internal fault. Wiring fault. Antenna fault.
Refer to symptom Poor or no radio reception in Audio Section 415-00.
One or more speakers not operating.
Internal fault Speaker fault Wiring fault
Refer to symptom One or more speakers not operating in Audio Section 415-00.
Subwoofer not working.
Internal fault Wiring fault Amplifier fault Speaker fault
Refer to symptom Subwoofer not working in Audio Section 415-00.
Steering wheel audio switch not operating.
Internal fault Wiring fault Switch fault
Refer to symptom Steering wheel audio switch not operating in Audio Section 415-00.
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Refer to symptom Auxiliary input not working in Audio Section 415-00.
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Interior Command Centre
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DIAGNOSIS AND TESTING (Continued) Service Procedures Service Procedure Illumination fault (Test A) Climate control button not working (Test B) Auxiliary switch fault (Test C) ICC visual damage (Test D) ICC display fault (Test E) Unusual noise from ICC (Test F) Faulty air register (Test G)
Description Identifies an illumination fault. Tests the ICC climate buttons and knobs for correct operation and identifies a fault. Tests the ICC auxiliary buttons for correct operation and identifies a fault. Visual inspection of ICC for physical damage. Checks the ICC for correct display operation and identifies a fault. Checks for any unusual noises or rattles from the ICC. Tests the air registers for correct operation.
TEST A : ILLUMINATION FAULT Using the WDS data logger function activate the following acronyms. RUN_POS, ACC_POS, POWER_SW Test Step
Result/Action to Take
Acronyms
A1 Turn the ignition on. Check Pid’s using data logger. Is the ignition on?
Yes Go to A2. No Repair faulty ignition system and retest.
Check that the accessories are on. Check Pid’s using data logger. Are the accessories on?
Yes Go to A3. No Repair faulty ignition system and retest.
Check to see if the ICC audio is turned on. Is the audio on?
Yes Go to A5. No Go to A4.
POWER_SW
Push the ICC audio power button. Check Pid’s using data logger. Does the ICC audio turn on?
Yes Go to A5 No Refer to symptom ICC does not turn on in the symptom chart of audio chapter 415-00.
POWER_SW
Turn the vehicle headlights on. Are the headlights on?
Yes Go to A6. No Repair faulty lighting system.
RUN_POS
A2
A3
A4
A5
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DIAGNOSIS AND TESTING (Continued) Test Step
Result/Action to Take
Acronyms
A6 Check for illumination of the ICC display. Does the display illuminate?
Yes Go to A8 No Continue.
Remove the ICC. Measure for battery voltage at the ICC instrument panel connector illumination pins. Refer to wiring diagrams. Does the battery voltage appear?
Yes Replace ICC and retest. No Repair faulty vehicle illumination wiring.
Check for illumination of the ICC switches. Do all the switches illuminate?
Yes No fault. ICC functioning correctly. No Continue.
Check for illumination of the ICC switches. Do any switches illuminate.
Yes Replace ICC and retest. No Continue.
Check for illumination of the vehicle instrument panel. Does the instrument panel illuminate?
Yes Go to A14. No Continue.
Inspect the instrument panel illumination fuse. Is the fuse blown?
Yes Go to A12. No Go to A14.
Turn the headlights off and replace the blown instrument panel illumination fuse with a new one of correct value. Turn the headlights on.
Yes Go to A13. No Go to A1 and retest.
Remove the ICC. Turn the headlights off and replace the blown instrument panel illumination fuse with a new one of correct value. Turn the headlights on. Did the fuse blow?
Yes ICC is OK. Repair faulty vehicle wiring and retest. No Replace ICC and retest.
Remove the ICC. Measure for battery voltage at the ICC instrument panel connector illumination pins. Refer to wiring diagrams. Does the battery voltage appear?
Yes Replace ICC and retest. No Repair faulty vehicle illumination wiring.
A7
A8
A9
A10
A11
A12
A13
A14
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Interior Command Centre
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DIAGNOSIS AND TESTING (Continued)
TEST B : CLIMATE CONTROL BUTTON NOT WORKING Using the WDS data logger function activate the following acronyms. RUN_POS, ACC_POS, POWER_SW, TEMPKNOB,
BLWR_FAN, AC_SEL_SW, PANEL_FLR, FLR_DEF, FLOOR, PANEL_FACE, DEF_SCRN, AUTO, OFF, RECIRC, RECIRC, FAN_MINUS, FAN_PLUS, TEMP_DECR, TEMP_INCR, REAR_DEF, PTMP_DECR, PTMP_DECR, PTMP_INCR, MODE_UP, MODE_DWN
Test Step
Result/Action to Take
Acronyms
B1 Turn the ignition on. Check Pid’s using data logger. Is the ignition on?
Yes Go to B2 No Repair faulty ignition system and retest.
RUN_POS
Check that the accessories are on. Check Pid’s using data logger. Are the accessories on?
Yes Go to B3 No Repair faulty ignition system and retest.
ACC_POS
Check to see if the ICC audio is turned on. Is the audio on?
Yes Go to B5 No Go to B4
Push the ICC audio power button.Check Pid’s using data logger. Does the ICC audio turn on?
Yes Go to B5 No Refer to symptom ICC does not turn on in the symptom chart of audio chapter 415-00
Operate each climate control switch / knob. Are any switches / knobs sticking or stuck?
Yes Replace ICC and retest. No Continue.
B2
B3
B4
B5
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Interior Command Centre
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DIAGNOSIS AND TESTING (Continued) Test Step
Result/Action to Take
Acronyms
B6 Check that each climate control switch / knob operates. Check Pid’s using data logger. Does each switch / knob operate?
Yes Go to B7 No Replace ICC and retest.
TEMPKNOB, BLWR_FAN, AC_SEL_SW, PANEL_FLR, FLR_DEF, FLOOR, PANEL_FACE, DEF_SCRN, AUTO, OFF, RECIRC, FAN_MINUS, FAN_PLUS, TEMP_DECR, TEMP_INCR, REAR_DEF, PTMP_DECR, PTMP_INCR, MODE_UP, MODE_DWN,
Control the following Pid’s using the WDS data logger function. Check for correct function operation for each switch / knob. Do all functions operate?
Yes No fault.ICC functioning correctly. No Replace ICC and retest.
As per acronym list step B6.
B7
TEST C : AUXILIARY FAULT Using the WDS data logger function activate the following acronyms. RUN_POS, ACC_POS, POWER_SW, TCSW, C_LOCK_SW, DOME_SW, TRIP_SW Test Step
Result/Action to Take
Acronyms
C1 Turn the ignition on. Check Pid’s using data logger. Is the ignition on?
Yes Go to C2 No Go to C2
RUN_POS
Check that the accessories are on. Are the accessories on?
Yes Go to C3 No Repair faulty ignition system and retest.
ACC_POS
Check to see if the ICC audio is turned on. Is the audio on?
Yes Go to C5 No Go to C4
C2
C3
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Interior Command Centre
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DIAGNOSIS AND TESTING (Continued) Test Step
Result/Action to Take
Acronyms
C4 Push the ICC audio power button. Check Pid’s using data logger. Does the ICC audio turn on?
Yes Go to C5 No Refer to symptom ICC does not turn on in the symptom chart of audio chapter 415-00.
Operate each auxiliary switch. Are any switches sticking or stuck?
Yes Replace ICC and retest. No Continue.
Check that each auxiliary switch operates. Check Pid’s using data logger. Does each switch operate?
Yes Go to C7 No Replace ICC and retest.
TCSW, C_LOCK_SW, DOME_SW, TRIP_SW
Control the following Pid’s using the WDS data logger function. Check for correct function operation for each switch.
Yes No fault.ICC functioning correctly. No Replace ICC and retest.
TCSW, C_LOCK_SW, DOME_SW, TRIP_SW
POWER_SW
C5
C6
C7
TEST D : ICC VISUAL DAMAGE Test Step
Result/Action to Take
Acronyms
D1 Inspect the ICC fascia for the following Scratches Dints Defective or peeling paint Wrong fascia colour Defective or missing print Broken mounting points Defective flashing or over trim Peeling or faulty decals Foreign substance on fascia Foreign material jammed into CTS slots Correct insertion of the ICC fascia CD slot clear of all obstructions Rattles or unusual sounds
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If damage cannot be rectified at the dealership submit a warranty claim. Include a detailed description of ICC damage.
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Interior Command Centre
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DIAGNOSIS AND TESTING (Continued) Test Step
Result/Action to Take
Acronyms
D2 Inspect the ICC buttons and knobs for the following Sticking or rubbing knobs Sticking or stuck buttons Defective or missing print Wrong buttons fitted Scratched or damaged buttons Loose buttons Foreign material jammed into button gaps Foreign substance on buttons Missing buttons Wrong coloured buttons fitted Wrong colour illumination
If damage cannot be rectified at the dealership submit a warranty claim. Include a detailed description of ICC damage.
Inspect the ICC display for the following Scratched or damaged display LCD leakage in display Protective sheet left on display during production Wrong colour illumination Foreign substance on the display
If damage cannot be rectified at the dealership submit a warranty claim. Include a detailed description of ICC damage.
D3
D4 Air Registers Refer to air register not working symptom in the symptom chart.
TEST E : ICC DISPLAY FAULT Using the WDS data logger function activate the following acronyms. RUN_POS, ACC_POS, POWER_SW, LCD_SEG Test Step
Result/Action to Take
Acronyms
E1 Turn the ignition on. Check Pid’s using data logger. Is the ignition on?
Yes Go to E2 No Repair faulty ignition system and retest.
RUN_POS
Check that the accessories are on. Check Pid’s using data logger. Are the accessories on?
Yes Go to E3 No Repair faulty ignition system and retest.
ACC_POS
Check to see if the ICC audio is turned on. Is the audio on?
Yes Go to E5 No Go to E4
E2
E3
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Interior Command Centre
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DIAGNOSIS AND TESTING (Continued) Test Step
Result/Action to Take
Acronyms
E4 Push the ICC audio power button. Check Pid’s using data logger. Does the ICC audio turn on?
Yes Go to E5 No Refer to symptom ICC does not turn on in the symptom chart of audio chapter 415-00.
Check operation of the ICC display. Does the ICC display operate?
Yes Go to E6 No Replace ICC and retest.
Check operation of the climate control display. Does only the air recirculation symbol appear?
Yes ICC functioning correctly.Refer to the climate control section. No Continue.
Check operation of the trip computer display. Is the trip computer display blank?
Yes ICC functioning correctly.Refer to the instrument cluster section. No Continue.
Check for operation of all display segments. Check Pid’s using data logger. Do all segments operate?
Yes No fault. ICC functioning correctly. No Replace ICC and retest.
LCD_SEG
Result/Action to Take
Acronyms
E5
E6
E7
E8
TEST F : UNUSUAL NOISE FROM ICC Test Step F1 Test the ICC for any unusual noises or rattles. Is there an unusual noise?
Yes Go to F2. No Retest.
Remove the ICC. Inspect the ICC to determine if the noise source can be located. Can the noise source be located?
Yes Go to F4. No Continue.
Refit the ICC and test for unusual noise or rattle. Ensure that the four yellow mounting clips are fitted to the ICC. Is there an unusual noise?
Yes Replace ICC and retest. No No fault.
F2
F3
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Interior Command Centre
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DIAGNOSIS AND TESTING (Continued) Test Step
Result/Action to Take
Acronyms
F4 Inspect the area causing the unusual noise or rattle. Yes Is the cause an ICC fault? Replace ICC and retest. No Rectify the noise.Replace the original ICC and retest.
TEST G : FAULTY AIR REGISTER Test Step
Result/Action to Take
Acronyms
G1 Check that all mechanical movements of the air register operate correctly. Do all mechanical movements operate correctly?
Yes Go to G2 No Replace air register.
Inspect the air register for physical damage? Is the air register damaged?
Yes Replace air register. No No fault.
G2
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Interior Command Centre
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REMOVAL AND INSTALLATION 4. Remove the clock cover fascia by gently lifting at the point illustrated below using a plastic spatula similar to a credit card and then run your finger Removal along the top edge. 1. Remove PRND dial or manual gear shift cover by NOTE: Using a screw driver or similar may cause lifting the cover evenly at the point illustrated damage to the instrument panel. below.
Interior Command Centre (ICC)
2. Remove the Console Wing retaining screws.
5. Disconnect antenna connector. Disconnect the 4 connectors under the body computer starting from Drivers side, working towards the passenger side. The connector closest to passenger must be removed last or you may hear relay chattering. If the vehicle is fitted with satellite navigation a 5th connector must also be disconnected. NOTE: Arrows indicate connector lock position.
3. Remove both Console Wings.
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Interior Command Centre
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REMOVAL AND INSTALLATION (Continued) 6. Unscrew the top M5 screw located at the top of the ICC.
8. Prise the top structure of the CDU away from the Instrument Panel. There are 4 yellow clips which provide secondary locks into the Instrument Panel. Grip Points
9. Once the clip-points have been disengaged, grip the CDU by its Side Wings and slide it out of the Instrument Panel. 10. Check that all 4 clips are still attached to the ICC. If one or more have separated, they may cause a vehicle rattle & must be removed from the IP and re-attached to the ICC.
7. Unscrew the 4 lower M6 bolts used to secure the ICC to the instrument panel.
11. The ICC must be carefully placed on its side on an appropriate clean, flat surface (less than 5° angle) to avoid scratching the class A surface (any part of the ICC module surface visible in the vehicle) and the screen. Any damage to the class A surface and/or screen during servicing will void warranty. 12. To return only the ICC for warranty, the Body Computer and Antenna Leadwire must be removed together from the ICC and retained with the vehicle. When returning the ICC only, the original antenna and original Body Computer MUST remain with the vehicle.
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Interior Command Centre
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REMOVAL AND INSTALLATION (Continued) Installation 1. Ensure that the Main Audio Self-Aligning Connector is reset. The white centre terminal block should be pulled to its furthermost outer position. A distinctive click will be heard as the connector is reset.
4. When the CDU is in place, tighten the top screw to 2.1 - 4.3 Nm.
2. Locate the ICC Side Spigots into the Crosscar Beam Rails and slide the ICC into the Instrument Panel. Firmly push the ICC to engage the Main Audio Self Aligning Connector. Do not apply excessive force. Do not push the screen or the button panel. If insertion is stopped before the end of travel, remove the ICC and ensure that the Main Audio Self-Aligning Connector is reset. Reset if necessary. Restart installation process. Do not apply excessive loading force.
3. Once the lower half of the ICC is in place, complete the installation by ensuring the 4 trim clips are fully engaged in the Instrument Panel. The clips are located on either side of the clock depression and on either side of the screen. Apply force at these points to ensure the clips are engaged in the Instrument Panel. Do not apply excessive force. Do not push the screen or the button panel.
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Interior Command Centre
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REMOVAL AND INSTALLATION (Continued) 5. Tighten the 4 lower bolts to 8.9 - 12.1 Nm.
7. Prior to replacing clock cover fascia make note of CTS calibration factor is fitted. Then replace the clock cover fascia, console wings and PRND cover.
6. Reconnect Body Computer connectors, starting from passenger’s side and working towards driver’s side, the connector closest to passenger must be inserted first or you may hear relay chattering. Navigation connector (if fitted) and the Radio Antenna connector.
8. If ICC has been replaced then retrain audio and CTS to vehicle. CTS calibration factor stored in BEM. Refer to section 419-10.
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Interior Command Centre
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REMOVAL AND INSTALLATION (Continued)
Service Body Computer (BEM)
4. Disconnect the remaining black connector from Body Computer.
Removal NOTE: The 6 CD Audio Mechanism for Mid and High Premium Sound Audio is very fragile. At no stage can the Audio Module cannot be shocked or excessively vibrated, especially when rotated beyond 90 degrees. If the Audio Module is shocked or excessively vibrated at any stage during removal, service or transport, the Audio warranty is voided. 1. To access the Body Computer, place the ICC on its side on a clean surface to prevent damage to the Class A surface. 2. Remove 4 X M5 screws used to hold the Body Computer to the Audio module. 5. Disconnect the antenna wire from the Audio Module and remove Body Computer together with the antenna cable.
3. If fitted with Satellite Navigation (TFT Screen connection), remove 2 X M3 screws to separate connector holder from Body Computer. 6. If only the Body Computer is to be serviced, remove the antenna cable from the Body Computer, and retain the antenna cable with the vehicle. NOTE: If only the Body Computer is to be returned, ensure that the original Antenna Leadwire remains with the vehicle & is fitted to the replacement Body Computer. If only the ICC is to be returned, ensure that both the original Body Computer and original Antenna Leadwire remain with the vehicle. Replacement Body Computers are NOT be supplied with Antenna Leadwires. Serviced ICC’s are NOT supplied with Body Computers OR Antenna Leadwires.
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Interior Command Centre
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REMOVAL AND INSTALLATION (Continued) 7. Disconnect the remaining black connector from Body Computer. Disconnect the antenna wire from the Audio Module and remove Body Computer together with the antenna cable.
3. If fitted with TFT Screen connection, locate connector holder and tighten 2 X M3 screws to 0.6 Nm.
4. Position Body Computer as shown on Audio Installation Module. NOTE: The 6 CD Audio Mechanism for Mid and High 5. Tighten 4 X M5 screws to 1.0 Nm. Premium Sound Audio is very fragile. At no stage can the Audio Module cannot be shocked or excessively vibrated, especially when rotated beyond 90 degrees. If the Audio Module is shocked or excessively vibrated at any stage during removal, service or transport, the Audio warranty is voided. 1. To install the Body Computer, place the ICC on its side on a clean surface to prevent damage to the Class A surface. 2. Connect black connector to Body Computer.
6. As appropriate, clip or screw the Antenna Cable to the Body Computer using M3 screw tightened to 0.6 Nm.
7. If BEM has been replaced, after ICC is fitted to vehicle, the BEM must be retrained to vehicle using procedure as defined in BEM section (Refer to section 419-10).
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Interior Command Centre
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REMOVAL AND INSTALLATION (Continued)
Service Remote Key Receiver (RKR) Removal 1. Remove 2 X M3 screws used to hold RKR to the Air Register.
Installation 1. Connect the RKR connector.
2. Position RKR on Air Register. 2. Remove RKR.
3. Tighten 2 X M3 screws to 0.5 Nm. 3. Disconnect the RKR connector.
Service Air Register 1. Remove the ICC, as described earlier in this section. 2. Remove the Remote Key Receiver. Refer to Service Remote Key Receiver in this section
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Interior Command Centre
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REMOVAL AND INSTALLATION (Continued) 3. Remove wire harness from Air Register.
Installation 1. Position Air Register.
4. Remove 3 X M5 screws from Air Register. 2. Tighten 3 X M5 screws to 1.5 Nm, top centre screw first.
5. Remove Air Register. 3. Reposition wire harness to Air Register.
4. Install the Remote Key Receiver. Refer to Service Remote Key Receiver in this section.
Cabin Temperature Sensor The Cabin Temperature Sensor is a non servicable component and if faulty, the entire ICC unit as a whole should be replaced after obtaining FCSD approval.
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Parking Aid
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SECTION : 413-13 Parking Aid VEHICLE APPLICATION : 2003.0 BA Falcon CONTENTS
PAGE
DESCRIPTION AND OPERATION Reverse Sensing System ......................................................................................................413-13-2 System Components ............................................................................................................413-13-3 Other Information .................................................................................................................413-13-4 DIAGNOSIS AND TESTING Parking Aid ............................................................................................................................413-13-6 Inspection and Verification ...................................................................................................413-13-6 WDS Test Procedure ...........................................................................................................413-13-6 DTC Chart ............................................................................................................................413-13-6 PID Chart .............................................................................................................................413-13-7 Symptom Chart PAM ...........................................................................................................413-13-8 Connector Circuit Reference ................................................................................................413-13-8 Pinpoint tests ........................................................................................................................413-13-9 REMOVAL AND INSTALLATION Reverse Sensing System ECU ...........................................................................................413-13-15 Sensors ...............................................................................................................................413-13-16
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Parking Aid
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DESCRIPTION AND OPERATION
Reverse Sensing System
The system consists of four ultrasonic sensors mounted in the rear bumper, a controller and an audio warning output that is emitted from the rear audio speakers or a speaker attached to the controller. The system measures the distance to the closest obstacle when reversing and emits a corresponding audible warning. The Reverse Sensing System is an auxiliary system that is not intended to relieve the driver of their responsibility for exercising due care and attention when reversing. The sensors sequentially transmit short ultrasonic pulses (48kHz) then listen for the echo reflected from the detected object. The electronic control unit using triangulation data from the four sensors calculates the distance. Various sound absorbing/reflecting materials or operating conditions can have an effect on the detection range: Ultrasonic waves, heavy rain and/or conditions causing disruptive reflections may lead to objects not being detected by the sensors. In addition, objects that absorb ultrasonic waves may not always be detected due to their unfavorable surface characteristics. Sensors that are covered in dirt, ice or mud may cause the system to detect objects incorrectly. If the vehicle sustains damage to the rear bumper/fascia, leaving it misaligned or bent, the G56520 en
sensing zone may be altered causing inaccurate measurement of obstacles or false alarms. The system is initialized after the ignition is turned on and reverse gear selected. An audible tone will then sound for 0.5 seconds. The Reverse Sensing System will detect objects within the sensor range (within approximately 180cm). The coverage area is decreased around the outer corners of the bumper.
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DESCRIPTION AND OPERATION (Continued) When towing a trailer a switch fitted to the Ford vehicle harness socket is used to disable the system. If using a bicycle rack on the tow bar then a number plate lamp and tail lamp should be fitted and plugged into the trailer socket. This will disable the parking aid, otherwise a disturbance to the sensor field will occur when reverse is engaged triggering the continuous audible warning. Depending on the type of Reverse Sensing System fitted to your vehicle, reverse warning tone system can be increased or decreased in volume. To change the volume of the Reverse Sensing System warning tone, turn off the audio system, then use the volume control to alter warning tone volume. To disable audible warning tone, set volume to minimum.
System Components The system comprises: Qty 1
4
Description Control unit without loud speaker LWB & SWB Fairmont Ghia Control unit with loud speaker Fairmont Ultrasonic sensor 3.1
4
Decoupling ring
4
Housings
4
Retaining Spring
4
Bezel
1
When an object is detected within the sensor range, an intermittent warning tone is emitted. As the distance between the object and the sensors decreases, the warning tone will sound at shorter intervals. A continuous warning tone sounds if the object is within 45cm of the rear bumper. A summary of the warning tones is included in the table below. Warning Range (cm) <=45 <=60 <=80 <=105 <=145 <=185 Hardware Error
Frequency Hz 1200 1200 1200 1200 1200 1200 600
Error Message
600
Ready Tone, reverse engaged
1200
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Tone On
Tone Off
Continuous 75ms 75ms 75ms 75ms 75ms Continuous at power up Continuous at power up 0.7sec
0ms 75ms 150ms 225ms 300ms 375ms
Part Number 3R23 15K866 AA 3R23 BA 3R23 AAW 3R23 AA 3R23 AA 3R23 AA 3R23 *AW
15K866 15K859 15A869 15K861 15A873 15A872
Sensor
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DESCRIPTION AND OPERATION (Continued) Fairmont Module (with speaker)
Sensor Assembly
Item 1 2 3 4 5 6
Description Bezel Bumper Fascia Housing Element Retaining Spring Decoupling Ring Sensor
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Other Information Painting specifications for Ultrasonic sensors The ultrasonic sensors are painted to match the vehicle colour range. Paint is applied to a maximum thickness of 120µm; additional paint must not be applied, as this will effect the operational range of the sensor.
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DESCRIPTION AND OPERATION (Continued) Aftermarket sensors Aftermarket sensors are unpainted and are packed in a cardboard package that exposes the aluminium membrane for spray painting, once painted remove the cardboard surround. The membrane has a yellow chromate finish so that the finish paint can adhere easily. This coating must be clean and dry before paint application. Alcohol may be applied with a clean lint free cloth, ensure the edge of the membrane is also cleaned. Ultrasonic cleaning must not be used. Scratched or damaged membranes are unserviceable; the complete sensor must be replaced. Aftermarket RPA kits comprising: Sensors, decoupling rings, housings, retaining springs, contour rings, ecu and harnesses.
Painting sensors Paint must be applied to a maximum thickness of 120µm with no runs. A waiting time of 24 hours is recommended after painting and drying to ensure a durable finish. The drying temperature must not exceed 105°C with a maximum drying time of 30 minutes, exceeding this will damage / render inoperable the sensor. Sensors are normally housed in a paint box that exposes only the areas to be painted.
Storage of unpainted sensors Storage temperature -57 to 100° Relative humidity 80% Storage duration 6 Months Longer storage times before painting will degrade the chromate surface. Operate a first in, first out parts supply.
ESD Protection All work that is carried where it is possible to touch the connector pins, proper ESD protection procedures must be followed. Eg a grounded wrist strap and an anti static mat.
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DIAGNOSIS AND TESTING WDS Test Procedures (if WDS is available) or Symptom chart and Pinpoint tests (if WDS is not available)
Parking Aid Inspection and Verification 1. Verify the customer’s concern by operating the Reverse Sensing System. 2. Visually inspect the Reverse Sensing System, referring to the following chart: Visual Inspection Chart Mechanical Electrical Damage to bumper Ignition is operational around sensors Check reverse gear is Damage to parcel able to be selected shelf near rear Audio system (rear speakers speakers) are Damage to left hand operational (for AA (passenger) side of modules only) parcel shelf Sensors are Sensors loose in connected to wiring bumper loom Sensors covered in Battery is charged dirt, snow, ice, etc Damage to connectors on sensors or wiring loom Trailer connector plug damaged / missing / loose? NOTE: Sonar parking system will NOT operate if reverse gear can not be selected. 3. If the cause of the customer concern is not visually obvious proceed to:
WDS Test Procedure Self Test and Functional Tests Self test: Using the WDS Tester it is possible to conduct an on demand self test. The pre-conditions for this test are as follows: Ignition key turned to the ignition on position, Vehicle must be in reverse Gear. There must be nothing in the field of view of the sensors. The Self Test checks application data integrity in ECU and performs attenuation test on all four sensors. The test takes approximately 4.5 seconds to run. Any errors are logged as On-demand Diagnostic Trouble Codes (DTCs). If any DTCs are logged please go to the DTC Chart for more information. Diagnostic functions: The Reverse Sensing System Module can be requested to either activate or silence its speaker with diagnostic commands. The speaker can be activated using the WDS Datalogger function r_chime.
Module Configuration The Reverse Sensing Module has several preset configurations to accommodate for various body styles/vehicles. The module can only be configured via the WDS.
DTC Chart DTC B1299
Description Power Supply Sensor Circuit Short To Ground
B1342
ECU is Faulted
B2477
Module Configuration Failure
C1699
Left Rear Sensor Circuit Short to Vbat
C1700
Left Rear Sensor Circuit Failure
C1701
Left Rear Sensor Circuit Fault
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Possible Cause The Sensor Supply circuit is shorted to Ground. ie. The voltage at ECU Pin 5 is < 2 V. Go to PinPoint Test C. There may be an internal fault in the ECU. Retry self test. If DTC is logged again then, replace ECU. ECU configuration has failed or not been set. Configure module using WDS. The Sensor Signal circuit is shorted to supply. ie.The voltage at ECU Pin1 is > 8 V. Go to PinPoint Test A. The Sensor Signal circuit is Open circuit or Shorted to Ground. ie. The voltage at ECU pin 1 is < 2 V. Go to PinPoint Test G. An incorrect signal has been received by the Sensor. There may be an internal fault in the ECU or Sensor. Replace Sensor.
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DIAGNOSIS AND TESTING (Continued) DTC C1702
Description Right Rear Sensor Circuit Short to Vbat
C1703
Right Rear Sensor Circuit Failure
C1704
Right Rear Sensor Circuit Fault
C1705
Left Rear Center Sensor Circuit Short to Vbat
C1706
Left Rear Center Circuit Failure
C1707
Left Rear Center Circuit Fault
C1708
Right Rear Center Sensor Circuit Short to Vbat
C1709
Right Rear Center Sensor Circuit Failure
C1710
Right Rear Center Sensor Circuit Fault
PID Chart PID CCNT
Description Number of Continuous Trouble Codes Set NTCSDT Number of Continuous Trouble Codes Set due to Diagnostic Test PAM_STAT ECU Operating States SYS_OZ System Output Zone BODY_TYPE Body Type FLT_COND Fault Condition TRAILINS Trailer Installed TRANSRV Transmission in Reverse
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Possible Cause The Sensor Signal circuit is shorted to supply. ie. The voltage at ECU Pin4 is > 8 V. Go to PinPoint Test A. The Sensor Signal circuit is Open circuit or Shorted to Ground. ie. The voltage at ECU Pin 4 is < 2 V. Go to PinPoint Test G. An incorrect signal has been received by the Sensor. There may be an internal fault in the ECU or Sensor. Replace Sensor. The Sensor Signal circuit is shorted to supply. ie. The voltage at ECU Pin2 is > 8 V. Go to PinPoint Test A. The Sensor Signal circuit is Open circuit or Shorted to Ground. ie. The voltage at ECU Pin 2 is < 2 V. Go to PinPoint Test G. An incorrect signal has been received by the Sensor. There may be an internal fault in the ECU or Sensor. Replace Sensor. The Sensor Signal circuit is shorted to supply. ie. The voltage at ECU Pin3 is > 8 V. Go to PinPoint Test A. The Sensor Signal circuit is Open circuit or Shorted to Ground. ie. The voltage at ECU Pin 3 is < 2 V. Go to PinPoint Test G. An incorrect signal has been received by the Sensor. There may be an internal fault in the ECU or Sensor. Replace Sensor.
PID FNT_SENS REAR_SENS PARK_SYS DEACTISY MSTATUS LC_DIST RC_DIST LM_DIST RM_DIST VER_MID BODY_MID
Description Parking Aid Front Sensor Status Parking Aid Rear Sensor Status Parking Aid System Status Deactivate System Module Configuration Status Echo value for Left Corner Sensor Echo value for Right Corner Sensor Echo value for Left Middle Sensor Echo value for Right Middle Sensor Module Type ID (Version) Module Type ID (Body Config.)
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Parking Aid
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DIAGNOSIS AND TESTING (Continued) Symptom Chart PAM Condition
Source
Action
No confirmation (roger) tone when reverse gear selected
No power or ground feeds to ECU
Check if vehicle is in Reverse. Check that Audio system is operatonal (if AA module) Check Power and Ground feeds to ECU. Go to PinPoint Test H (BA module only). If AA module, replace ECU.
Speaker beeping continuously.
ECU fault
Check for object behind car. Replace ECU.
No sound output
W iring fault Speaker Fault ECU fault
Check that audio system is operational (if AA module) Go to PinPoint Test H (BA module only). If AA module, replace ECU.
Speaker beeping continuously when trailer connected
W iring fault Speaker Fault Audio fault ECU fault Trailer plug switch fault
Check that Trailer is Plugged into vehicle trailer plug. Go to PinPoint Test L.
Connector Circuit Reference Sensor Connector Diagram
Pin Number(s) 1 2 3
Circuit Designation/Description Normal Condition/Measurement Sensor Signal Sensor Connected and with No object in Sensor’s field of view. Voltage = approx. 7.8V ± 0.5V Sensor Return 0 Volts (Ground) Sensor Power Supply 8 - 8.5 Volts
Module Connector Diagram
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DIAGNOSIS AND TESTING (Continued) Pin Number(s) 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
Circuit Designation/Description 1441 W (SIG_LC) Sensor Signal LH Corner 1442 G-W (SIG_LM) Sensor Signal LH Middle 1443 G (SIG_RM) Sensor Signal RH Middle 1444 L-Y (SIG_RC) Sensor Signal RH Corner 1439 Y-R (Sensor_feed) Sensor Feed 1440 G-Y (GND) Sensor ground NC NC NC NC NC 57 E B (GND) Ground 140D R-B (KL15) Power Reverse switch 1355 BR (Disable) O.C.= trailer not connected NC NC NC NC NC 70 SB-W (Diagnose) Diagnostic Signal NC 1347 B-P (Speaker -) Speaker 1438 G (Speaker +) Speaker +
Normal Condition/Measurement No object in Sensor’s field of view Voltage = approx. 7.8V ± 0.5V As above As above As above 8.5V ±0.5V < 0.5V
< 0.5V + 12V
When Spkr is activated = approx. 2V less than the Spkr Supply Voltage. With Spkr Connected = approx. 1.5V less than VBat
Pinpoint tests PINPOINT TEST A : SENSOR SHORT CIRCUIT TO VBAT Test Step A1
Result / Action to Take
CHECK SENSOR SIGNAL WIRE Remove bumper. Refer to Bumper section for instructions for removal of bumper
Yes
Unplug sensor.
No
Is Voltage < 1V?
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Go to A2
Go to B1
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DIAGNOSIS AND TESTING (Continued) Test Step A2
CHECK SENSOR SIGNAL WIRE WITH SENSOR ATTACHED Yes
Plug in sensor Measure voltage on sensor signal wire.
Go to C1
CHECK SENSOR SIGNAL WIRE WITH SENSOR ATTACHED AND OBJECT DETECTED BY SENSOR Yes
Plug in sensor. Monitor voltage on sensor signal wire. Place your hand in front of the sensor. Does the voltage drop when your hand is placed in front of the sensor?
A4
Go to A3
No
Is voltage > 5V?
A3
Result / Action to Take
Go to A4
No
Internal short circuit in sensor. Replace sensor. Retest system for correct operation.
CHECK CONTINUITY OF THE SENSOR SIGNAL WIRE BETWEEN THE SENSOR AND THE ECU Unplug Reverse Sensing System ECU and sensor Measure resistance of sensor signal wire between sensor connector and ECU connector. Is resistance = open circuit?
Yes
Open circuit in wiring loom. Please refer to schematics section for information on wiring.
No
Replace Reverse Sensing System ECU. Retest for correct operation.
PINPOINT TEST B : SENSOR SHORT CIRCUIT TO VBAT Test Step B1
Result / Action to Take
CHECK RESISTANCE BETWEEN SENSOR SIGNAL WIRE AND SENSOR SUPPLY WIRE Unplug Reverse Sensing System ECU and sensor. Refer to removal and installation section of entry for instructions for accessing module. Measure resistance between sensor signal wire and sensor supply wire Is resistance = open circuit?
Yes
Internal short circuit in ECU. Replace Reverse Sensing System ECU. Retest for correct operation.
No
Short circuit in wiring loom. Check wiring loom for short circuit. Please refer to schematics section for information on wiring.
PINPOINT TEST C : SENSOR POWER SUPPLY SHORT CIRCUIT TO GROUND Test Step C1
Result / Action to Take
CHECK SENSOR SUPPLY WIRE Remove bumper. Refer to Bumper section for instructions for removal of bumper
Yes
Unplug all 4 sensors.
No
Measure voltage on sensor supply wire.
Go to C2
Go to C3
Is Voltage > 7V?
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Parking Aid
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DIAGNOSIS AND TESTING (Continued) Test Step C2
Result / Action to Take
CHECK SENSOR SIGNAL WIRE WITH SENSOR ATTACHED Plug in each sensor ( one at a time ) Measure voltage on sensor supply wire. Is voltage < 5V ?
Yes
Internal short circuit in sensor. Replace sensor. Retest system for correct operation.
No
Retest for correct operation. If the same Fault is constantly present, Replace ECU.
C3
CHECK RESISTANCE BETWEEN SENSOR SUPPLY, SENSOR EARTH WIRE AND VEHICLE GROUND Unplug Reverse Sensing System ECU and sensor. Measure resistance between sensor supply wire, and sensor ground wire and vehicle ground. Is resistance = short circuit?
Yes
Short circuit in wiring loom. Check wiring loom for short circuit. Please refer to schematics section for information on wiring.
No
Go to C4.
C4
CHECK CONTINUITY OF THE SENSOR SUPPLY WIRE BETWEEN THE SENSOR AND THE ECU Unplug Reverse Sensing System ECU and sensor. Measure resistance of sensor supply wire between sensor connector and ECU connector. Is resistance = open circuit?
Yes
Open circuit in wiring loom. Please refer to schematics section for information on wiring.
No
Replace Reverse Sensing System ECU. Retest for correct operation.
PINPOINT TEST D : RESISTANCE TEST Test Step D1
Result / Action to Take
CHECK RESISTANCE BETWEEN SENSOR SIGNAL WIRE AND SENSOR RETURN WIRE (IE.GROUND) Unplug connector from Reverse Sensing System ECU. Refer to removal and installation section of entry for instructions for accessing module. Remove bumper from vehicle. Refer to Bumper section for instructions for removal of bumper Unplug sensor from wiring loom.
Yes
Short circuit in wiring loom. Locate fault and repair harness. Please refer to schematics section for information on wiring.
No
Go to D2
Measure resistance between sensor signal wire and sensor return (ground) wire or vehicle ground. Is measured resistance short circuit?
D2
CHECK CONTINUITY OF SENSOR SIGNAL WIRE Check continuity of sensor signal wire between the Reverse sensing system ECU and sensor connectorS. Is there an open circuit in the harness?
Yes
Fault in wiring loom. Locate fault and repair harness. Please refer to schematics section for information on wiring.
No
Go to C1
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DIAGNOSIS AND TESTING (Continued) PINPOINT TEST E : VOLTAGE TEST Test Step E1
Result / Action to Take
MEASURE VOLTAGE OF SENSOR SIGNAL WIRE AT REVERSE SENSING ECU CONNECTOR Yes
Measure voltage of sensor signal wire at Reverse Sensing ECU connector.
Go to E2
Is voltage >7V?
No
Go to E3
E2
CHECK SENSOR SIGNAL WIRE WITH SENSOR ATTACHED AND OBJECT DETECTED BY SENSOR Yes
Plug in sensor. Measure voltage on sensor signal wire. Place your hand in front of the sensor. Does the voltage vary when your hand is placed in front of the sensor? ( 2V - 8V )
E3
Retest for correct operation. If the same Fault Code is constantly present, Replace ECU.
No
Go to A1
CHECK SENSOR SUPPLY WIRE Measure voltage on sensor supply wire.
Yes
Go to D1
Is Voltage > 7V
No
Go to C1
PINPOINT TEST F : NO SOUND FROM SPEAKER (BA MODULES ONLY) Test Step F1
Result / Action to Take
CHECK SPEAKER SUPPLY WIRE Yes
Measure voltage on speaker supply wire whilst speaker is still connected. Refer to removal and installation section of entry for instructions for accessing module.
Go to H1
Is the measured voltage > 9V?
Go to G1
No
PINPOINT TEST G : NO SOUND FROM SPEAKER — PART 2 Test Step G1
Result / Action to Take
MEASURE FOR SHORT BETWEEN SPEAKER SUPPLY WIRE AND VEHICLE GROUND Unplug Reverse Sensing System ECU and speaker. Measure resistance between speaker supply wire and vehicle ground. Is measured resistance short circuit?
Yes
Fault in wiring loom. Locate fault and repair wiring. Please refer to schematics section for information on wiring.
No
Go to G2
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DIAGNOSIS AND TESTING (Continued) Test Step G2
Result / Action to Take
CHECK CONTINUITY OF SPEAKER SUPPLY WIRE Check continuity of speaker supply wire between the Reverse Sensing System ECU and speaker connectors Is the measured resistance open circuit?
Yes
Fault in wiring loom. Locate fault and repair wiring. Please refer to schematics section for information on wiring.
No
Fault in Reverse sensing system ECU. Replace ECU. Retest for correct operation.
PINPOINT TEST H : NO SOUND FROM SPEAKER - PART 3 Test Step H1
H2
Result / Action to Take
CHECK SPEAKER SIGNAL WIRE Yes
Measure voltage on speaker signal wire whilst speaker is still connected. Refer to removal and installation section of entry for instructions for accessing module.
Go to H2
Is the measured voltage > 9V?
Go to I2
No
CHECK SPEAKER SIGNAL WIRE VOLTAGE WHILST TOGGLING SPEAKER ON AND OFF Measure voltage on the speaker signal wire whilst toggling the speaker on/off using the WDS function test Does speaker voltage drop by at least 2V when speaker is switched on?
Yes
Speaker is faulty. Replace speaker. Retest for correct operation.
No
Go to I1
PINPOINT TEST I : NO SOUND FROM SPEAKER - PART 4 Test Step I1
Result / Action to Take
MEASURE FOR SHORT BETWEEN SPEAKER SIGNAL WIRE AND SPEAKER SUPPLY WIRE Unplug Reverse Sensing System ECU and speaker Measure resistance between speaker signal wire and speaker supply wire. Is measured resistance short circuit?
Yes
Fault in wiring loom. Locate fault and repair wiring. Please refer to schematics section for information on wiring.
No
Go to I3
I2
MEASURE FOR SHORT BETWEEN SPEAKER SUPPLY WIRE AND VEHICLE GROUND Unplug Reverse Sensing System ECU and speaker Measure resistance between speaker supply wire and vehicle ground Is measured resistance short circuit?
Yes
Fault in wiring loom. Locate fault and repair wiring. Please refer to schematics section for information on wiring.
No
Go to G2
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DIAGNOSIS AND TESTING (Continued) Test Step I3
Result / Action to Take
CHECK CONTINUITY OF SPEAKER SIGNAL WIRE Check continuity of speaker supply wire between the Reverse Sensing System ECU and speaker connectors Is the measured resistance open circuit?
Yes
Fault in wiring loom. Locate fault and repair wiring. Please refer to schematics section for information on wiring.
No
Fault in Reverse sensing system ECU. Replace ECU. Retest for correct operation.
PINPOINT TEST J : CHECK TRAILER PLUG SWITCH Test Step J1
CHECK TRAILER PLUG SWITCH SIGNAL WIRE Remove Trailer plug and access wire connections. Measure voltage on Trailer Switch Signal wire. Is Voltage > 9V
J2
W ith the Cover OPEN Is voltage < 1.5V ?
Go to J2
No
Go to J3
Yes
Replace ECU. Retest system for correct operation.
No
Go to J4
CHECK CONTINUITY OF WIRE BETWEEN THE ECU AND TRAILER PLUG Unplug Reverse Sensing System ECU. Measure resistance of signal wire between ECU Trailer input ( Pin 14 ) and the Trailer plug. Is resistance = short circuit?
J4
Yes
CHECK TRAILER PLUG SWITCH Measure voltage on Trailer Plug Switch Signal wire while operating switch by opening and closing the Trailer Plug Connector Cover
J3
Result / Action to Take
Yes
Go to J5
No
Open circuit in wiring loom. Please refer to schematics section for information on wiring.
CHECK GROUND ON SWITCH Measure for continuity to ground between the trailer switch and vehicle ground.
Yes
Is resistance = short circuit?
No
Replace Trailer plug.
Open circuit in wiring loom. Please refer to schematics section for information on wiring.
J5
CHECK CONTINUITY OF WIRE BETWEEN THE ECU AND GROUND Unplug Reverse Sensing System ECU. Measure resistance of signal wire between ECU Trailer input ( Pin 14 ) and Vehicle Ground. Is resistance = short circuit?
G56521 en
Yes
Short circuit in wiring loom. Please refer to schematics section for information on wiring.
No
Replace ECU.
01/2003 2003.0 BA Falcon
413-13-15
Parking Aid
413-13-15
REMOVAL AND INSTALLATION
Reverse Sensing System ECU
5. Remove the electrical connector from module.
Removal 1. Lower the rear seats.
6. Use a stubby phillips head screw driver to remove the two screws, and remove the module. 2. Remove Fir trees on parcel shelf
Installation 1. To install, reverse the removal process. 3. Remove anchor point from top of parcel shelf.
4. Lift up parcel shelf and move it up of the way. For additional information refer to section 501-05.
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01/2003 2003.0 BA Falcon
413-13-16
Parking Aid
413-13-16
REMOVAL AND INSTALLATION (Continued)
Sensors Removal 1. Detach bumper from vehicle. For additional information refer to Bumper in section 501-19.
Item 1 2 3 4 5 6
Description Disconnect wiring from sensor. Remove sensor from holder by gently prying catches on holder. Remove sensor. Remove retaining spring. Pull spring out gently so that spring is not damaged. Remove main body of sensor holder from bezel by gently prying catches on the main body.
G56524 en
Item 7 8 9
Description Remove main body of sensor. Remove bezel. Remove Decoupling ring.
Installation 1. To install, reverse the removal process.
01/2003 2003.0 BA Falcon
414-00-1
Charging System - General Information
414-00-1
SECTION : 414-00 Charging System - General Information VEHICLE APPLICATION : 2003.0 BA Falcon CONTENTS
PAGE
DESCRIPTION AND OPERATION Description and Principles of Operation ................................................................................414-00-2
01/2003 2003.0 BA Falcon
414-00-2
Charging System - General Information
414-00-2
DESCRIPTION AND OPERATION disconnected while the engine is running or damage may occur to the rectifier and/or control box semi-conductor devices. For this reason the practice of using a slave battery to start the The charging system consists of an alternator, engine, then reconnecting the original battery alternator regulator, battery, charge indicator light and whilst the engine is running must not be the necessary wiring to connect to the components. attempted. It is likewise inadvisable to break or All vehicles are equipped with a non-adjustable make any other connections in the alternator integral electronic regulator. Six cylinder vehicles use circuit while the engine is running. a Mitsubishi alternator and eight cylinder vehicles use 5. Alternator Main Output Cable a Visteon alternator. These alternators are essentially the same internally but the exterior casing varies. The cable connecting the alternator and the Both the Mitsubishi (6 Cyl.) and Visteon (8 Cyl.) battery is ’live’ even when the engine is not alternators are three phase alternating current (AC) running. Care must be taken not to earth this generators with integrally mounted diodes that convert live cable if it should ever be removed, or the AC into direct current (DC) suitable for charging damage to the cable will occur. the battery. The alternator must never be run with the Charging system troubles such as low alternator main output cable disconnected either at the output, no alternator output (indicated by the indicator alternator or battery end while the field light being on while the engine is running), or remains energised or the rectifiers may be alternator output voltage too high, require testing of damaged. both the alternator and the alternator regulator. 6. Arc Welding. The possibility of damage to the Alternator regulator failures are usually not recognized semiconductor devices during arc welding except by the direct effect on the alternator output, operations on a vehicle is very slight. However, it and, hence, consequently battery discharge. As the is a worthwhile precaution to isolate the control regulator is the control valve for the alternator, it acts box and alternator by disconnecting their wiring to protect the battery by preventing excessive voltage connectors prior to carrying out any arc welding output. on the vehicles. Discharge of the battery to ground through the alternator is prevented by the diodes of the alternator Removal notes which permit current flow in one direction (to the 7. Ensure battery shroud is not damaged or battery) only. A discharged battery is not always due dislodged during battery removal. to charging system defects. Excessive use of lights 8. Use a universal battery removal tool to enable and accessories while the engine is either off or removal of battery with shroud in situ. running at low idle; corroded battery cables and connectors; low acid level in the battery; or prolonged 9. Ensure shroud and venting pipes are installed correctly. disuse of the battery, which would permit self-discharge; are all possible reasons which should be considered when a battery is run down or low in charge. The procedures which follow will assist in a logical sequence of pinpointing specific troubles. Always determine the cause of failure as well as making the repair. 1. Polarity and connections. The alternator is for use on negative earth electrical systems only. Polarity cannot be reversed by ’flashing’ the field terminals as with the dynamo. Any attempt to do so will damage the alternator. 2. Refitting Vehicle Battery. Reversed battery connections will damage the alternator rectifiers. When refitting, first fit the positive (+) connector to the battery positive (+) terminal. Then fit the negative (-) connector to the negative (-) battery terminal. 3. Battery Charging. First disconnect the battery negative cable, thus isolating the alternator from the battery and external charging equipment. 4. Battery Connections. The battery must never be
Description and Principles of Operation
G34560 en
01/2003 2003.0 BA Falcon
414-01-1
Battery, Mounting and Cables
414-01-1
SECTION : 414-01 Battery, Mounting and Cables VEHICLE APPLICATION : 2003.0 BA Falcon CONTENTS
PAGE
SPECIFICATIONS Specifications .........................................................................................................................414-01-2 DESCRIPTION AND OPERATION Battery and Cables ................................................................................................................414-01-3 DIAGNOSIS AND TESTING Battery ....................................................................................................................................414-01-4 Inspection and Verification ...................................................................................................414-01-4 Pinpoint Tests ......................................................................................................................414-01-4 Component Tests .................................................................................................................414-01-4 REMOVAL AND INSTALLATION Battery and Cables ................................................................................................................414-01-6 Battery Shroud .......................................................................................................................414-01-6
01/2003 2003.0 BA Falcon
414-01-2
Battery, Mounting and Cables
414-01-2
SPECIFICATIONS Battery All vehicles - 53 A/H 12 Volt 520 Cold Cranking (Amps) 95 Reserve Capacity (Min) Torque Specifications Description Battery Hold Down Support Bolt
G86840 en
Nm 2-4
01/2003 2003.0 BA Falcon
414-01-3
Battery, Mounting and Cables
414-01-3
DESCRIPTION AND OPERATION
Battery and Cables Vehicles are equipped with a 12 volt maintenance-free battery. The battery and cable system consists of the following components: battery battery cable assembly battery tray Ford Motor Company strongly recommends that lead-acid batteries be returned to an authorized recycling facility for disposal. WARNING: Keep out of the reach of children. Batteries contain sulfuric acid. Avoid contact with skin, eyes, or clothing. Also, shield your eyes when working near batteries to protect against possible splashing of the acid solution. In case of acid contact with skin or eyes, flush immediately with water for a minimum of 15 minutes and get prompt medical attention. If acid is swallowed, call a physician immediately. Failure to follow these instructions may result in personal injury. WARNING: Batteries normally produce explosive gases which can cause personal injury. Therefore, do not allow flames, sparks or lighted substances to come near the battery. When charging or working near a battery, always shield your face and protect your eyes. Always provide ventilation. WARNING: When lifting a plastic-cased battery, excessive pressure on the end walls could cause acid to spew through the vent caps resulting in personal injury or damage to the vehicle or to the battery. Lift with a battery carrier or with your hands on opposite corners. WARNING: To avoid accidental deployment and possible injury, the backup power supply must be depleted before repairing or installing any front or side air bag supplemental restraint system (SRS) components and before repairing, installing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. Failure to follow these procedures may result in personal injury. Refer to the appropriate vehicle shop manual to determine location of the front air bag sensors. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Failure to follow these instructions may result in personal injury.
G86841 en
01/2003 2003.0 BA Falcon
414-01-4
Battery, Mounting and Cables
414-01-4
DIAGNOSIS AND TESTING
Battery Inspection and Verification 1. Verify the customer concern by operating the system. 2. Visually inspect for obvious signs of mechanical or electrical damage. Visual Inspection Chart Mechanical Electrical Battery Battery cables Battery mounting Battery posts
3. If the inspection reveals obvious concern(s) that can be readily identified, service as required. 4. If an obvious cause for a concern is found, correct the cause before proceeding to the next step. 5. Measure the open circuit battery voltage. If the battery voltage is less than 12.0 volts, test and recharge the battery before continuing with diagnosis 6. If the fault is not visually evident, proceed to the pinpoint test below.
Pinpoint Tests PINPOINT TEST A : BATTERY CONDITION Test Step A1
Result / Action to Take
TEST BATTERY CONDITION NOTE: Failure to fully charge the battery before retesting may cause false readings. Verify the battery condition using the Battery Analyzer. Is the battery OK?
Yes
Does the meter read, Good Battery? Return the battery to service. Refer to Section 414-00. Does the meter read, Good Recharge? Charge the battery and return to service. Refer to Section 414-00. Does the meter read, Good charge & Retest Fully Charge the battery and retest. Refer to Section 414-00.
No
Does the meter read. Replace Battery? INSTALL a new battery. Does the meter read. Bad cell replace? INSTALL a new battery.
Component Tests Battery Tests Tests are made on a battery to determine the state of charge and also the condition. The aim of these tests is to check if the battery is good, needs recharging, or must be replaced. If a battery has failed, is low in charge, or requires water frequently, good service demands that the reason for this condition be found. It may be necessary to follow trouble shooting procedures to locate the cause of the trouble. Hydrogen and oxygen gases are produced during normal battery operation. This gas mixture can explode if flames or sparks are brought near the vent openings of the battery. The sulphuric acid in the battery electrolyte can cause a serious burn if spilled on the skin or spattered in the eyes. It should be flushed away with large quantities of clear water.
Visual Check Some batteries incorporate a single one-piece cover which completely seals the top of the battery and the individual cell connectors. This cover must not be pierced with test probes to perform individual cell tests. Before attempting to test a battery, it is G86842 en
important that it be given a thorough visual examination to determine if it has been damaged. The presence of moisture on the outside of the case and/or low electrolyte level in one or more of the cells are indications of possible battery damage.
Battery Capacity Test A battery can be tested by determining its ability to deliver current. This may be determined by conducting a Battery Capacity Test. A high rate discharge tester (Battery-Starter) in conjunction with a voltmeter is used for this test. 1. Turn the control knob on the Battery-Starter Tester to the OFF position. 2. Turn the voltmeter selector switch to the 16 or 20 volt position. 3. Connect both positive test leads to the positive battery post. The voltmeter clips must contact the battery posts and not the high rate discharge tester clips. Unless this is done the actual battery terminal voltage will not be indicated. 4. Turn the load control knob in a clockwise direction until the ammeter reads approx. three times the ampere hour rating of the battery. (A 61 ampere 01/2003 2003.0 BA Falcon
414-01-5
Battery, Mounting and Cables
414-01-5
DIAGNOSIS AND TESTING (Continued)
5.
6.
7. 8. 9.
10.
11.
hour battery should be tested at 180 ampere load.) With the ammeter reading the required load for 15 seconds, note the voltmeter reading. Avoid leaving the high discharge load on the battery for periods longer than 15 seconds. If the voltmeter reading is 9.6 volts or more, the battery has good output capacity and will readily accept a charge, if required. Check the specific gravity. If the specific gravity reading is 1.230 or below, add water if necessary and charge the battery until it is fully charged. The battery is fully charged when the cells are all gassing freely and the specific gravity ceases to rise for three successive readings taken at hourly intervals. Additional battery testing will not be necessary after the battery has been properly charged. If the voltage reading obtained during the capacity test is below 9.6 volts, check the specific gravity of each cell. If the difference between any two cells is more than 50 points (0.050), the battery is not satisfactory for service and should be replaced. If the difference between cells is less than 50 points (0.050), the battery should be charged according to the charging schedule. In some cases the electrolyte level may be too low to obtain a specific gravity reading. In such cases water should be added until the electrolyte level just covers the ring in the filler well, then charge the battery at 35 amperes for the maximum charging time indicated in specifications, for capacity of the battery being tested. After the battery has been charged, repeat the capacity test. If the capacity test battery voltage is still less than 9.6 volts, replace the battery. If the voltage is 9.6 or more the battery is satisfactory for service. If the battery is found to be discharged only, check for a loose drive belt, loose electrical connections, charging system performance, and make a battery drain test.
Battery Drain Test This test will determine if there is any external load that would cause unwanted battery discharge. Disconnect the battery ground cable and connect the positive lead of a voltmeter to the cable. Connect the negative leads of the voltmeter to the battery negative post. With all circuits off, the meter should read <50mA. Any battery external load will cause the voltmeter to read full battery voltage.
G86842 en
01/2003 2003.0 BA Falcon
414-01-6
Battery, Mounting and Cables
414-01-6
REMOVAL AND INSTALLATION
Battery and Cables Removal 1. Disconnect the battery cables. 2. Remove the battery.
Item 1 2 3
Description Battery Assembly Bolt M8x190 Battery Hold-Down Clamp
3. Remove the hold down bolts. 4. Remove the hold-down. 5. Remove the battery. Installation 1. Reverse removal procedure.
Battery Shroud Removal 1. Remove shroud as shown in figure.
Item 1 2 3
Description Clip Battery Shield Venting Tube
Installation 1. Reverse removal procedure. G86843 en
01/2003 2003.0 BA Falcon
414-02-1
Alternator and Regulator
414-02-1
SECTION : 414-02 Alternator and Regulator VEHICLE APPLICATION : 2003.0 BA Falcon CONTENTS
PAGE
SPECIFICATIONS Specifications ........................................................................................................................414-02-2 DESCRIPTION AND OPERATION Alternator ..............................................................................................................................414-02-3 Description ...........................................................................................................................414-02-3 Operation .............................................................................................................................414-02-3 DIAGNOSIS AND TESTING Alternator and Regulator .......................................................................................................414-02-5 Inspection and Verification ...................................................................................................414-02-5 Symptom Chart ....................................................................................................................414-02-5 Component Tests .................................................................................................................414-02-6 Pinpoint Tests ......................................................................................................................414-02-7 REMOVAL AND INSTALLATION Alternator Installation — 6 Cylinder ....................................................................................414-02-14 Alternator Installation — 8 Cylinder ....................................................................................414-02-14
01/2003 2003.0 BA Falcon
414-02-2
Alternator and Regulator
414-02-2
SPECIFICATIONS General Specifications Description Specification Mitsubishi LC30 6 Cylinder Current Output 110 Amps @ Ambient Temp Set Voltage 14.5 Volts @ 20°C Alternator Speed (RPM) 1300/32 / Output Current (Amps) 2500/81 in Hot 5000/102 Earth Polarity Negative Mass 6.3 kg Regulator Performance - 14.5 +/- 0.3 V Set voltage Regulator Performance - -5 mV/°C Temp Compensation Synthetic Resistance: L 10 - 100 W / 12 V terminal to Battery Speed In Use 1000 - 19000 r / min Rotor Inertia 3.4 x 10-3 kg m2 Pulley Pitch Diameter 51.25 mm +/- 0.5 Rear Fan Diameter 96.5 mm Visteon 8 Cylinder Current Output 130 Amps @ Ambient Temp Set Voltage 14.45 Volts @ 25°C Alternator Speed (RPM) 1300/32 / Output Current (Amps) 2500/81 in Hot 5000/102 Earth Polarity Negative Mass 6.3 kg Regulator Performance - 14.45 +/- 10.3 mV/°C Set voltage Regulator Performance - 14.45 +/- 10.3 mV/°C Temp Compensation Output Ramp Up Time 7s Max Speed In Use 19600 r / min Max Ambient Temp 115 °C Torque Specifications Description Mitsubishi LC30 6 Cylinder Retaining Bracket Bolts Bearing Retainer Plate Through Bolts Pulley Securing Torque Rectifier B+ Nut Mitsubishi LC30 8 Cylinder Retaining Bracket Bolts Bearing Retainer Plate Through Bolts G86726 en
Description Pulley Securing Torque Rectifier B+ Nut
Nm 98 - 137 Nm Riveted 8 +/- 1.2
Nm 25 Nm 7.7 +/- .8 Nm 8.8 +/- .8 Nm 98 - 137 Nm Riveted 8 +/- 1.2 25 Nm 7.7 +/- .8 Nm 8.8 +/- .8 Nm 01/2003 2003.0 BA Falcon
414-02-3
Alternator and Regulator
414-02-3
DESCRIPTION AND OPERATION
Alternator
field coil. This circuit is connected back to the load distribution point and is a protected circuit.
Description Both the Mitsubishi (6 Cyl.) and Visteon (8 Cyl.) alternators are three phase alternating current (AC) generators with integrally mounted diodes that convert the AC into direct current (DC) suitable for charging the battery. The alternator is inherently self current limiting and the diodes (shown in the circuit diagrams in Fig 2 & 4) prevent reverse current flow from the battery. The alternator consists of the following major parts: The Stator: a laminated frame which carries the three phase star connected output winding in slots. The Rotor: comprising the slip rings and field (exciter) windings. It is constructed of interfaced poles or fingers which form alternate north and south poles. The field winding is wound concentric with the shaft inside the claw and has its ends connected to the slip rings. The rectifier pack contains eight output diodes on the six cylinder alternator (as shown in Fig 2), and six output diodes on the eight cylinder alternator (as shown in Fig 4). The diodes are arranged in a three phase bridge connection having three diodes of positive polarity and three diodes of negative polarity. The two end heads carry the ball races. The drive end head incorporates the mounting lug, while the slip ring end head contains the brush gear, regulator and rectifier pack. The electronic regulator is integrated with the alternator assembly. The regulator consists of a static compact assembly, consisting of a Hybrid circuit, transistor and diode, soldered to a printed circuit board. The electronic voltage regulator and the brush gear are an integral assembly mounted on the slip ring end head. The regulator is not adjustable and if tested and found defective it must be replaced.
CAUTION: DO NOT reverse battery sense and warning lamp connections as this will destroy the warning lamp circuitry. If replacing the alternator warning lamp bulb, use of a bulb over 2 Watts capacity may cause voltage regulator failure.
Operation
With the ignition switch turned on and the engine running, the flow of current through the rotor field coil energises the twelve pole rotating electromagnet. The rotation of the energised rotor unit induces an A.C. voltage in the three phase stator winding. This is converted into D.C. by the diode rectifiers and conducted to the B+ terminal. The electronic regulator operation is similar to that of the conventional electro-mechanical regulator in that the field current is varied to maintain the output voltage within close limits. However, switching is performed by a transistor instead of vibrating contacts. The rectifiers, which only conduct current flow in the one direction through the alternator output diodes, prevent the battery (which is directly and permanently connected to the alternator output terminal) from discharging through the alternator. This characteristic of the rectifiers eliminates the need for a cut-out relay, (However, the battery must always be connected with the negative terminal to ground. Failure to connect a battery with the correct polarity will damage the alternator and regulator. Disconnect the negative battery lead when using a battery charger.) As the speed of the rotor increases, the induced voltage in the stator winding increases, causing more current to flow to satisfy the load requirements. However, the inductive reactance of the stator winding provides an automatic self-regulating upper limit on the current output of the alternator. The regulator senses the battery voltage via the B+ Battery Connection battery sense wire and controls this voltage by The B connection is used to connect the alternator to switching the alternator excitation field current on and the Power Distribution Box (PDB) located in the front off. If battery voltage is below regulated voltage, the power transistor is switched on. When the battery right hand side of the engine bay. voltage exceeds the specified limit, the transistor is ’I’ Warning light switched off, causing output voltage to drop. A diode The ’I’ circuit (or ignition circuit), is used to turn on the protects the transistor and regulator circuitry from voltage transients when the field is switched off by the voltage regulator. This circuit is powered up with the transistor. Switching the regulator on and off ensures ignition key in the ON position. This circuit is also used to turn the indicator lamp on, if there is a fault in the output voltage is maintained constant at the required regulated level. the charging system operation or associated wiring circuits. ’A’ Battery sense (V8 only) The ’A’ circuit (or battery sense circuit) is used to sense the battery voltage. This voltage is used by the regulator to determine the alternator output. This circuit is also used to supply power to the alternator G86727 en
01/2003 2003.0 BA Falcon
414-02-4
Alternator and Regulator
414-02-4
DESCRIPTION AND OPERATION (Continued) 8 Cylinder Visteon Alternator
6 Cylinder Mitsubishi Alternator Regulator Circuit Diagram
8 Cylinder Visteon Alternator Regulator Circuit Diagram
6 Cylinder Mitsubishi Alternator
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01/2003 2003.0 BA Falcon
414-02-5
Alternator and Regulator
414-02-5
DIAGNOSIS AND TESTING
Alternator and Regulator Inspection and Verification
Visual Inspection Chart Mechanical Battery Alternator drive belt Alternator pulley
Electrical Battery charge Main Fuse (140A) Electrical connectors Electrical connections Battery charge warning indicator Other electrical systems malfunctions
WARNING: Batteries contain Sulfiric Acid. Avoid contact with skin, eyes, or clothing. Also, shield your eyes when working near batteries to protect against possible splashing of the acid solution. In case of acid contact with skin or eyes, flush immediately with water for a minumumof 15 minutes and get prompt medical. If acid is 3. If the inspection reveals obvious concern(s) that shallowed, call a physician. can be readily identified, service as required. 4. Measure the open circuit battery voltage. If the WARNING: Batteries normally produce battery voltage is less than 12.0 volts, test and explosive gases which can pause personal injuiry. recharge the battery before continuing with Therefore, do not allow flames, sparks or lighted diagnosis. substances to come the near. When charging or 5. Observe charging system warning indicator status working near a battery, always shield your face against the following conditions: and protect your eyes. Always provide ventilation. The charging system warning indicator will illuminate with the ignition switch in RUN and WARNING: When lifting a plastic-cased the engine OFF. battery, excessive pressure on the end walls could cause acid to spew through the vent caps The charging system warning indicator will be resulting injuiry or demage to the vehicle or to the OFF with the engine running. c) The charging battery. Lift with a battery carrier or with your system warning indicator will be OFF with the hands on opposite corners. ignition switch OFF. 1. Verify the customer’s concern by operating the 6. Check the battery voltage before and after starting vehicle to duplicate the concern. the engine to determine if the battery voltage increases. 2. Inspect to determine if one of the following Refer to the Normal Charging System Voltages mechanical or electrical concerns apply: chart.
Symptom Chart Condition
Source
Action
Charging system warning indicator is ON with the engine running (the battery voltage does not increase)
A Circuit 36 (Y/W). Circuit 36 (Y/W). Main Fuse (140 A). I Circuit 904 (GY/R). Voltage Regulator. Alternator
GO to Pinpoint Test A.
Charging system warning indicatoris OFF with the ignition switch inthe RUN position and the engineOFF (battery voltage does notIncrease)
Voltage Regulator connector. I Circuit 904 (GY/R). Main Fuse (140 A). Voltage Regulator. Loose or damaged Alternator. Harness connector
GO to Pinpoint Test B.
Charging system warning indicatoris ON with the engine running andthe battery voltage increases
Alternator. Voltage Regulator
GO to Pinpoint Test C.
Charging system warning indicatoris OFF with the ignition switch inthe RUN position and the engineOFF (battery voltage increases)
Charging system warning indicator lamp bulb. Instrument cluster. Alternator. Voltage Regulator.
GO to Pinpoint Test D.
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01/2003 2003.0 BA Falcon
414-02-6
Alternator and Regulator
414-02-6
DIAGNOSIS AND TESTING (Continued) Condition
Source
Action
Charging system warning indicatoroperates correctly but the batteryvoltage does not increase.
Circuit 36 (Y/W). Main Fuse (140A). Loose or damaged harness connector. Battery cables. Alternator. Voltage regulator
GO to Pinpoint Test E.
The battery is dead or will not staycharged or low battery or alternator voltage
Corroded terminal(s). Loose connection(s). High key-off load. Alternator. Voltage Regulator
GO to Pinpoint Test F.
Charging system warning indicatorflickers/is intermittent .
Loose connection(s). I Circuit loose. A Circuit loose. Alternator. Voltage regulator
Replace/Repair as required.
The system overcharges (batteryvoltage greater than 15.5 volts)
A Circuit 36 (Y/W). Alternator (low output). Voltage regulator. I Circuit 904 (GY/R)
GO to Pinpoint Test G.
Battery leakage or damage
A Circuit 36 (Y/W). Alternator. Voltage regulator. Battery
GO to Pinpoint Test H.
The voltage gauge reads high or low
Alternator (low output). Voltage regulator. Voltage gauge. Instrument cluster/wiring
GO to Pinpoint Test I.
The alternator is noisy
Loose bolts/brackets. Drive belt. Alternator/Pulley
GO to Pinpoint Test J.
Radio interference
Alternator. Wiring/routing. In-vehicle entertainment system
GO to 413-08.
Component Tests Alternator Tests Perform an alternator output test before testing the Voltage Regulator. Use care when connecting any test equipment to the alternator system, as the alternator output terminal is connected to the battery at all times. Alternator Output Test-Off Engine When the alternator output test is conducted off the vehicle, a test bench must be used. Follow the procedure given by the test bench equipment manufacturer. When the alternator is removed from the vehicle for this purpose always disconnect a battery cable as the alternator output connector is connected to the battery at all times. On Engine A variable load such as a Carbon pile rheostat must be available to place across the battery. A switched lamp bank of 800 Watt capacity is a suitable substitute for a carbon pile. All output testing is to be made with the alternator warm. Run alternator on full load for 5 minutes prior to making tests. The regulator cannot be isolated from the circuit when carrying out this test. If rated output is not achieved, the alternator G86728 en
must be removed from the engine for testing of the regulator. 1. 2. 3. 4.
5. 6. 7. 8. 9. 10. 11.
Ensure that the ignition is switched off. Disconnect the battery earth cable. Remove the leads from the alternator main (B+). Connect the + lead of a moving coil 100 amp ammeter to the B + terminal of the alternator. Connect the - lead to the B + terminal in the wiring harness. Connect the positive lead of a good quality voltmeter to the alternator B+ terminal. Connect the negative lead to ground. Connect the battery earth cable. Connect the carbon pile rheostat or the switched lamp bank to the battery terminals. (Ensure that the load control is in the off position). Connect a tachometer to the engine. Start the engine and slowly increase engine speed to obtain 6000 rpm alternator speed. Adjust the carbon pile or lamp bank until a constant voltage of 14.0 is achieved. The ammeter should now register the rated output. 01/2003 2003.0 BA Falcon
414-02-7
Alternator and Regulator
414-02-7
DIAGNOSIS AND TESTING (Continued) 12. Reduce engine speed to idle rpm and remove the 3. Readjust the alternator speed if necessary. battery load. 4. Read the regulator output voltage within one minute and compare with specifications. The CAUTION: Never remove the battery load electronic regulator is temperature compensated while the engine is running at speed. and a decrease in regulated voltage of 0.07V will 13. Switch off the engine and remove the battery occur. earth cable. Terminal A I Alt B+ Batt Eng To 14. Remove the test meters and replace the original Bat Gnd wiring to the alternator. Key OFF 12V 0V 12V 12V 0V 15. Replace the battery earth cable. Should the Key ON 12V 1-3V 12V 12V 0V alternator fail to produce the rated output it must Engine OFF be removed from the vehicle for further tests and repairs. Engine 12- 12- 12-15V 120V running 15V 15V 15V
Voltage Regulator
NOTE: The alternator must always be connected to the battery during testing otherwise the diodes might be damaged. 1. Connect a voltmeter between the B + terminal and the alternator housing. 2. Increase the alternator speed to 6000 rpm. Set the load current to 5 amps.
Pinpoint Tests CAUTION: Do not make jumper connections except as directed. Improper connections may damage the voltage regulator test terminals. CAUTION: Do not allow any metal object to come in contact with the alternator housing and internal diode cooling fins. PINPOINT TEST A : THE CHARGING SYSTEM WARNING INDICATOR IS ON WITH THE ENGINE RUNNING (THE BATTERY VOLTAGE DOES NOT INCREASE) Test Step A1
Result / Action to Take
CHECK CIRCUIT 36 (Y/W) Measure the voltage between the B+ terminal on the alternator Circuit 36 (Y/W).
Yes
Is the voltage equal to battery positive voltage (B+)?
No
Go to A2
REPAIR Circuit 36 (Y/W). Test the system for normal operation.
A2
CHECK CIRCUIT 36 (Y/W) Key in OFF position. Disconnect Alternator connector C161. Measure the voltage between alternator connector Pin C161-A Circuit 36 (Y/W) and ground. Is the voltage equal to battery positive voltage (B+)?
G86728 en
Yes
Go to A3
No
REPAIR Circuit 36 (Y/W). Test the system for normal operation.
01/2003 2003.0 BA Falcon
414-02-8
Alternator and Regulator
414-02-8
DIAGNOSIS AND TESTING (Continued) Test Step A3
CHECK I CIRCUIT 904 (GY/R) FOR AN OPEN Connect Alternator connector C161. Check C390.
Yes
Go to A4
Key in ON position. Measure the voltage between the alternator I - terminal, Circuit 904 (GY/R) and ground. Measure the voltage between the alternator I - terminal, Circuit 904 (GY/R) and ground.
A4
Result / Action to Take
No
Repair Circuit 904 (GY/R) for an open or short. Test the system for normal operation.
CHECK THE ALTERNATOR OUTPUT With the engine running, ground the F pin on the alternator regulator. Does the battery voltage increase and the charging system warning indicator turn off?
Yes
REPLACE the voltage regulator. Test the system for normal operation.
No
REPLACE the alternator. Test the system for normal operation.
PINPOINT TEST B : THE CHARGING SYSTEM WARNING INDICATOR IS OFF WITH THE IGNITION SWITCH IN THE RUN POSITION AND THE ENGINE OFF (BATTERY VOLTAGE DOES NOT INCREASE) Test Step B1
INSPECT ALTERNATOR CONNECTOR C161 Disconnect Alternator connector C161. Check alternator connector for bent, or damaged pins. Ensure connector C390 is installed in PDB. Is the connector OK?
B2
Result / Action to Take
Yes
Go to B2
No
Test the system for normal operation. REPAIR Connector C161 as necessary.
CHECK THE ALTERNATOR GROUNDS Check all ground connections between the alternator voltage regulator Yes and the battery. Go to B3 Are the ground connections OK?
No
REPAIR Connections as necessary. Test the system for normal operation.
B3
CHECK I CIRCUIT 904 (GY/R) Connect Alternator connector C161. Check C390. Key in ON position. Measure the voltage between the alternator I - terminal, Circuit 904 (GY/R) and ground. Is the voltage greater than 1 volt?
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Yes
REPLACE the voltage regulator.
No
Repair Circuit 904 (GY/R) for an open. Test the system for normal operation.
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DIAGNOSIS AND TESTING (Continued) PINPOINT TEST C : THE CHARGING SYSTEM WARNING INDICATOR IS ON WITH THE ENGINE RUNNING (THE BATTERY VOLTAGE INCREASES) Test Step C1
Result / Action to Take
CHECK CONNECTOR C161 Make sure that connector C161 is correctly mated to the alternator and making contact.
Yes
Is the connection OK?
No
Go to C2
REPAIR connector C161 as necessary. Test the system for normal operation.
C2
CHECK THE ALTERNATOR OUTPUT VOLTAGE With the engine running at 2000 rpm, measure the voltage output at the alternator B+ terminal. Is the voltage output less than 16 volts?
Yes
REPLACE voltage regulator. Test the system for normal operation.
No
Go to H1
PINPOINT TEST D : THE CHARGING SYSTEM WARNING INDICATOR IS OFF WITH THE IGNITION SWITCH IN THE RUN POSITION AND THE ENGINE OFF (THE BATTERY VOLTAGE INCREASES) Test Step D1
Result / Action to Take
CHECK THE CHARGING SYSTEM WARNING INDICATOR OPERATION Yes
Key in ON position. Disconnect The alternator connector C161. Ground the alternator connector C161 I circuit with the ignition switch in the RUN position and the engine OFF. Ensure connector C390 is correctly assembled.
Go to D2
No
REPAIR connector C161, I Circuit 904 (GY/R) as necessary. Test the system for normal operation.
Is the warning indicator ON?
D2
CHECK THE ALTERNATOR Connect C161 connector. Observe the warning indicator. Is the warning indicator ON?
Yes
REPLACE the alternator. Test the system for normal operation.
No
REPLACE the voltage regulator. Test the system for normal operation.
PINPOINT TEST E : THE CHARGING SYSTEM WARNING OPERATES CORRECTLY BUT THE BATTERY VOLTAGE DOES NOT INCREASE. Test Step E1
Result / Action to Take
CHECK CIRCUIT 36 (Y/W) Key in ON position. Measure the voltage between the B+ terminal on the alternator Circuit 36 (Y/W). Is the voltage equal to battery positive voltage (B+)?
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Yes
Go to E2
No
REPAIR Circuit 36 (Y/W) as necessary. Test the system for normal operation.
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DIAGNOSIS AND TESTING (Continued) Test Step E2
Result / Action to Take
CHECK THE ALTERNATOR CONNECTORS Check the battery terminals and alternator connectors C161 & C390for corrosion and tightness. Are all the connectors clean and tight?
Yes
Perform the Alternator On-Vehicle Tests; REFER to Component Tests in this section.
No
REPAIR the connectors as necessary. Test the system for normal operation.
PINPOINT TEST F : THE BATTERY IS DEAD OR WILL NOT STAY CHARGED OR LOW BATTERY OR ALTERNATOR VOLTAGE Test Step F1
CHECK THE BATTERY DRAIN Key in OFF position. Make sure that all interior and exterior lamps and switches are off. Check the battery drain. Is the drain greater than 0.5 amps?
F2
Result / Action to Take
Yes
PERFORM Battery - Drain Testing. REFER to Component Tests in this section.
No
Go to F2
CHECK THE ALTERNATOR OUTPUT Check the alternator output. Perform Alternator On-Vehicle Tests; refer to Component Tests in this section.
Yes
Is the alternator OK?
No
Go to F3
REPLACE the alternator. Test the system for normal operation.
F3
CHECK THE BATTERY CONDITION Check the battery capacity. with the Midtronic handheld battery tester. Is the battery OK?
Yes
Go to F4
No
REPLACE the battery. Test the system for normal operation.
F4
CHECK OTHER ELECTRICAL SYSTEMS FOR DRAINS Yes
Check the drains from electronic modules. Perform the test for Battery-Electronic Drains Which Shut Off When the Battery Cable is Disconnected; refer to Component Tests in this section.
RECHARGE the battery. Test the system for normal operation.
Are the electronic modules OK?
No
REPLACE the module or REPAIR the circuit causing the electrical drain as necessary. Test the system for normal operation.
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DIAGNOSIS AND TESTING (Continued) PINPOINT TEST G : THE SYSTEM OVERCHARGES (BATTERY VOLTAGE IS GREATER THAN 15.5 VOLTS) Test Step G1
CHECK FOR A VOLTAGE DROP Key in ON position. Check for voltage drop from the battery positive post and the voltage regulator ’A’ terminal. Is the voltage drop less than 0.5 volts?
G2
With the engine running, turn off all accessories. Does the battery voltage remain less than 15 volts?
Measure the voltage at the voltage regulator F terminal. Does the voltage equal battery voltage?
No
REPAIR Circuit 36 (Y/W) for high resistance as necessary. Test the system for normal operation.
Yes
Go to G3
No
Go to G6
Yes
Go to G5
No
Go to G4
CHECK FOR GROUNDED SLIP RINGS Key in OFF position. Disconnect The alternator connector C161. Remove the voltage regulator from the alternator. Measure the resistance from both alternator slip rings to ground. Is the resistance greater than 1K ohms?
G5
Go to G2
CHECK THE ALTERNATOR FOR LOW VOLTAGE Key in OFF position.
G4
Yes
CHECK THE BATTERY VOLTAGE Increase the engine speed and monitor the voltage at the battery.
G3
Result / Action to Take
Yes
REPLACE the alternator. Test the system for normal operation.
No
REPLACE the voltage regulator. Test the system for normal operation.
CHECK THE WARNING SYSTEM INDICATOR OPERATION With the engine running, increase the engine speed, check the indicator operation and check for a battery voltage increase. Does the battery voltage increase above 15 volts or does the indicator flicker?
Yes
REPAIR circuit 904 (GY/R) as necessary. Test the system for normal operation.
No
REPLACE the alternator. Test the system for normal operation
G6
CHECK THE WARNING SYSTEM INDICATOR OPERATION With the engine running, increase the engine speed, check the indicator operation and check for a battery voltage increase. Does the battery voltage increase above 15 volts or does the indicator flicker?
Yes
REPAIR circuit 904 (GY/R) as necessary. Test the system for normal operation.
No
REPLACE the alternator. Test the system for normal operation.
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DIAGNOSIS AND TESTING (Continued) PINPOINT TEST H : BATTERY LEAKAGE OR DAMAGE Test Step H1
Result / Action to Take
CHECK FOR ACID LEAKAGE OR DAMAGE Check for acid damage to the vehicle harnesses and to the body. Is there acid damage?
Yes
REPAIR the damaged areas as necessary.
No
Go to H2
H2
CHECK THE CHARGING SYSTEM FOR OVERCHARGING With the engine running, turn off all the accessories. Increase the engine speed and monitor the voltage at the battery.
Yes
Does battery voltage increase more than 15 volts?
No
Go to G1
Go to H3
H3
CHECK THE BATTERY MOUNTING Make sure the battery is properly mounted and level in the battery tray.
Yes
Is the battery properly mounted?
No
Go to H4
Install the battery. Test the system for normal operation.
H4
CHECK FOR BATTERY CONTACT Make sure that there are no fasteners or other parts contacting the battery case causing excess pressure. Is there anything contacting the battery case?
Yes
REMOVE or REPOSITION these items as necessary. Test the system for normal operation.
No
Go to H5
H5
CHECK THE BATTERY LEAKAGE OR DAMAGE Check the battery case for damage such as cracks or poor seals.
Yes
The charging system is OK. Test the system for normal operation.
Is the battery OK?
No
REPLACE the battery. Test the system for normal operation.
PINPOINT TEST I : THE VOLTAGE GAUGE READS HIGH OR LOW Test Step I1
Result / Action to Take
CHECK THE BATTERY VOLTAGE With the engine running, turn off all accessories. Increase the engine speed and monitor the voltage at the battery.
Yes
Is the battery voltage more than 15 volts?
No
Go to G1
Go to I2
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DIAGNOSIS AND TESTING (Continued) Test Step I2
Result / Action to Take
CHECK THE VOLTAGE GAUGE OPERATION With the engine running, monitor the voltage gauge reading and the battery voltage.
Yes
Are the voltage readings consistent?
No
The charging system is operating normally.
Check Instrument Cluster section to continue diagnostics.
PINPOINT TEST J : THE ALTERNATOR IS NOISY Test Step J1
CHECK FOR ACCESSORY DRIVE NOISE Check the drive belt for damage and verify the installation. Check the alternator mounting for loose bolts or misalignment. Check for a bent alternator pulley. Is everything OK?
J2
Result / Action to Take
Yes
Go to J2
No
For further diagnostics, refer to the Accessory Drive System section.
SUBSTITUTE A KNOWN GOOD ALTERNATOR Key in OFF position. Install a known good alternator.
INSTALL the original alternator and CHECK other accessories to FIND the cause of the noise.
Start up the engine.
No
Disconnect The alternator connector C161.
Is the noise present with a known good alternator?
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Yes
REPLACE the alternator. RETEST the system for normal operation.
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REMOVAL AND INSTALLATION
Alternator Installation — 6 Cylinder
Alternator Installation — 8 Cylinder
Removal 1. Disconnect the battery ground cable. For additional information, refer to Section 414-01. 2. Remove the Front End Accessories Drive belt, For additional information, refer to Section 303-05. 3. Remove the Nut from connector B on the alternator and remove wiring from alternator.
Removal 1. Disconnect the battery ground cable. For additional information, refer to Section 414-01. 2. Remove the Front End Accessories Drive belt, For additional information, refer to Section 303-05. 3. Remove the Nut on the B connector and remove wiring from Alternator Wiring Harness.
4. Remove the 5 M8 Bolts holding the Alternator in place.
4. Remove the 4 Upper Bracket bolts.
5. Remove the 2 lower retaining bolts and remove the alternator.
5. Remove the Alternator. Installation 1. To reinstall, reverse the Removal Procedure. G86729 en
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SECTION : 415-00 Entertainment System — General Information VEHICLE APPLICATION : 2003.0 BA Falcon CONTENTS
PAGE
DIAGNOSIS AND TESTING Audio System ........................................................................................................................415-00-2 Principles of Operation .........................................................................................................415-00-2 Self Tests .............................................................................................................................415-00-2 Function Tests ......................................................................................................................415-00-2 DTC Chart ............................................................................................................................415-00-3 Symptom Chart ....................................................................................................................415-00-4 PID Chart .............................................................................................................................415-00-5 Service Procedures ..............................................................................................................415-00-6
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DIAGNOSIS AND TESTING Parameter identifiers (PID’s) Module configuration
Audio System Principles of Operation The following diagnostics are available by connecting the WDS tester to the diagnostic link connector located on the right hand side of the fuse box.
Module Configuration The CDU has the following configuration options: Audio security Sonar parking enable/disable on premium sound audio Module configuration is carried out by using the WDS tester.
Self Tests
The WDS tester will support the following modes Self tests Service Procedures (Using the Data Logger function ) Diagnostic trouble codes (DTC’s)
The following tests are carried out within seconds, during the On Demand Self Test. Antenna connection Speaker line short circuit Subwoofer connection Speaker tone test AM signal strength check FM signal strength check Subwoofer speaker short circuit Trip computer data unavailable Invalid vehicle speed data Invalid ambient temperature data
On Demand Self Test Step Test 1 Connect WDS tester Turn radio on Tune FM radio to known station and set one of the presets. Carry out self test 2 Speaker tone test function
3 4
Is DTC logged For AM signal strength tune to known AM station set a preset and repeat the above test
Action —
Listen to speakers. Tone to each speaker is 1.5 sec on and 0.5 sec off. Sequence. Front right > rear right > rear left > front left NOTE: Subwoofer output is not tested Refer to DTC chart —
Function Tests Function test Steering wheel switch test ICC switch test
Description Tests steering wheel switches and wiring and identifies faulty circuit Tests audio switch functionality and identifies faulty switch or function
Input status test Subwoofer Is Subwoofer connected G68759 en
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DIAGNOSIS AND TESTING (Continued) Function test Auxiliary Navigation Sonar parking Phone Multi CD test
Description Is Auxiliary input connected Is Navigation signal present Is Sonar parking aid set Is Phone mute input enabled Checks for presence of CD’s in mechanism
DTC Chart DTC B1342
Description ECU is faulty
Possible Causes Faulty Audio unit
B1318
Battery voltage low
Low system voltage detected.
B2103
Antenna not connected
Antenna connection not made/damaged
B2203
CD error
CD inserted incorrectly, data CD inserted
B2403
Multi CD mechanical error
CD stuck etc.
B2404
Audio steering wheel Audio steering wheel switches faulty switch jammed
B2406
Single CD mechanical error
CD stuck etc.
B2408
Speaker line short
Detects speaker line shorted to ground or B+
B2409
AM tuner fault
No AM signal (Antenna test)
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Action Document and clear the DTC’s. Carry out the self test. If the DTC is registered again replace ICC. Test the system for correct operation. Document and clear the DTC’s. Run vehicle for 2 minutes. If the DTC is registered again check / correct battery. Document and clear the DTC’s. Carry out the self test. If the DTC is registered again refer to Poor radio reception symptom in the symptom chart. Document and clear the DTC’s. Remove all CD’s then reload CD’s and read CM (continuously monitored) DTC’s. If the DTC is registered again refer to CD does not play symptom in the symptom chart. Document and clear the DTC’s. Remove all CD’s then reload 6 CD’s and play each momentarily. Read CM DTC’s. If the DTC is registered again refer to Unable to load / eject CD’s (multi player ) symptom in the symptom chart Document and clear the DTC’s. Read CM DTC’s If the DTC is registered again refer to Steering wheel audio switch not operating symptom in the symptom chart. Document and clear the DTC’s. Remove and then reload CD. Read CM DTC’s. If the DTC is registered again refer to Unable to load / eject CD’s (single player ) symptom in the symptom chart. Document and clear the DTC’s. Carry out the self test. If the DTC is registered again refer to One or more speakers not operating symptom in the symptom chart. Document and clear the DTC’s. Carry out the self test. If the DTC is registered again refer to Poor radio reception symptom in the symptom chart.
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DIAGNOSIS AND TESTING (Continued) DTC B2410
Description FM tuner fault
Possible Causes No FM signal (antenna test)
B2924
Audio button stuck
Audio button jammed
B2922
Auxiliary button stuck Auxiliary button jammed
B2925
Subwoofer speaker short
Subwoofer line shorted to ground or B+
U2014
Audio subwoofer not connected
Subwoofer disconnected/not fitted
B2923
Climate control button stuck.
Climate control button jammed.
B2911
Trip computer data invalid.
Instrument cluster did not have valid data available.
U1900
CAN communication fault.
CAM messages not received.
U2201
Ambient temperature HIM did not have valid data invalid. data available.
Action Document and clear the DTC’s. Carry out the self test. If the DTC is registered again refer to Poor or no radio reception symptom in the symptom chart. Document and clear the DTC’s. Read CM DTC’s. If the DTC is registered again refer to Audio button not working symptom in the symptom chart. Document and clear the DTC’s. Read CM DTC’s. If the DTC is registered again refer to the following symptoms in the symptom chart of ICC diagnostics 413-08. Traction button not working. Trip / Reset button no working. Interior lamp button not working. Lock/Unlock button not working. Document and clear the DTC’s. Read CM DTC’s. If the DTC is registered again refer to Subwoofer not working symptom in the symptom chart. Document and clear the DTC’s. Carry out the self test. If the DTC is registered again refer to Subwoofer not working symptom in the symptom chart. Document and clear the DTC’s. Read CM DTC’s. If the DTC is registered again refer to Climate control button not working symptom in the symptom chart of ICC diagnostics 413-08. Document and clear the DTC’s. Read DTC’s. If the DTC is registered again referto instrument cluster section 413-01. Document and clear the DTC’s. Read DTC’s. If the DTC is registered again referto CAN bus diagnostics section 303-14. Document and clear the DTC’s. Read DTC’s. If the DTC is registered again refer toRefer to HIM section 412-00.
Symptom Chart Condition
Source
Action
Audio button not working.
Low system voltage Internal fault
Service Procedure: Audio Button not working. (Test A)
Navigation not working.
Internal fault Remote control fault Navi module fault Wiring fault
Service Procedure: Navigation not working. (Test J)
Telephone input not working
Internal fault Wiring fault Telephone fault
Service Procedure: Telephone input not working. (Test K)
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DIAGNOSIS AND TESTING (Continued) Condition
Source
Action
Auxiliary input not working
Input fault Wiring fault Source fault
Service Procedure: Auxiliary input not working. (Test L)
Sonar not operating
Internal fault Wiring fault ICC not correctly configured Sonar module fault
Service Procedure: Sonar not operating. (Test M)
ICC does not turn on
Internal fault Wiring fault Speaker fault Antenna fault
Service Procedure: ICC does not operate. (Test E)
Unable to load/eject CDs ( Single CD )
Internal fault Faulty CDs
Service Procedure: Single CD player mechanical fault (Test B)
CD does not play
Internal fault Faulty CD
Service Procedure: CD focus error (Test D)
Poor or no radio reception
Internal fault Wiring fault Antenna fault
Service Procedure: Poor radio reception (Test H)
One or more speakers not operating
Internal fault Speaker fault Wiring fault
Service Procedure: Speaker fault (Test G)
Subwoofer not working
Internal fault Wiring fault Amplifier fault Speaker fault
Service Procedure: Subwoofer fault (Test F)
Steering Wheel audio switch not operating
Internal fault Wiring fault Switch fault
Service Procedure: Audio steering wheel switch not functioning (Test I)
PID Chart Command CCNT NTCSDT AUD_VOL AUSTCRES AUTO_VCG ATNN_RSS AUDIO_SI LCD_SEG SEC_STAT ACM_STAT MOD_ID CONPROV CANDSV VOL_UP VOL_DN SEEK_BTN G68759 en
Description Number of Continuous Trouble Codes Set Number of Trouble Codes Set due to Diagnostic Test Audio Volume Audio Steering Switch Circuit Resistance Automatic Volume Control Gain Antenna Reception Signal Strength Audio Security Identification LCD Segment Display Security Status ECU Operating State Module ID Check Configuration and Programming Version CAN Diagnostic Specification Version (+) Volume button (-) Volume button (+) Seek button
Command MODE_SW NAV_PRES REVRS_INP MENU_SW CLK_DSPL PHONE_AT VOLI_SW VOLD_SW TUNE_UP TUNE_DN SEEK_UP PLUS_SW AM_SWT FM_SWT CD_SWT AUTO_SW EJECT_SW PRE1_SW PRE2_SW PRE3_SW PRE4_SW
Description Mode Switch Navigation Reverse Menu switch Clock Display Enable Status Phone Transceiver Active Volume Increase Switch Volume Decrease Switch Tune Increase Switch Tune Decrease Switch Seek Increase Switch (+) Switch AM Switch FM Switch CD Switch Autoset Eject Preset 1 Switch Preset 2 Switch Preset 3 Switch Preset 4 Switch 01/2003 2003.0 BA Falcon
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DIAGNOSIS AND TESTING (Continued) Command PRE5_SW PRE6_SW POWER_SW SUB_AMP VID_SRC AUD_SR CLK_ODV LOAD_SW LOUD_SW
Description Preset 5 Switch Preset 6 Switch Power Switch Subwoofer Amplifier Video Source Audio Source Clock Overlay Display on Video Load Switch pressed Loudness Switch pressed
Command CD_SLOT6 CD_SLOT5 CD_SLOT4 CD_SLOT3 CD_SLOT2 CD_SLOT1 RUN_POS ACC_POS
Description CD in slot 6 CD in slot 5 CD_SLOT4 CD in slot 3 CD in slot 2 CD in slot 1 Run ACC Position
Service Procedures Service Procedure Audio button not working (Test A) Single CD player mechanical fault (Test B) Multi CD player mechanical fault (Test C) CD focus error (Test D) ICC does not operate (Test E) Subwoofer fault (Test F) Speaker fault (Test G) Poor radio reception (Test H) Audio steering wheel switch not functioning (Test I) Navigation not working (Test J) Telephone input not working (Test K) Auxiliary input not working (Test L) Sonar not operating (Test M)
Description Tests the ICC audio switches for correct operation and identifies a fault. Tests the loading, ejection and operation of the single CD player and identifies a fault. Tests the loading, ejection and operation of the multi CD player and identifies a fault. Tests single and multi CD players for correct operation and identifies a fault. Identifies a fault when the ICC does not operate. Tests the subwoofer system for correct operation and identifies a fault. Tests the speaker system for correct operation and identifies a fault. Tests for poor radio reception and identifies a fault. Tests the audio steering wheel switches for correct operation and identifies a fault. Tests for connection of the navigation system to the ICC and tests the remote control operation.Identifies faults. Checks the telephone input function and identifies a fault. Tests the auxiliary input function and identifies a fault. Tests for operation of the sonar function in a vehicle with sonar fitted and identifies a fault.
TEST A : AUDIO BUTTON NOT WORKING Using the WDS data logger function activate the following acronyms. RUN_POS, ACC_POS, POWER_SW, VOLI_SW, VOLD_SW, SEEK_BTN, MENU_SW, TUNE_UP, TUNE_DN, AM_SWT, FM_SWT, CD_SWT, AUTO_SW, PRE1_SW, PRE2_SW, PRE3_SW, PRE4_SW, PRE5_SW, PRE6_SW, LOUD_SW, LOAD_SW, EJECT_SW Test Step
Result/Action to Take
Acronyms
A1 Turn the ignition on. Check pid’s using data logger. Is the ignition on?
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Yes Go to A2 No Repair faulty ignition system and retest.
RUN_POS
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DIAGNOSIS AND TESTING (Continued) Test Step
Result/Action to Take
Acronyms
A2 Check that the accessories are on.. Check pid’s using data logger Are the accessories on?
Yes Go to A3 No Repair faulty ignition system and retest
Check to see if the ICC audio is turned on. Is the audio on?
Yes Go to A5 No Go to A4
Push the ICC audio power button. Check pid’s using data logger. Does the ICC audio turn on?
Yes Go to A5 No Go to ICC does not turn on symptom in the symptom chart.
Operate each audio switch / knob. Are any switches / knobs sticking or stuck?
Yes Replace ICC and retest. No Continue.
Check that each audio switch / knob operates. Check pid’s using data logger. Does each audio switch / knob operate?
Yes Go to A7 No Replace ICC and retest.
POWER_SW, VOLI_SW, VOLD_SW, SEEK_BTN, MENU_SW, TUNE_UP, TUNE_DN, AM_SWT, FM_SWT, CD_SWT, AUTO_SW, PRE1_SW, PRE2_SW, PRE3_SW, PRE4_SW, PRE5_SW, PRE6_SW, LOUD_SW, LOAD_SW, EJECT_SW
Control the following Pid’s using the WDS data logger function. Check for correct function operation for each switch / knob. Do all functions operate?
Yes Go to A8 No Replace ICC and retest.
As per acronym list step A6.
ACC_POS
A3
A4 POWER_SW
A5
A6
A7
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DIAGNOSIS AND TESTING (Continued) Test Step
Result/Action to Take
Acronyms
A8 Check that the ICC function for each audio switch operates correctly. Do all functions operate?
Yes No fault. ICC functioning correctly. No Replace ICC and retest.
TEST B : SINGLE CD PLAYER MECHANICAL FAULT Using the WDS data logger function activate the following acronyms. RUN_POS, ACC_POS, POWER_SW, CD_SWT, EJECT_SW, CD_SLOT1 Test Step
Result/Action to Take
Acronyms
B1 Turn the ignition on. Check pid’s using data logger. Is the ignition on?
Yes Go to B2 No Repair faulty ignition system and retest.
Check that the accessories are on. Check pid’s using data logger. Are the accessories on?
Yes Go to B3 No Repair faulty ignition system and retest.
Check to see if the ICC audio is turned on. Is the audio on?
Yes Go to B5 No Go to B4
Push the ICC audio power button. Check pid’s using data logger. Does the ICC audio turn on?
Yes Go to B5 No Go to ICC does not turn on symptom in the symptom chart.
POWER_SW
Push the CD button. Check pid’s using data logger. Does the CD button operate?
Yes Go to B6 No Replace ICC and retest.
CD_SWT
Check that the ICC displays "no CD" when the CD button is pressed. Does the ICC display "no CD"
Yes Go to B9 No Go to B7
Press the ICC eject button. Check pid’s using data logger. Does the CD eject button operate?
Yes Go to B8 No Replace ICC and retest.
RUN_POS
B2
B3
B4
B5
B6
B7
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EJECT_SW
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DIAGNOSIS AND TESTING (Continued) Test Step
Result/Action to Take
Acronyms
B8 Check to see if the CD ejected when the eject button was pressed. Check pid’s using data logger. Did the CD eject?
Yes Go to B9 No Replace ICC and retest.
CD_SLOT1
Insert a known good original genuine CD. Ensure that the CD is inserted with the label facing up. Check pid’s using data logger. Is the CD inserted?
Yes Go to B10 No Replace the ICC and retest.
CD_SLOT1
Check that the CD plays correctly. Does the CD play correctly?
Yes Go to B11 No Go to CD does not play symptom in the symptom chart.
Press the ICC eject button. Check pid’s using data logger. Does the CD eject button operate?
Yes Go to B12 No Replace ICC
EJECT_SW
Check to see if the CD ejected when the eject button was pressed. Check pid’s using data logger. Did the CD eject?
Yes No fault. ICC functioning correctly. No Replace ICC and retest.
CD_SLOT1
B9
B10
B11
B12
TEST C : MULTI CD PLAYER MECHANICAL FAULT Using the WDS data logger function activate the following acronyms. RUN_POS, ACC_POS, POWER_SW, CD_SWT, EJECT_SW, LOAD_SWT, CD_SLOT1, CD_SLOT2, CD_SLOT3, CD_SLOT4, CD_SLOT5, CD_SLOT6, PRE6_SW Test Step
Result/Action to Take
Acronyms
C1 Turn the ignition on. Check pid’s using data logger. Is the ignition on?
Yes Go to C2 No Repair faulty ignition system and retest.
RUN_POS
Check that the accessories are on. Check pid’s using data logger. Are the accessories on?
Yes Go to C3 No Repair faulty ignition system and retest.
ACC_POS
Check to see if the ICC audio is turned on. Is the audio on?
Yes Go to C5 No Go to C4
C2
C3
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DIAGNOSIS AND TESTING (Continued) Test Step
Result/Action to Take
Acronyms
C4 Push the ICC audio power button. Check pid’s using data logger. Does the ICC audio turn on?
Yes Go to C5 No Go to ICC does not turn on symptom in the symptom chart.
POWER_SW
Push the CD button. Check pid’s using data logger. Does the CD button operate?
Yes Go to C6 No Replace ICC and retest.
CD_SWT
Check that the ICC displays "NO DISC" when the CD button is pressed. Does the ICCdisplay "NO DISC"
Yes Go to C9 No Go to C7
Press the ICC eject button. Check pid’s using data logger. Does the CD eject button operate?
Yes Go to C8 No Replace ICC and retest.
EJECT_SW
Eject all CD’s from the ICC. Check pid’s using data logger. Did all CD’s eject?
Yes Go to C9 No Replace ICC and retest.
CDSLOT1, CDSLOT2, CDSLOT3, CDSLOT4, CDSLOT5, CDSLOT6
Press the ICC load button. Check pid’s using data logger. Does the CD load button operate?
Yes Go to C9 No Replace ICC
LOAD_SW, PRE6_SW
Load 6 known good original genuine CD’s. Ensure that the CD’s are inserted with the label facing up. Check pid’s using data logger. Did all CD’s load?
Yes Go to C11 No Replace the ICC and retest.
CDSLOT1, CDSLOT2, CDSLOT3, CDSLOT4, CDSLOT5, CDSLOT6
Check that all CD’s play correctly. Do all the CD’s play correctly?
Yes Go to C12 No Go to CD does not play symptom in the symptom chart.
Press the ICC eject button. Check pid’s using data logger. Does the CD eject button operate?
Yes Go to C13 No Replace ICC and retest.
C5
C6
C7
C8
C9
C10
C11
C12
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EJECT_SW
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Entertainment System — General Information
415-00-11
DIAGNOSIS AND TESTING (Continued) Test Step
Result/Action to Take
Acronyms
Yes No fault. ICC functioning correctly. No Replace ICC and retest.
CDSLOT1, CDSLOT2, CDSLOT3, CDSLOT4, CDSLOT5, CDSLOT6
C13 Eject all CD’s from the ICC. Check pid’s using data logger. Did all CD’s eject?
TEST D : CD FOCUS ERROR Using the WDS data logger function activate the following acronyms. RUN_POS, ACC_POS, POWER_SW, CDSLOT1 Test Step
Result/Action to Take
Acronyms
D1 Turn the ignition on. Check pid’s using data logger. Is the ignition on?
Yes Go to D2 No Repair faulty ignition system and retest.
RUN_POS
Check that the accessories are on. Check pid’s using data logger. Are the accessories on?
Yes Go to D3 No Repair faulty ignition system and retest.
ACC_POS
Check to see if the ICC audio is turned on. Check pid’s using data logger. Is the audio on?
Yes Go to D5 No Go to D4
Push the ICC audio power button. Check pid’s using data logger. Does the ICC audio turn on?
Yes Go to D5 No Go to ICC does not turn on symptom in the symptom chart.
Insert a known good original genuine CD. Ensure that the CD is inserted with the label facing up. Check pid’s using data logger. Is the CD inserted?
Yes Go to D6 No Replace the ICC and retest.
Check that the CD plays correctly. Does the CD play correctly?
Yes ICC functioning correctly. No Continue
D2
D3
D4 POWER_SW
D5 CDSLOT_1
D6
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01/2003 2003.0 BA Falcon
415-00-12
Entertainment System — General Information
415-00-12
DIAGNOSIS AND TESTING (Continued) Test Step
Result/Action to Take
Acronyms
D7 Insert the ICC head cleaning CD and operate as per procedures. Remove the head cleaning CD. Insert a known good original genuine CD. Ensure that the CD is inserted with the label facing up. Check pid’s using data logger. Is the CD inserted?
Yes Go to D8 No Replace the ICC and retest.
Check that the CD plays correctly. Does the CD play correctly?
Yes ICC functioning correctly. No Replace ICC and retest.
CDSLOT_1
D8
TEST E : ICC DOES NOT OPERATE Using the WDS data logger function activate the following acronyms. RUN_POS, ACC_POS, POWER_SW Test Step
Result/Action to Take
Acronyms
E1 Turn the ignition on. Check pid’s using data logger. Is the ignition on?
Yes Go to E2 No Repair faulty ignition system and retest.
Check that the accessories are on. Check pid’s using data logger. Are the accessories on?
Yes Go to E3 No Repair faulty ignition system and retest.
Check to see if the ICC audio is turned on. Check pid’s using data logger. Is the audio on?
Yes Go to E5 No Go to E4
Push the ICC audio power button. Check pid’s using data logger. Does the ICC audio turn on?
Yes No fault. ICC functioning correctly. No Continue.
Check to see if the ICC fuse is blown. Is the fuse blown?
Yes Go to E6 No Go to E8
Replace the blown ICC fuse with a new fuse of correct value. Does the fuse blow again?
Yes Go to E7 No Retest ICC
RUN_POS
E2
E3
E4 POWER_SW
E5
E6
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01/2003 2003.0 BA Falcon
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Entertainment System — General Information
415-00-13
DIAGNOSIS AND TESTING (Continued) Test Step
Result/Action to Take
Acronyms
E7 Remove the ICC. Replace the blown ICC fuse with a new fuse of correct value. Does the fuse blow again?
Yes Repair/replace wiring as per wiring procedure Install the ICC and replace blown fuse. Retest ICC. No ICC is faulty. Replace with a new ICC and retest.
Check that the battery voltage is greater than 10.5 Volts with the ignition on. Is the battery voltage greater than 10.5Volts?
Yes Go to E9 No Rectify vehicles power supply and retest.
Remove the ICC. Inspect both halves of the ICC self-aligning connector. Is the self-aligning connector damaged?
Yes Go to E10 No Go to E12
Inspect both halves of the ICC self-aligning connector. Are both halves of the connector damaged?
Yes Replace the ICC.Replace the instrument panel selfaligning connector. No Continue.
Inspect the self- aligning connector on the Instrument panel. Is this half of the connector faulty?
Yes Replace the instrument panel self- aligning connector.Re-fit ICC and retest. No Replace ICC and retest.
Check for a ICC supply voltage of 10.5 Volts minimum at the ICC instrument panel self-aligning connector. Refer to vehicle wiring diagram.
Yes Replace ICC and retest. No Repair wiring to the ICC instrument panel connector and retest.
E8
E9
E10
E11
E12
TEST F : SUBWOOFER FAULT Using the WDS data logger function activate the following acronyms. RUN_POS, ACC_POS, POWER_SW Test Step
Result/Action to Take
Acronyms
F1 Turn the ignition on. Check pid’s using data logger. Is the ignition on?
G68759 en
Yes Go to F2 No Repair faulty ignition system and retest.
RUN_POS
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Entertainment System — General Information
415-00-14
DIAGNOSIS AND TESTING (Continued) Test Step
Result/Action to Take
Acronyms
F2 Check that the accessories are on. Check pid’s using data logger. Are the accessories on?
Yes Go to F3 No Repair faulty ignition system and retest.
Check to see if the ICC audio is turned on. Is the audio on?
Yes Go to F5 No Go to F4
Push the ICC audio power button. Check pid’s using data logger. Does the ICC audio turn on?
Yes Go to F5 No Go to ICC does not turn on symptom in the symptom chart.
Tune to a known radio station. Is the subwoofer speaker working correctly?
Yes No Fault. No Continue.
Check the subwoofer amplifier fuse. Is the fuse OK?
Yes Go to F8. No Continue.
ACC_POS
F3
F4
F5
F6
F7 Remove the faulty fuse and replace with a new fuse Yes of correct value. Go to F8. Does the fuse blow again? No Retest for correct operation. F8 Check the amplifier power and ground connections. Yes Are connections correct? Go to F9 No Repair/replace wiring as per wiring procedureReplace fuse if blown and retest. F9 Check connections between the amplifier and subwoofer speaker. Are connections correct?
G68759 en
Yes Go to F10. No Repair/replace wiring as per wiring procedureReplace fuse if blown and retest.
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415-00-15
Entertainment System — General Information
415-00-15
DIAGNOSIS AND TESTING (Continued) Test Step
Result/Action to Take
Acronyms
F10 Check that the wiring connections between the ICC Yes and amplifier. Go to F11. Are connections correct? No Repair/replace wiring as per wiring procedure Replace fuse if blown and retest. F11 Replace the subwoofer amplifier.Replace the fuse if Yes blown. Original amplifier is faulty. Is the subwoofer speaker working correctly? Retest with a new amplifier. No Refit the original amplifier and continue. F12 Replace the subwoofer speaker. Replace the fuse if blown. Is the subwoofer speaker working correctly?
Yes Original subwoofer is faulty. Retest with a new subwoofer. No Replace the ICC. Refit the original subwoofer speaker. Replace fuse if blown and retest.
TEST G : SPEAKER FAULT Using the WDS data logger function activate the following acronyms. RUN_POS, ACC_POS, POWER_SW Test Step
Result/Action to Take
Acronyms
G1 Turn the ignition on. Check pid’s using data logger.
Yes Go to G2. No Repair faulty ignition system and retest.
RUN_POS
Check that the accessories are on. Check pid’s using data logger. Are the accessories on?
Yes Go to G3. No Repair faulty ignition system and retest.
ACC_POS
Check to see if the ICC audio is turned on. Is the audio on?
Yes Go to G5. No Go to G4.
G2
G3
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Entertainment System — General Information
415-00-16
DIAGNOSIS AND TESTING (Continued) Test Step
Result/Action to Take
Acronyms
G4 Push the ICC audio power button. Check pid’s using data logger. Does the ICC audio turn on?
Yes Go to G5. No Go to ICC does not turn on symptom in the symptom chart.
Cycle the ICC balance and fade controls. Inspect the ICC balance and fade displays. Do the balance and fade displays operate?
Yes Go to G6. No Replace ICC and retest.
Cycle the ICC balance and fade controls. Check for correct operation of all speakers. Do all speakers operate correctly?
Yes No fault. No Continue.
Check vehicle speaker wiring for short to power or ground. Is wiring OK?
Yes Go to G8. No Repair/replace wiring as per wiring procedure
Substitute any faulty speakers with a new speaker. Do all speakers operate correctly?
Yes Original speaker is faulty.Fit new speaker and retest. No Continue.
Remove the ICC. Check for continuity of vehicle speaker wires between the ICC instrument panel connector and any faulty speaker. Refer to wiring diagram. Are connections correct?
Yes Replace ICC and retest. No Repair/replace wiring as per wiring procedure
G5
G6
G7
G8
G9
TEST H : POOR RADIO RECEPTION Using the WDS data logger function activate the following acronyms. RUN_POS, ACC_POS, POWER_SW, ATNN_RSS Test Step
Result/Action to Take
Acronyms
H1 Turn the ignition on. Check pid’s using data logger. Are the accessories on?
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Yes Go to H2 No Repair faulty ignition system and retest.
RUN_POS
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Entertainment System — General Information
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DIAGNOSIS AND TESTING (Continued) Test Step
Result/Action to Take
Acronyms
H2 Check to see if the ICC audio is turned on. Is the audio on?
Yes Go to H4. No Go to ICC does not turn on symptom in the symptom chart.
POWER_SW
Push the ICC audio power button. Check pid’s using data logger. Does the ICC audio turn on?
Yes Go to H4. No Go to ICC does not turn on symptom in the symptom chart.
POWER_SW
H3
H4 Turn on the heater backlight. Check for poor AM and FM radio reception. Check pid’s using data logger. Is the radio reception poor? NOTE: Tinting of the rear window may affect radio reception.
ATNN_RSS
Yes Go to H5. No Go to H6
H5 Check that the rear window FM Antenna and the AM antenna are not damaged. Are the antennas OK?
Yes Go to H6 No Replace / rectify faulty antenna.
Check reception with engine running. Start the vehicles engine. Check pid’s using data logger. Is the radio reception poor?
Yes Go to H7 No Correct operation.
RUN_POS, ATNN_RSS
Check / repair the vehicles suppressor and the antenna module ground connection. Check pid’s using data logger. Is the radio reception poor?
Yes Go to H8. No Fault rectified. Retest ICC.
ATNN_RSS
H6
H7
H8 Check that the on glass antenna module has power Yes connected. Go to H12. Is there power to the module? No Continue. H9 Check the antenna fuse. Is the fuse blown?
Yes Go to H10. No Go to H12.
H10 Remove the faulty fuse and replace with a new fuse Yes of correct rating. Go to H11. Does the fuse blow? No Retest.
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Entertainment System — General Information
415-00-18
DIAGNOSIS AND TESTING (Continued) Test Step
Result/Action to Take
Acronyms
H11 Check for a short in the antenna module wiring. Is the wiring OK?
Yes Replace the antenna module and retest.Ensure that the faulty fuse is replaced. No Repair/replace wiring as per wiring procedureEnsure that the faulty fuse is replaced.
Check the antenna module by substituting with another module. Check pid’s using data logger. Is the radio reception poor?
Yes Install original antenna module and Go to H13. No Original antenna module is faulty.
Check antenna rear coaxial cable and connection at left hand cowl side. Is cable / connection OK.
Yes Go to H14. No Rectify faulty cable / connection and retest.
Remove the ICC. Check that the coaxial cable and connections to the ICC are OK. Is cable / connection OK?
Yes Replace ICC and retest. No Rectify faulty cable / connection and retest.
H12 ATNN_RSS
H13
H14
TEST I : AUDIO STEERING WHEEL SWITCH NOT FUNCTIONING Using the WDS data logger function activate the following acronyms. RUN_POS, ACC_POS, POWER_SW, VOL_UP, VOL_DN, SEEK_BTN, MODE_SW Test Step
Result/Action to Take
Acronyms
I1 Turn the ignition on. Check pid’s using data logger. Is the ignition on?
Yes Go to I2. No Repair faulty ignition system and retest.
RUN_POS
Check that the accessories are on. Check pid’s using data logger. Are the accessories on?
Yes Go to I3. No Repair faulty ignition system and retest.
ACC_POS
Check to see if the ICC audio is turned on. Is the audio on?
Yes Go to I5. No Go to I4.
I2
I3
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Entertainment System — General Information
415-00-19
DIAGNOSIS AND TESTING (Continued) Test Step
Result/Action to Take
Acronyms
I4 Push the ICC audio power button. Check pid’s using data logger. Does the ICC audio turn on?
Yes Go to I5. No Go to ICC does not turn on symptom in the symptom chart.
POWER_SW
Check that each steering wheel audio switch functions correctly. Check pid’s using data logger. Does each switch function correctly?
Yes Correct operation No Continue
VOL_UP, VOL_DN , SEEK_BTN, MODE_SW
Remove steering wheel airbag as per airbag removal procedure. Disconnect audio steering wheel connection. Do switch resistance check Volume- 0 Ohm Volume+ 560 Ohm Seek 1,560 Ohm Media 3,360 Ohm Is switch resistance correct
Yes Go to I7 No Replace switches
Check wiring connection between ICC Instrument panel connector and steering column Is wiring OK?
Yes Go to I8 No Repair/replace wiring as per wiring procedure
Check wiring connection between steering wheel clock spring and audio steering wheel switches. Is wiring OK?
Yes Go to I9 No Repair/replace wiring as per wiring procedure
I5
I6
I7
I8
I9 Remove ICC and check resistance readings at ICC Yes instrument panel connector. Replace faulty ICC with a Are resistance readings correct? new ICC and retest. No Replace original ICC and retest. TEST J : NAVIGATION NOT WORKING Using the WDS data logger function activate the following acronyms. RUN_POS, ACC_POS, POWER_SW, NAV_PRES Test Step
Result/Action to Take
Acronyms
J1 Turn the ignition on. Check pid’s using data logger. Is the ignition on?
G68759 en
Yes Go to J2 No Repair faulty ignition system and retest.
RUN_POS
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Entertainment System — General Information
415-00-20
DIAGNOSIS AND TESTING (Continued) Test Step
Result/Action to Take
Acronyms
J2 Check that the accessories are on. Check pid’s using data logger. Are the accessories on?
Yes Go to J3 No Repair faulty ignition system and retest.
Check to see if the ICC audio is turned on. Is the audio on?
Yes Go to J5 No Go to J4
Push the ICC audio power button. Check pid’s using data logger. Does the ICC audio turn on?
Yes Go to K5 No Go to ICC does not turn on symptom in the symptom chart.
POWER_SW
Turn on the navigation display using the navigation remote control. Check pid’s using data logger. Does the navigation display appear?
Yes ICC functioning correctly. No Continue
NAV_PRES
Select the ICC navigation diagnostics display as per procedures. Does the navigation diagnostics display appear?
Yes Go to J7. No Repeat procedure. Replace ICC if diagnostics screen does not operate.
Check the IR response on the navigation diagnostics display. Does the IR response state OK?
Yes Go to J9 No Continue
Check that the navigation system / wiring is correct as per navigation procedures. Is the system / wiring O.K
Yes Replace ICC and retest. No Rectify faulty system / wiring and retest.
Check that the REM response toggles between OK and NG on the diagnostics display when the remote control is operated. Does the response toggle?
Yes ICC functioning correctly. Refer to navigation diagnostics. No Continue
ACC_POS
J3
J4
J5
J6
J7
J8
J9
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Entertainment System — General Information
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DIAGNOSIS AND TESTING (Continued) Test Step
Result/Action to Take
Acronyms
J10 Check that the REM response toggles between OK Yes and NG using a known good remote control. Original remote control is Does the response toggle? faulty. No Replace ICC and retest. TEST K : TELEPHONE INPUT NOT WORKING Using the WDS data logger function activate the following acronyms. RUN_POS, ACC_POS, POWER_SW, PHONE_AT Test Step
Result/Action to Take
Acronyms
K1 Turn the ignition on. Check pid’s using data logger. Is the ignition on?
Yes Go to K2 No Repair faulty ignition system and retest.
RUN_POS
Check that the accessories are on. Check pid’s using data logger. Are the accessories on?
Yes Go to K3 No Repair faulty ignition system and retest.
ACC_POS
Check to see if the ICC audio is turned on Is the audio on?
Yes Go to K5 No Go to K4
Push the ICC audio power button. Check pid’s using data logger. Does the ICC audio turn on?
Yes Go to K5 No Go to ICC does not turn on symptom in the symptom chart.
POWER_SW
Check that the ICC telephone input function operates when a telephone signal is inputted. Check pid’s using data logger. Does the telephone input function operate?
Yes No fault. ICC functioning correctly. No Continue
PHONE_AT
Check that the telephone input system / wiring is correct as per procedures Is the system / wiring OK?
Yes Replace ICC and retest. No Repair faulty system / wiring and retest.
K2
K3
K4
K5
K6
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Entertainment System — General Information
415-00-22
DIAGNOSIS AND TESTING (Continued) TEST L : AUXILIARY INPUT NOT WORKING Using the WDS data logger function activate the following acronyms. RUN_POS, ACC_POS, POWER_SW, AUD_SR Test Step
Result/Action to Take
Acronyms
L1 Turn the ignition on. Check pid’s using data logger. Is the ignition on?
Yes Go to L2 No Repair faulty ignition system and retest.
RUN_POS
Check that the accessories are on. Check pid’s using data logger. Are the accessories on?
Yes Go to L3 No Repair faulty ignition system and retest.
ACC_POS
Check to see if the ICC audio is turned on. Is the audio on?
Yes Go to L5 No Go to L4
Push the ICC audio power button. Check pid’s using data logger. Does the ICC audio turn on?
Yes Go to L5 No Go to ICC does not turn on symptom in the symptom chart.
POWER_SW
Check that the ICC auxiliary input function operates. Does the auxiliary input function operate?
Yes No fault. ICC functioning correctly. No Continue
AUD_SR
Check that the auxiliary input system / wiring is correct as per procedures. Is the system /wiring OK?
Yes Replace ICC and retest. No Repair faulty system /wiring and retest.
L2
L3
L4
L5
L6
TEST M : SONAR NOT OPERATING Using the WDS data logger function activate the following acronyms. RUN_POS, ACC_POS, POWER_SW, REVRS_INP Test Step
Result/Action to Take
Acronyms
M1 Turn the ignition on. Check pid’s using data logger. Is the ignition on?
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Yes Go to M2 No Repair faulty ignition system and retest
RUN_POS
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Entertainment System — General Information
415-00-23
DIAGNOSIS AND TESTING (Continued) Test Step
Result/Action to Take
Acronyms
M2 Check that the accessories are on. Check pid’s using data logger. Are the accessories on?
Yes Go to M3 No Repair faulty ignition system and retest.
Check to see if the ICC audio is turned on. Is the audio on?
Yes Go to M5 No Go to M4
Push the ICC audio power button. Check pid’s using data logger. Does the ICC audio turn on?
Yes Go to M5 No Go to ICC does not turn on symptom in the symptom chart.
POWER_SW
Check that the rear speakers mute and a sonar beeping alert sounds when the vehicle is placed in reverse. Check pid’s using data logger. Does the sonar operate correctly?
Yes No fault. ICC functioning correctly. No Continue
REVRS_INP
Check that the sonar system / wiring is correct as per procedures. Is the system / wiring OK?
Yes Replace ICC and retest. No Repair faulty system / wiring and retest.
ACC_POS
M3
M4
M5
M6
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01/2003 2003.0 BA Falcon
415-01-1
Audio Unit
415-01-1
SECTION : 415-01 Audio Unit VEHICLE APPLICATION : 2003.0 BA Falcon CONTENTS
PAGE
SPECIFICATIONS Specifications ........................................................................................................................415-01-2 DESCRIPTION AND OPERATION Audio System ........................................................................................................................415-01-3 DIAGNOSIS AND TESTING Audio System ........................................................................................................................415-01-4 REMOVAL AND INSTALLATION Audio System Security ..........................................................................................................415-01-5 Audio Unit .............................................................................................................................415-01-5 Amplifier ................................................................................................................................415-01-5 Steering Wheel Audio Controls .............................................................................................415-01-5 Capacitor ...............................................................................................................................415-01-5 Ground Strap ........................................................................................................................415-01-5
01/2003 2003.0 BA Falcon
415-01-2
Audio Unit
415-01-2
SPECIFICATIONS Torque Specifications Description Intake manifold suppressor bolt Steering wheel switch screws Ground strap belt - engine Ground strap belt - chassis
G73347 en
Nm 19 - 24 1.8 - 2.2 40.3 - 54.7 10.2 - 13.8
01/2003 2003.0 BA Falcon
415-01-3
Audio Unit
415-01-3
DESCRIPTION AND OPERATION
Audio System The audio system consists of the following components: Audio unit Amplifier (where fitted) Steering wheel controls The audio controls on the steering wheel allows the driver to control volume, media selection, memory presets and radio station and CD track seek. The audio controls are located on the left side of the steering wheel. There are 3 audio units available with features as indicated in the following table. Feature AM/FM stereo radio CD player single disc CD player 6 disc in dash 100 watt power output 250 watt power output Subwoofer amplifier Steering wheel remote control: volume, mode, tuner scan & seek & cd track increment Speed dependant volume Speed dependant bass Sound position control Digital signal processing (dsp) studio, stadium, hall CD compression clock Telephone interface and mute Navigation audio interface Sonar parking audio interface Auxillary audio input Output power limiting to 10% thd (total harmonic distortion) System diagnostics
Low Series X X
Mid Series X
High Series X
X
X
X
X
X X X
X
X
X
Vehicles are equipped with 4, 6 or 11 speakers depending on the equipment level. Refer to Section 415-03. The subwoofer amplifier incorporates "thermo protection" which shuts down the output when the luggage compartment temperature exceeds 90°C. This automatically protects the unit from internal damage during times of extreme heat. Should this situation occur, allow the unit to cool down or open the deck lid for a short period. The unit will return to normal operation after the temperature drops to an acceptable level.
X X
X X
X X X
Radio Frequency Interference Suppression The radio ignition interference capacitor reduces interference transmitted through the radio speakers by the engine ignition and electrical system.
X X
X X
X
X
X
X
X
X
X
X X X
X X
X X
X
X
X
Refer to the owners manual for complete operating guidelines. All audio systems include an Auxillary audio input function, where an external device can be connected to provide audio functionality via the vehicle audio
G73348 en
controls. Suitable audio units are portable cassette players, CD players, DVD or MP3 players. For this function to be enabled, an aux jumper harness available through Ford must be connected.
Item 1
Description Interference capacitor attached here
01/2003 2003.0 BA Falcon
415-01-4
Audio Unit
415-01-4
DIAGNOSIS AND TESTING
Audio System Refer to Section 415-00.
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415-01-5
Audio Unit
415-01-5
REMOVAL AND INSTALLATION
Audio System Security WARNING: All audio systems fitted are protected by an electronic security system, which renders it inoperative if removed from its originally fitted vehicle. Owner provided security cards are not required as the audio system links to other electronics in that vehicle. All audio units will be coded when they leave the factory and re-training can only be carried out by using the WDS tester.
3. Remove the steering wheel audio control screws. NOTE: Some steering wheels are leather wrapped and should be protected when removing the steering wheel controls. Remove the steering wheel audio control. Disconnect the electrical connectors.
Audio Unit 1. See information in Section 413-08 for Audio Unit removal and installation.
Amplifier Removal 1. Remove left hand side interior quarter trim. 2. Remove 2 rivets. 3. Remove amplifier and disconnect wiring.
Installation 1. Reverse the removal procedure. NOTE: When reinstalling screws set gap between switch buttons and horn pad to 0.7mm.
Capacitor Removal 1. Follow removal procedure shown in figure.
Item 1 2 3
Description Amplifier Rivets Bracket
Installation 1. Connect wiring to amplifier. 2. Locate amplifier in position. 3. Install 2 rivets. 4. Refit interior quarter trim.
Steering Wheel Audio Controls
Item 1
Description Interference capacitor attached here
Installation 1. Reverse the removal procedure.
Ground Strap Removal 1. Disconnect the battery ground cable. For Removal additional information, refer to Section 414-01. 1. Disconnect the battery cables. For additional 2. Remove the steering wheel air bag. For additional information, refer to Section 414-01. information, refer to Section 501-20B.
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415-01-6
Audio Unit
415-01-6
REMOVAL AND INSTALLATION (Continued) 2. Remove bolts I6
V8
Installation 1. Reverse the removal procedure, torque to specifications.
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01/2003 2003.0 BA Falcon
415-02-1
Antenna
415-02-1
SECTION : 415-02 Antenna VEHICLE APPLICATION : 2003.0 BA Falcon CONTENTS
PAGE
SPECIFICATIONS Specifications ........................................................................................................................415-02-2 DESCRIPTION AND OPERATION Antenna .................................................................................................................................415-02-3 DIAGNOSIS AND TESTING Antenna .................................................................................................................................415-02-4 GENERAL PROCEDURES Antenna Grid Wire Repair .....................................................................................................415-02-5 REMOVAL AND INSTALLATION Antenna — Sedan .................................................................................................................415-02-6 Antenna — Wagon ................................................................................................................415-02-6 Antenna — Ute .....................................................................................................................415-02-6 Antenna Lead — in Cable .....................................................................................................415-02-6
01/2003 2003.0 BA Falcon
415-02-2
Antenna
415-02-2
SPECIFICATIONS Torque Specifications Description Antenna module
G56749 en
Nm 10.2-13.8
01/2003 2003.0 BA Falcon
415-02-3
Antenna
415-02-3
DESCRIPTION AND OPERATION
Antenna All vehicles are equipped with On Glass Antenna’s which consist of the following components: On glass printed elements Amplifier module Cable assemblies Sedan The sedan antenna uses a combination of the heated backlite grid (FM) and several elements on the glass above the heated backlite (AM). The amplifier module is located on the left hand side C pillar structure. Wagon The wagon antenna is located on the left hand rear quarter glass and uses the inner elements for FM and the outer elements for AM. The amplifier module is located on the upper side rail directly above the center of the left hand side quarter glass. Ute The ute antenna uses elements on the backlite as well as the two quarter glass’s. The heated backlite elements are used for FM and the two quarter glass elements as well as the elements above the heated backlite are used for AM. The amplifier module is located on the left hand side quarter panel adjacent to the heated backlite connection. Wiring attached to the quarter trims links the AM elements between the rear and side glass’s. Window Tint Warning Window tinting is not recommended on glass with printed antenna elements. Metallised window tint material significicantly degrades radio reception on both the AM and FM bands. Non metallised dye based tint material is an improvement over metallised tint material but still degrades radio reception.
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415-02-4
Antenna
415-02-4
DIAGNOSIS AND TESTING
Antenna Refer to Section 415-00.
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01/2003 2003.0 BA Falcon
415-02-5
Antenna
415-02-5
GENERAL PROCEDURES
Antenna Grid Wire Repair 1. To maintain optimum radio performance breaks in the heated backlight or antenna elements grids must be repaired. 2. Repair kits are available through automative accessory outlets, and repair instructions must be followed to ensure a satisfactory and permanent fix.
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01/2003 2003.0 BA Falcon
415-02-6
Antenna
415-02-6
REMOVAL AND INSTALLATION
Antenna — Sedan
3. Disconnect the in line trim wiring to module connector.
Removal 1. Remove the left hand side C pillar trim. Refer to Section 501-05/2. 2. Remove the module attachment bolt. 3. Disconnect the coaxial connector, antenna element connector and power connector.
Installation 1. To install, reverse the procedure.
Antenna — Wagon Removal 1. Remove the headliner. Refer to Section 501-05. 2. Remove the module attachment bolt. 3. Disconnect the coaxial connector, antenna element connector and power connector.
Installation 1. To install, reverse the procedure.
Antenna — Ute Removal 1. Disconnect the left hand quarter glass button terminal and the two left hand rear glass terminals. 2. Remove the left hand side quarter panel trim. Refer to Section 501-05. G56753 en
4. Remove the module attachment bolt. 5. Disconnect the coaxial and power connectors. 6. Disconnect the right hand quarter glass button terminal and the right hand rear glass button terminal. 7. Remove the right hand side quarter trim panel. Refer to Section 501-05. Installation 1. To install, reverse the procedure.
Antenna Lead — in Cable Removal 1. Remove the instrument panel. Refer to Section 501-12 2. Remove CDU assembly. Refer to Section 413-08
3. Disconnect the antenna connector from the instrument panel CDU mounting bracket. 4. Remove the antenna cable from the instrument panel assembly. Installation 1. To install, reverse the procedure.
01/2003 2003.0 BA Falcon
415-03-1
Speakers
415-03-1
SECTION : 415-03 Speakers VEHICLE APPLICATION : 2003.0 BA Falcon CONTENTS
PAGE
SPECIFICATIONS Specifications ........................................................................................................................415-03-2 DESCRIPTION AND OPERATION Speakers ...............................................................................................................................415-03-3 Model and Usage .................................................................................................................415-03-3 REMOVAL AND INSTALLATION Speakers — Door Mounted ..................................................................................................415-03-4 Speakers — Package Tray ...................................................................................................415-03-4 Speaker — Package Tray Subwoofer ..................................................................................415-03-4 Speaker — Tweeter A-pillar ..................................................................................................415-03-4 Speaker — Wagon Rear Quarter Panel ...............................................................................415-03-5 Speaker — Ute Rear Quarter Panel .....................................................................................415-03-5
01/2003 2003.0 BA Falcon
415-03-2
Speakers
415-03-2
SPECIFICATIONS Torque Specifications Description Door speakers Package tray speakers excluding subwoofer Wagon quarter panel speakers Subwoofer
G43920 en
Nm 1.2-1.8 1.2-1.8 1.2-1.8 1.5-1.9
01/2003 2003.0 BA Falcon
415-03-3
Speakers
415-03-3
DESCRIPTION AND OPERATION
Speakers The Falcon sedan range has three speaker variants depending on model and option. All speakers are rated at 25 watts nominal with the exception of the subwoofer, which is 150 watts. 4 speaker system for base level audio. 6 speaker system for mid level audio. 11 speaker system for premium audio. The 11 speakers are contained in 7 speaker assemblies. The Falcon wagon range uses a 4 speaker system The Falcon Ute range has 3 speaker variants depending on model and option 2 speaker system for base vehicle. 4 speaker system for mid vehicle. 6 speaker system for mid option audio.
Model and Usage Description Sedan 4 speaker Sedan 6 speaker
Front speakers 1R23-18808-BA 1R23-18808-EA
Rear speakers 1R23-18808-BA 1R23-18808-BA
Premium sound
WR2A-18808-CA
WR2A-18971-FA
Wagon Ute 2 speaker Ute 4 speaker Ute 6 speaker
1R23-18808-BA 1R23-18808-BA 1R23-18808-BA 1R23-18808-EA
1R23-18971-EA — 1R23-18808-GA 1R23-18808-GA
G43921 en
Tweeters — WR2A-18808DA/FA WR2A-18808DA/FA — — — WR2A-18808DA/FA
Subwoofer — — 1R23-18971-GA — — — —
01/2003 2003.0 BA Falcon
415-03-4
Speakers
415-03-4
REMOVAL AND INSTALLATION
Speakers — Door Mounted
Speaker — Package Tray Subwoofer
Removal and Installation 1. Remove the front door trim panel. For additional information refer to Section 501-05.
Removal and Installation 1. Remove the package tray trim panel. For additional information refer to Section 501-05.
Item 1 2
Description Door trim panel Speaker
Item 1 2 3 4 5
Description Package tray Screw Body sheetmetal Speaker Foam gasket
2. Remove the speaker retaining screws. 3. Remove the speaker and disconnect the electrical connector. 4. To install, reverse the procedure 2. Remove the foam gasket located on top of the speaker. Speakers — Package Tray 3. Remove the speaker retaining screws. Removal and Installation 4. Remove the speaker and disconnect the electrical connector. 1. Remove the package tray trim panel. For additional information refer to Section 501-05. 5. To install, reverse the procedure
Speaker — Tweeter A-pillar Removal and Installation 1. Remove the A-pillar trim. For additional information refer to Section 501-05.
Item 1 2
Description Package tray Speaker
2. Remove the speaker retaining screws. 3. Remove the speaker and disconnect the electrical connector. 4. To install, reverse the procedure
G43922 en
Item 1 2
Description A-Pillar trim panel Dashboard 01/2003 2003.0 BA Falcon
415-03-5
Speakers
415-03-5
REMOVAL AND INSTALLATION (Continued) Item 3 4 5
Description Rivet Tweeter Body sheetmetal
2. Remove the rivet attaching the tweeter bracket to the sheetmetal . 3. Remove the speaker and disconnect the electrical connector. 4. To install, reverse the procedure
Speaker — Ute Rear Quarter Panel Removal and Installation 1. Remove the quarter trim panel. For additional information refer to Section 501-05.
Speaker — Wagon Rear Quarter Panel Removal and Installation 1. Remove the C pillar to quarter panel trim. For additional information refer to Section 501-05.
Item 1 2 3 4
Description Quarter trim panel Screw Body sheetmetal Speaker
2. Remove the speaker retaining screws. 3. Remove the speaker and disconnect the electrical connector . 4. To install, reverse the procedure Item 1 2 3 4
Description Screw Electrical connector Body sheetmetal Speaker
2. Remove the speaker retaining screws. 3. Remove the speaker and disconnect the electrical connector. 4. To install, reverse the procedure
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01/2003 2003.0 BA Falcon
417-01-1
Exterior Lighting
417-01-1
SECTION : 417-01 Exterior Lighting VEHICLE APPLICATION : 2003.0 BA Falcon CONTENTS
PAGE
SPECIFICATIONS Specifications .........................................................................................................................417-01-3 DESCRIPTION AND OPERATION Exterior Lighting .....................................................................................................................417-01-4 Twilight Sensor/Sun Load Sensor ........................................................................................417-01-4 DIAGNOSIS AND TESTING Headlamps .............................................................................................................................417-01-5 Connector Circuit Reference ................................................................................................417-01-5 Inspection and Verification ...................................................................................................417-01-8 Symptom Chart ....................................................................................................................417-01-8 Pinpoint Tests ......................................................................................................................417-01-9 Turn Signal and Hazard Lamps ...........................................................................................417-01-15 Connector Circuit Reference ..............................................................................................417-01-15 Inspection and Verification .................................................................................................417-01-20 Symptom Chart ..................................................................................................................417-01-20 Pinpoint Tests ....................................................................................................................417-01-20 Stop Lamps ..........................................................................................................................417-01-23 Connector Circuit Reference ..............................................................................................417-01-23 Inspection and Verification .................................................................................................417-01-27 Symptom Chart ..................................................................................................................417-01-27 Pinpoint Tests ....................................................................................................................417-01-27 Fog Lamps ...........................................................................................................................417-01-30 Connector Circuit Reference ..............................................................................................417-01-30 Inspection and Verification .................................................................................................417-01-31 Symptom Chart ..................................................................................................................417-01-32 Pinpoint Tests ....................................................................................................................417-01-32 Parking, Rear and License Lamps .......................................................................................417-01-34 Connector Circuit Reference ..............................................................................................417-01-34 Inspection and Verification .................................................................................................417-01-39 Symptom Chart ..................................................................................................................417-01-39 Pinpoint Tests ....................................................................................................................417-01-40 Reverse Lamps ....................................................................................................................417-01-42 Connector Circuit Reference ..............................................................................................417-01-42 Inspection and Verification .................................................................................................417-01-45 Symptom Chart ..................................................................................................................417-01-45 Pinpoint Tests ....................................................................................................................417-01-45 GENERAL PROCEDURES Headlamp Adjustment ..........................................................................................................417-01-48 REMOVAL AND INSTALLATION Headlamp Assembly ............................................................................................................417-01-52 Headlamp Bulb — High Beam H7 .......................................................................................417-01-52 Headlamp Bulb — Low Beam H4 ........................................................................................417-01-52 Turn Signal Bulb ..................................................................................................................417-01-53 01/2003 2003.0 BA Falcon
417-01-2
Exterior Lighting
417-01-2
(Continued) Parklamp Bulb ......................................................................................................................417-01-53 Auxiliary Lamp .....................................................................................................................417-01-53 Auxiliary Lamp Bulb .............................................................................................................417-01-53 Fog Lamp .............................................................................................................................417-01-54 Fog Lamp Bulb .....................................................................................................................417-01-54 Tail Lamp Assembly — Sedan ............................................................................................417-01-54 Tail Lamp Assembly — Wagon ...........................................................................................417-01-55 Tail Lamp, Reverse Lamp and Rear Indicator Bulb — Sedan And Wagon .........................417-01-55 Tail Lamp Assembly — Style Side Box ...............................................................................417-01-55 Rear Light Bulbs Replacement — Style Side Box ...............................................................417-01-56 Reverse Light Replacement — Style Side Box ...................................................................417-01-56 Tail Lamp Assembly — Tray ................................................................................................417-01-56 Rear Light Bulbs Replacement — Cable/Chassis and Tray ................................................417-01-57 Licence Plate Lamp Assembly .............................................................................................417-01-57 Licence Plate Bulb ...............................................................................................................417-01-58 Rear Licence Plate Lamp Replacement — Style Side Box .................................................417-01-58 Rear Licence Plate Lamp Replacement — Chassis/Cab and Tray .....................................417-01-58 Side Indicator Lamps ...........................................................................................................417-01-58 High Mount Stop Lamp — Sedan (Except LWB) .................................................................417-01-59 High Mount Stop Lamp — XR Series Sedan ......................................................................417-01-59 High Mount Stop Lamp Bulb — Wagon ...............................................................................417-01-59 High Mount Stop Lamp — LWB ...........................................................................................417-01-60 Twilight Sensor/Sun Load Sensor ........................................................................................417-01-60
01/2003 2003.0 BA Falcon
417-01-3
Exterior Lighting
417-01-3
SPECIFICATIONS BULB USAGE UNIT Park Lamp Auxiliary Lamp High/Low Beam High Beam Fog Lamp (XR) Turn Signal Side Indicator Stop/Tail Lamp High Mount Stop Lamp High Mount Stop Lamp (XR, rear spoiler option & LWB) Licence Plate Lamp Reverse Lamp Luggage Compartment Interior Dome Lamp Front Reading Lamps Front Footwell Lamp Rear Reading Lamps Rear Centre Console Lamp Glove Compartment Cigarette Lighter Door Mounted Interior Lamp Instrumentation / Display / Warning Lamps Automatic Transmission Control Indicator
TYPE 5W wedge 5W wedge Cool Blue 60/55W H4 55W H7 55W H3 amber 21W amber 5W wedge 21/5W 21cp or 18 W wedge Sealed LED
Torque Specifications Description Head lamp Bolts Tail lamp Screws (Sedan & Wagon) Tail lamp screws (Style Side Box Ute) Position Lamp (Ghia, Fairlane & LTD)
G86726 en
5W wedge 21W 10W 10W 5W 3W 5W 3W 4W 2W 3W Service by Technician Service by Technician
Nm 3.2-4.5 2.5-2.9 4.5-6.3 0.5
01/2003 2003.0 BA Falcon
417-01-4
Exterior Lighting
417-01-4
DESCRIPTION AND OPERATION
Exterior Lighting The exterior lighting consists of the following: headlamps side lamps/front turn signal lamps rear lamps high-mounted stop lamps fog lamps parking lamps reversing lamps license plate lamps fog lamp switch multifunction switch brake pedal position (BPP) switch The headlamp switch is integrated into the multifunction switch.
Twilight Sensor/Sun Load Sensor The combined twilight and sun load sensor is contained in a compact package, which is installed on the instrument panel of a vehicle. It measures both the sunlight intensity and twilight. The twilight sensor provides the information about low light conditions and is used to control automatic headlights (where fitted). The Sun Load sensor is used by the automatic climate control system, to adjust the ACC settings for different sun intensity levels.
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01/2003 2003.0 BA Falcon
417-01-5
Exterior Lighting
417-01-5
DIAGNOSIS AND TESTING
Headlamps Connector Circuit Reference
C-159 RH High Beam Headlamp
Pin Number(s) 1 2
Circuit Designation/Description 12A (G-O) RH high beam headlamp power input Circuit 57AJ (B) RH high beam headlamp ground
Normal Condition/Measurement 0 voltage, less than 5 ohms between RH high beam headlamp and high beam headlamp relay 0 voltage, less than 5 ohms between RH high beam headlamp and chassis ground
C-159 RH Low Beam Headlamp
Pin Number(s) 1 2 3
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Circuit Designation/Description 12C (G-O) RH high beam headlamp power input 13A (R-B) RH low beam headlamp power input Circuit 57AJ (B) RH low beam headlamp ground
Normal Condition/Measurement 0 voltage, less than 5 ohms between RH low beam headlamp and high beam headlamp relay 0 voltage, less than 5 ohms between RH low beam headlamp and low beam headlamp relay 0 voltage, less than 5 ohms between RH low beam headlamp and chassis ground
01/2003 2003.0 BA Falcon
417-01-6
Exterior Lighting
417-01-6
DIAGNOSIS AND TESTING (Continued) C-160 LH High Beam Headlamp
Pin Number(s) 1 2
Circuit Designation/Description 12D (G-O) LH high beam headlamp power input Circuit 57AC (B) LH high beam headlamp ground
Normal Condition/Measurement 0 voltage, less than 5 ohms between LH high beam headlamp and high beam headlamp relay 0 voltage, less than 5 ohms between LH high beam headlamp and chassis ground
C-160 LH Low Beam Headlamp
Pin Number(s) 1 2 3
G86728 en
Circuit Designation/Description 12E (G-O) LH high beam headlamp power input 13C (R-B) LH low beam headlamp power input Circuit 57AD (B) LH low beam headlamp ground
Normal Condition/Measurement 0 voltage, less than 5 ohms between LH low beam headlamp and high beam headlamp relay 0 voltage, less than 5 ohms between LH low beam headlamp and low beam headlamp relay 0 voltage, less than 5 ohms between LH low beam headlamp and chassis ground
01/2003 2003.0 BA Falcon
417-01-7
Exterior Lighting
417-01-7
DIAGNOSIS AND TESTING (Continued) C-163 Power Distribution Box (PDB)
Pin Number(s) 1 2 3 4 5 6
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Circuit Designation/Description Circuit 18 (O) Multifunction switch low beam headlamp input Circuit 20 (G-R) Multifunction switch high beam headlamp input 12B (G-O) RH high beam headlamp power input Circuit 12G (G-O) LH High beam headlamp power input 13A (RG-B) RH low beam headlamp power input 13C (R-B) LH low beam headlamp power input
Normal Condition/Measurement 0 voltage, less than 5 ohms between Multifunction switch and low beam headlamp relay 0 voltage, less than 5 ohms between Multifunction switch and high beam headlamp relay 0 voltage, less than 5 ohms between RH high beam headlamp and high beam headlamp relay 0 voltage, less than 5 ohms between RH low beam headlamp and low beam headlamp relay 0 voltage, less than 5 ohms between LH high beam headlamp and high beam headlamp relay 0 voltage, less than 5 ohms between LH low beam headlamp and low beam headlamp relay
01/2003 2003.0 BA Falcon
417-01-8
Exterior Lighting
417-01-8
DIAGNOSIS AND TESTING (Continued) C-167 Multifunction Switch
Pin Number(s) 1 2 3
Circuit Designation/Description Circuit 18 (O) Multifunction switch low beam headlamp input Circuit 20 (G-R) Multifunction switch high beam headlamp input Circuit 57CL (B) Multifunction switch ground
Normal Condition/Measurement 0 voltage, less than 5 ohms between Multifunction switch and low beam headlamp relay 0 voltage, less than 5 ohms between Multifunction switch and high beam headlamp relay 0 voltage, less than 5 ohms between Multifunction switch and chassis ground
Inspection and Verification Visual Inspection Chart Mechanical Multifunction switch
G86728 en
Electrical Power Distribution Box (PDB): fuse 15 (15A) fuse 16 (15A) fuse 24 (15A) fuse 25 (15A) relay 4 (40A) relay 5 (40A) Circuitry Lamp bulbs
01/2003 2003.0 BA Falcon
417-01-9
Exterior Lighting
417-01-9
DIAGNOSIS AND TESTING (Continued) Symptom Chart Condition
Source
Action
Both headlamps are inoperative
Battery Circuitry Multifunction switch C-167
Go to PinPoint Test A
The low beams are inoperative
PDB: relay 5 Circuitry Multifunction switch C-167
Go to PinPoint Test B
The high beams are inoperative
PDB: relay 4 Circuitry Multifunction switch C-167
Go to PinPoint Test C
One low beam headlamp is inoperative
PDB: fuse 24 (15A) fuse 25 (15A) Circuitry Headlamp bulb
Go to PinPoint Test D
One high beam headlamp is inoperative
PDB: fuse 15 (15A) fuse 16 (15A) Circuitry Headlamp bulb
Go to PinPoint Test E
The headlamps are on continuously
PDB: relay 4 relay 5 Circuitry Multifunction switch C-167
Go to PinPoint Test F
The flash-to-pass feature is inoperative
Multifunction switch C-167
Perform the Multifunction switch testing in Section 211-05. Test the system for normal operation.
Pinpoint Tests Both headlamps are inoperative Possible causes: Battery Multifunction Switch C-167 Circuit 57CL (B) open PINPOINT TEST A : BOTH HEADLAMPS ARE INOPERATIVE Test Step A1
Result / Action to Take
CHECK THE MULTIFUNCTION SWITCH GROUND Disconnect: Multifunction switch C-167. Measure the resistance between Multifunction switch C-167, circuit 57CL (B), harness side and ground. Is the resistance less than 5 ohms?
Yes
Perform the Multifunction switch testing in Section 211-05. Test the system for normal operation.
No
Repair circuit 57CL (B). Test the system for normal operation.
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01/2003 2003.0 BA Falcon
417-01-10
Exterior Lighting
417-01-10
DIAGNOSIS AND TESTING (Continued) The low beams are inoperative
Circuit 13 (R-B) open or short to ground
Possible causes: Low beam headlamp relay Circuit 18 (O) open Multifunction Switch C-167 PINPOINT TEST B : THE LOW BEAMS ARE INOPERATIVE Test Step B1
Result / Action to Take
CHECK CIRCUIT 13 (R-B) FOR A SHORT TO GROUND Disconnect: RH low beam headlamp C-159 or LH low beam headlamp C-160. Measure the resistance between RH low beam headlamp C-159, circuit 13A (R-B), harness side or LH low beam headlamp C-160, circuit 13C (R-B), harness side and ground.
Yes
Repair circuit 13 (R-B). Test the system for normal operation.
No
Go to B2
Is the resistance less than 5 ohms?
B2
CHECK CIRCUIT 13 (R-B) FOR AN OPEN Disconnect: Low beam headlamp relay, PDB C-163 relay 5 (40A). Measure the resistance between RH low beam headlamp C-159, circuit 13A (R-B), harness side or LH low beam headlamp C-160, circuit 13C (R-B), harness side and low beam headlamp relay, PDB C-163 relay 5 (40A), circuit 13 (R-B), harness side.
Yes
Go to B3
No
Repair circuit 13 (R-B). Test the system for normal operation.
Is the resistance less than 5 ohms?
B3
CHECK CIRCUIT 18 (O) FOR AN OPEN Yes
Disconnect: Multifunction switch C-167. Measure the resistance between the low beam headlamp relay, PDB C-163 relay 5 (40A), circuit 18 (O), harness side and Multifunction switch C-167, circuit 18 (O), harness side. Is the resistance less than 5 ohms?
B4
Go to B4
No
Repair circuit 18 (O). Test the system for normal operation.
CHECK THE MULTIFUNCTION SWITCH Perform the Multifunction switch testing in Section 211-05. Is the Multifunction switch operating correctly?
Yes
Replace the low beam headlamp relay Test the system for normal operation
No
See Multifunction switch in Section 211-05.
The high beams are inoperative
Circuit 12 (G-O) open or short to ground
Possible causes: Headlamp high beam relay Circuit 20 (G-R) open Multifunction Switch C-167
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01/2003 2003.0 BA Falcon
417-01-11
Exterior Lighting
417-01-11
DIAGNOSIS AND TESTING (Continued) PINPOINT TEST C : THE HIGH BEAMS ARE INOPREATIVE Test Step C1
Result / Action to Take
CHECK CIRCUIT 12 (G-O) FOR A SHORT TO GROUND Disconnect: RH high beam headlamp C-159 or LH high beam headlamp C-160. Measure the resistance between RH high beam headlamp C-159, circuit 12A (G-O), harness side or LH high beam headlamp C-160, circuit 12C (G-O), harness side and ground.
Yes
Repair circuit 12 (G-O). Test the system for normal operation.
No
Go to C2
Is the resistance less than 5 ohms?
C2
CHECK CIRCUIT 12 (G-O) FOR AN OPEN Disconnect: Headlamp high beam relay, PDB C-163 relay 4 (40A). Measure the resistance between RH high beam headlamp C-159, circuit 12A (G-O), harness side or LH high beam headlamp C-160, circuit 12C (G-O), harness side and headlamp high beam relay, PDB relay 4 (40A), circuit 12 (G-O), harness side.
Yes
Go to C3
No
Repair circuit 12 (G-O). Test the system for normal operation.
Is the resistance less than 5 ohms?
C3
CHECK CIRCUIT 20 (G-R) FOR AN OPEN Disconnect: Multifunction Switch C-167. Measure the resistance between the headlamp high beam relay, PDB C-163 relay 4 (40A), circuit 20 (G-R), harness side and Multifunction switch C-167, circuit 20 (G-R, harness side. Is the resistance less than 5 ohms?
C4
Yes
Go to C4
No
Repair circuit 20 (G-R). Test the system for normal operation.
CHECK THE MULTIFUNCTION SWITCH Perform the Multifunction switch testing in Section 211-05. Is the Multifunction switch operating correctly?
Yes
Replace the high beam headlamp relay. Test the system for normal operation.
No
See Multifunction switch in Section 211-05.
One low beam headlamp is inoperative Possible causes: Circuit 13 (R-B) short to ground Circuit 57 (B) open PINPOINT TEST D : ONE LOW BEAM HEADLAMP IS INOPERATIVE Test Step D1
Result / Action to Take
CHECK THE HEADLAMP LOW BEAM VOLTAGE INPUT Disconnect: Inoperative low beam headlamp. Turn ON low beam headlamps. Measure the voltage between RH low beam C-159, circuit 13A (R-B), harness side or LH low beam C-160, circuit 13C (R-B), harness side and ground. Is the voltage greater than 10 volts?
G86728 en
Yes
Repair circuit 57 (B). Test the system for normal operation.
No
Repair circuit 13 (R-B). Test the system for normal operation.
01/2003 2003.0 BA Falcon
417-01-12
Exterior Lighting
417-01-12
DIAGNOSIS AND TESTING (Continued) One high beam headlamp is inoperative Possible causes: Circuit 12 (G-O) short to ground Circuit 57 (B) open PINPOINT TEST E : ONE HIGH BEAM HEADLAMP IS INOPERATIVE Test Step E1
Result / Action to Take
CHECK THE HEADLAMP HIGH BEAM VOLTAGE INPUT Disconnect: Inoperative high beam headlamp. Turn ON high beam headlamps.
Yes
Repair circuit 57 (B). Test the system for normal operation.
Measure the voltage between RH high beam C-159, circuit 12A (G-O ), harness side, RH low beam C-159, circuit 12C (G-O ), harness side, No Repair circuit 12 (G-O). LH low beam C-160, circuit 12E (G-O ), harness side or LH high Test the system for normal operation. beam C-160, circuit 12D (G-O), harness side and ground. Is the voltage greater than 10 volts?
The headlamps are on continuously Possible causes: Multifunction switch C-167 Low beam headlamp relay Circuit 18 (O) short to ground Circuit 13 (R-B) short to power High beam headlamp relay Circuit 20 (G-R) short to ground Circuit 12 (G-O) short to power PINPOINT TEST F : THE HEADLAMPS ARE ON CONTINUOUSLY Test Step F1
Result / Action to Take
CHECK THE MULTIFUNCTION SWITCH Disconnect: Multifunction switch C-167. Are the headlamps illuminated?
Yes
Go to F2
No
Perform the Multifunction switch testing in Section 211-05. Test the system for normal operation.
F2
CHECK CIRCUIT 18 (O) FOR A SHORT TO GROUND Measure the resistance between Multifunction switch C-167, circuit 18 Yes (O), harness side and ground. Repair circuit 18 (O). Test the system for normal operation. Is the resistance less than 5 ohms?
No
Go to F3
F3
CHECK CIRCUIT 20 (G-R) FOR A SHORT TO GROUND Measure the resistance between Multifunction switch C-167, circuit 20 Yes (G-R), harness side and ground. Repair circuit 20 (G-R). Test the system for normal operation. Is the resistance less than 5 ohms?
No
Go to F4
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01/2003 2003.0 BA Falcon
417-01-13
Exterior Lighting
417-01-13
DIAGNOSIS AND TESTING (Continued) Test Step F4
Result / Action to Take
CHECK HEADLAMP LOW BEAM RELAY Disconnect: Low beam headlamp relay, PDB C-163 relay 5 (40A). Are the headlamps illuminated?
Yes
Go to F5
No
Install a new low beam headlamp relay. Test the system for normal operation.
F5
CHECK CIRCUIT 13 (R-B) FOR A SHORT TO POWER Measure the voltage between the low beam headlamp relay, PDB C-163 relay 5 (40A), circuit 13 (R-B) harness side and ground. Is the voltage greater than 10 volts?
Yes
Repair circuit 13 (R-B). Test the system for normal operation.
No
Go to F6
F6
CHECK THE HEADLAMP HIGH BEAM RELAY Disconnect: High beam headlamp relay, PDB C-163 relay 4 (40A). Are the headlamps illuminated?
Yes
Repair circuit 12 (G-O). Test the system for normal operation.
No
Install a new high beam headlamp relay. Test the system for normal operation.
PINPOINT TEST G : TWILIGHT SENSOR/SUN SENSOR NOT WORKING NOTE: The sunload sensor must not be covered with a dash mat or other item, as this will prevent the optimum performance of the automatic climate control system and the automatic headlamp operation. Test Step G1
CHECK HEADLAMPS Turn on the ignition. Turn the headlamp switch to AUTO position. Cover the Sun Sensor. Do the headlamps turn on after 2 Seconds?
G2
Yes
Go to G2
No
Go to G3
CHECK HEADLAMPS With the ignition on and the headlamp switch in the AUTO position, uncover the Sun Sensor.
Yes
Shine a torch on the light sensor.
No
Do the headlamps turn off after 15 Seconds?
G3
Result / Action to Take
System OK.
Go to G3
CHECK DTC LOG Turn off the ignition. Connect WDS. Turn on the ignition. Is DTC $9790 or $9791 logged?
G86728 en
Yes
Go to G4
No
Refer to BEM Diagnostics.
01/2003 2003.0 BA Falcon
417-01-14
Exterior Lighting
417-01-14
DIAGNOSIS AND TESTING (Continued) Test Step G4
Result / Action to Take
CHECK PIN J 1/18 FREQUENCY Disconnect J1 from BEM. Turn Head lamp Switch to AUTO position. Turn Ignition ON. Using CRO on WDS back probe J 1/18.
Yes
Go to G5
No
Go to G6
Are the following values as specified?Sensor Covered:J1= approx 400HzSensor uncovered and torch shining:J1 = approx 50Hz
G5
CHECK IN J 2/6 VOLTAGE Disconnect J2 from BEM. Turn Head lamp Switch on AUTO. Turn Ignition ON. Using Voltmeter back probe J 2/6.
Yes
Refer to BEM Diagnostics
No
Go to G7
Are the following values as specified?Sensor Covered:J2 = approx 0.7VSensor uncovered and torch shining:J2 = approx 4.5V
G6
CHECK CIRCUIT 234D CONTINUITY Disconnect harness connector from Sun Sensor. Check for short to B+, short to ground and continuity of circuit 234D. Is circuit 234D OK?
G7
Check for short to B+, short to ground and continuity of circuit 234E. Is circuit 234E OK?
No
Check & Repair circuit 234D.
Yes
Go to G8
No
Check & Repair circuit 234E.
CHECK CIRCUIT CN 1-3 RESISTANCE Disconnect harness connector from Sun Sensor. Back probe CN1 - 3 with an ohmmeter to ground. Is the following value as specified?Less than 1 ohm
G9
Go to G7
CHECK CIRCUIT 234E CONTINUITY Disconnect harness connector from Sun Sensor.
G8
Yes
Yes
Go to G9
No
Check & Repair ground circuit to Sun Sensor.
CHECK CIRCUIT CN 2-2 RESISTANCE Disconnect harness connector from Sun Sensor. Turn Ignition ON. Back probe CN2 - 2 with an ohmmeter to ground. Is the following value as specified?Battery voltage to be 9-13 volts with ignition OFF.
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Yes
Replace Sun Sensor.
No
Check & Repair Power Supply Circuit to Sun Sensor. (including Head Lamp Switch assembly)
01/2003 2003.0 BA Falcon
417-01-15
Exterior Lighting
417-01-15
DIAGNOSIS AND TESTING (Continued) Turn Signal and Hazard Lamps Connector Circuit Reference C-44 Wagon LH Tail Lamp
Pin Number(s) 1 2
Circuit Designation/Description Circuit 3A (G) LH turn signal power input Circuit 57EJ (B) LH tail lamp ground
Normal Condition/Measurement 0 voltage, less than 5 ohms between LH turn signal and cluster 0 voltage, less than 5 ohms between LH tail lamp and chassis ground
C-45 Wagon RH Tail Lamp
Pin Number(s) 1 2
Circuit Designation/Description Circuit 2A (G-L) RH turn signal power input Circuit 57EK (B) RH tail lamp ground
Normal Condition/Measurement 0 voltage, less than 5 ohms between RH turn signal and cluster 0 voltage, less than 5 ohms between RH tail lamp and chassis ground
C-46 LH Side Marker
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01/2003 2003.0 BA Falcon
417-01-16
Exterior Lighting
417-01-16
DIAGNOSIS AND TESTING (Continued) Pin Number(s) 1 2
Circuit Designation/Description Circuit 3B (G) LH side marker power input Circuit 57BL (B) LH side marker ground
Normal Condition/Measurement 0 voltage, less than 5 ohms between LH side marker and cluster 0 voltage, less than 5 ohms between LH side marker and ground
Circuit Designation/Description Circuit 2A (G-L) RH turn signal power input Circuit 57EK (B) RH tail lamp ground
Normal Condition/Measurement 0 voltage, less than 5 ohms between RH turn signal and cluster 0 voltage, less than 5 ohms between RH tail lamp and ground
Circuit Designation/Description Circuit 3A (G) LH turn signal power input Circuit 57EJ (B) LH tail lamp ground
Normal Condition/Measurement 0 voltage, less than 5 ohms between LH turn signal and cluster 0 voltage, less than 5 ohms between LH tail lamp and ground
C-77 RH Tail Lamp
Pin Number(s) 1 2 C-78 LH Tail Lamp
Pin Number(s) 1 2 C-154 RH Side Marker
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417-01-17
Exterior Lighting
417-01-17
DIAGNOSIS AND TESTING (Continued) Pin Number(s) 1 2
Circuit Designation/Description Circuit 2B (G-L) RH side marker power input Circuit 57AQ (B) RH side marker ground
Normal Condition/Measurement 0 voltage, less than 5 ohms between RH side marker and cluster 0 voltage, less than 5 ohms between RH side marker and ground
Circuit Designation/Description Circuit 2A (G-L) RH turn signal power input Circuit 57AP (B) RH turn signal ground
Normal Condition/Measurement 0 voltage, less than 5 ohms between RH turn signal and cluster 0 voltage, less than 5 ohms between RH turn signal and ground
Circuit Designation/Description Circuit 3A (G) LH turn signal power input Circuit 57BG (B) LH turn signal ground
Normal Condition/Measurement 0 voltage, less than 5 ohms between LH turn signal and cluster 0 voltage, less than 5 ohms between LH turn signal and ground
C-159 RH Turn Signal
Pin Number(s) 1 2 C-160 LH Turn Signal
Pin Number(s) 1 2
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417-01-18
Exterior Lighting
417-01-18
DIAGNOSIS AND TESTING (Continued) C-167 Multifunction Switch
Pin Number(s) 1 2 3
Circuit Designation/Description Circuit 2 (G-L) RH turn signal feed Circuit 3 (G) LH turn signal feed Circuit 8 (G-B) Turn signal flasher feed
Normal Condition/Measurement 0 voltage, less than 5 ohms between cluster and Multifunction switch 0 voltage, less than 5 ohms between cluster and Multifunction switch 0 voltage, less than 5 ohms between Multifunction switch and ignition relay
Circuit Designation/Description Circuit 2 (G-L) RH turn signal feed Circuit 2C (G-L) RH turn signal lamp power input Circuit 3 (G) LH turn signal feed Circuit 3C (G) LH turn signal lamp power input Circuit 383C (Y) Hazard lights B+ input
Normal Condition/Measurement 0 voltage, less than 5 ohms between cluster and Multifunction switch 0 voltage, less than 5 ohms between cluster and RH turn signal lamps 0 voltage, less than 5 ohms between cluster and Multifunction switch 0 voltage, less than 5 ohms between cluster and LH turn signal lamps Greater than 10 volts, 10,000 ohms between hazard lights input and chassis ground
C-171 Cluster
Pin Number(s) 1 2 3 4 5
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417-01-19
Exterior Lighting
417-01-19
DIAGNOSIS AND TESTING (Continued) C-705 Ute Cab Chassis RH Tail Lamp
Pin Number(s) 1 2
Circuit Designation/Description Circuit 2B (G-L) RH turn signal power input Circuit 57A (B) RH tail lamp ground
Normal Condition/Measurement 0 voltage, less than 5 ohms between RH tail lamp and cluster 0 voltage, less than 5 ohms between RH tail lamp and chassis ground
C-707 Ute Cab Chassis LH Tail Lamp
Pin Number(s) 1 2
Circuit Designation/Description Circuit 3B (G) LH turn signal power input Circuit 57B (B) LH tail lamp ground
Normal Condition/Measurement 0 voltage, less than 5 ohms between LH tail lamp and cluster 0 voltage, less than 5 ohms between LH tail lamp and chassis ground
C-706 Ute Style Side Box RH Tail Lamp
Pin Number(s) 1 2
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Circuit Designation/Description Circuit 2B (G-L) RH turn signal power input Circuit 57A (B) RH tail lamp ground
Normal Condition/Measurement 0 voltage, less than 5 ohms between RH tail lamp and cluster 0 voltage, less than 5 ohms between RH tail lamp and chassis ground
01/2003 2003.0 BA Falcon
417-01-20
Exterior Lighting
417-01-20
DIAGNOSIS AND TESTING (Continued) C-708 Ute Style Side Box LH Tail Lamp
Pin Number(s) 1 2
Circuit Designation/Description Circuit 3B (G) LH turn signal power input Circuit 57E (B) LH tail lamp ground
Normal Condition/Measurement 0 voltage, less than 5 ohms between LH tail lamp and cluster 0 voltage, less than 5 ohms between LH tail lamp and chassis ground
Inspection and Verification Visual Inspection Chart Mechanical Multifunction switch
Electrical Junction Box (JB): fuse 17 (15A) Circuitry Turn Signal and Hazard Lamp Bulbs Multifunction switch Cluster
Symptom Chart Condition
Source
Action
The turn signal lamps are inoperative
Circuitry Multifunction switch Cluster
Go to PinPoint Test H
The turn signal lamps are always on
Multifunction switch Cluster
Go to PinPoint Test I
One turn signal/hazard lamp is inoperative
Circuitry
Go to PinPoint Test J
The hazard lamps are inoperative
Circuitry Cluster
Go to PinPoint Test K
The hazard lamps are always on
Cluster
Perform the cluster testing in Section 413-01.
Pinpoint Tests The turn signal lamps are inoperative
Cluster C-171 Circuit 2C (G-L) or 3C(G) open or short to ground
Possible causes: Circuit 8 (G-B) open or short to ground Multifunction switch C-167 Circuit 2 (G-L) or 3 (G) open or short to ground
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Exterior Lighting
417-01-21
DIAGNOSIS AND TESTING (Continued) PINPOINT TEST H : THE TURN SIGNAL LAMPS ARE INOPERATIVE Test Step H1
CHECK MULTIFUNCTION SWITCH INPUT VOLTAGE Disconnect: Multifunction switch C-167. Turn ON ignition. Measure the voltage between the Multifunction switch C-167, circuit 8 (G-B), harness side and ground. Is the voltage greater than 10 volts?
H2
Yes
Go to H2
No
Repair circuit 8 (G-B). Test the system for normal operation.
CHECK THE MULTIFUNCTION SWITCH Turn OFF ignition. Perform the Multifunction switch testing in Section 211-05. Is the Multifunction switch functioning correctly?
H3
Result / Action to Take
Yes
Go to H3
No
Replace the Multifunction switch, see Section 211-05. Test the system for normal operation.
CHECK CLUSTER INDICATOR INPUT Connect: Multifunction switch C-167. Disconnect: Cluster C-171. Turn ON ignition. Turn ON inoperative indicator.
Yes
Go to H4
No
Repair circuit. Test the system for normal operation.
Measure the voltage between inoperative indicator harness side and ground for RH indicator use cluster C-171, circuit 2 (G-L), harness side and ground. for LH indicator use cluster C-171, circuit 3 (G), harness side and ground. Is the voltage greater than 10 volts?
H4
CHECK INDICATOR LAMP POWER INPUT FOR A SHORT TO GROUND Turn OFF ignition. Disconnect: Inoperative lamp. Measure the resistance between the inoperative lamp, harness side and ground for RH indicator use circuit 2 (G-L), harness side and ground.
Yes
Repair circuit. Test the system for normal operation.
No
Go to H5
for LH indicator use circuit 3 (G), harness side and ground. Is the resistance less than 5 ohms?
H5
CHECK INDICATOR LAMP POWER INPUT FOR AN OPEN Measure the resistance between the inoperative lamp, harness side and cluster C-171, harness side for RH indicator measure between, inoperative lamp, circuit 2 (G-L), harness side and cluster C-171, circuit 2C (G), harness side. for LH indicator measure between, inoperative lamp, circuit 3 (G), harness side and cluster C-171, circuit 3C (GL), harness side. Is the resistance less than 5 ohms?
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Yes
Perform the cluster testing in Section 413-01. Test the system for normal operation.
No
Repair circuit. Test the system for normal operation.
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417-01-22
Exterior Lighting
417-01-22
DIAGNOSIS AND TESTING (Continued) The turn signal lamps are always on
Circuit 2C (G-L) or 3C (G) short to power
Possible causes: Multifunction switch C-167 Circuit 2 (G-L) or 3 (G) short to power Cluster C-171 PINPOINT TEST I : THE TURN SIGNAL LAMPS ARE ALWAYS ON Test Step I1
Result / Action to Take
CHECK THE MULTIFUNCTION SWITCH Disconnect: Multifunction switch C-167. Are the turn signals always on?
Yes
Go to I2
No
Perform the Multifunction switch testing in Section 211-01. Test the system for normal operation.
I2
CHECK CLUSTER Disconnect: Cluster C-171. Are the turn signals always on?
Yes
Repair circuit 3C (G) if LH lights are illuminated or circuit 2C (G-L) if RH lamps are illuminated. Test the system for normal operation.
No
Go to I3
I3
CHECK INDICATOR LAMP POWER INPUT FOR AN OPEN Measure the voltage between malfunctioning indicator, harness side and ground for RH indicator use cluster C-171, circuit 2 (G-L), harness side and ground. for LH indicator use cluster C-171, circuit 3 (G), harness side and ground. Is the voltage greater than 10 volts?
Yes
Repair circuit. Test the system for normal operation.
No
Perform the cluster testing in Section 413-01. Test the system for normal operation.
One turn signal/hazard lamp is inoperative Possible causes: Circuit 2 (G-L) or 3 (G) open Circuit 57 (B) open PINPOINT TEST J : ONE TURN SIGNAL HAZARD LAMP IS INOPERATIVE Test Step J1
Result / Action to Take
CHECK INOPERATIVE LAMP INPUT Disconnect: Inoperative lamp. Turn ON ignition. Turn ON hazard lights. Measure the voltage between the inoperative lamp, harness side and ground for RH lamp use circuit 2 (G-L), harness side and ground.
Yes
Repair circuit 57 (B). Test the system for normal operation.
No
Repair circuit 2 (G-L) or 3 (G). Test the system for normal operation.
for LH lamp use circuit 3 (G), harness side and ground. Is the voltage greater than 10 volts?
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417-01-23
Exterior Lighting
417-01-23
DIAGNOSIS AND TESTING (Continued) The hazard lamps are inoperative Possible causes: Circuit 383C (Y) open or short to ground Cluster C-171 PINPOINT TEST K : THE HAZARD LAMPS ARE INOPERATIVE Test Step K1
Result / Action to Take
CHECK CIRCUIT 383C (Y) VOLTAGE Disconnect: cluster.
Yes
Perform the cluster testing in Section 413-01. Measure the voltage between cluster C-171, circuit 383C (Y), harness Test the system for normal operation. side and ground. Is the voltage greater than 10 volts?
No
Repair circuit 383C (Y). Test the system for normal operation.
Stop Lamps Connector Circuit Reference C-39 High Mount Stop Lamp
Pin Number(s) 1 2
Circuit Designation/Description Circuit 10D (G-R) Stop lamp power input Circuit 57EL (B) Stop lamp ground
Normal Condition/Measurement 0 voltage, less than 5 ohms between stop lamp and brake switch 0 voltage, less than 5 ohms between stop lamp and chassis ground
C-44 Wagon LH Tail Lamp
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417-01-24
Exterior Lighting
417-01-24
DIAGNOSIS AND TESTING (Continued) Pin Number(s) 1 2
Circuit Designation/Description Circuit 10A (G-R) Stop lamp power input Circuit 57EJ (B) LH tail lamp ground
Normal Condition/Measurement 0 voltage, less than 5 ohms between stop lamp and brake switch 0 voltage, less than 5 ohms between LH tail lamp and chassis ground
C-45 Wagon RH Tail Lamp
Pin Number(s) 1 2
Circuit Designation/Description Circuit 10B (G-R) Stop lamp power input Circuit 57EK (B) RH tail lamp ground
Normal Condition/Measurement 0 voltage, less than 5 ohms between stop lamp and brake switch 0 voltage, less than 5 ohms between RH tail lamp and chassis ground
C-77 Sedan Right Tail Lamp
Pin Number(s) 1 2
Circuit Designation/Description Circuit 10B (G-R) Stop lamp power input Circuit 57EK (B) RH tail lamp ground
Normal Condition/Measurement 0 voltage, less than 5 ohms between stop lamp and brake switch 0 voltage, less than 5 ohms between RH tail lamp and chassis ground
C-78 Sedan Left Tail Lamp C-78
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01/2003 2003.0 BA Falcon
417-01-25
Exterior Lighting
417-01-25
DIAGNOSIS AND TESTING (Continued) Pin Number(s) 1 2
Circuit Designation/Description Circuit 10A (G-R) Stop lamp power input Circuit 57EJ (B) LH tail lamp ground
Normal Condition/Measurement 0 voltage, less than 5 ohms between stop lamp and brake switch 0 voltage, less than 5 ohms between LH tail lamp and chassis ground
Circuit Designation/Description Circuit 10AA (G-R) Brake switch power input Circuit 10Y (G-R) Brake switch output to stop lamps
Normal Condition/Measurement 0 voltage, less than 5 ohms between the brake switch and ignition relay 0 voltage, less than 5 ohms between the brake switch and stop lamps
C-191 Brake Switch
Pin Number(s) 1 2
C-710 Ute After Market High Mount Stop Lamp
Pin Number(s) 1 2
Circuit Designation/Description Normal Condition/Measurement Circuit 10C (G-R) 0 voltage, less than 5 ohms between stop lamp Stop lamp power input and brake switch Circuit 140M (R-B) 0 voltage, less than 5 ohms between stop lamp and reverse lamps
C-705 Ute Cab Chassis RH Tail Lamp
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01/2003 2003.0 BA Falcon
417-01-26
Exterior Lighting
417-01-26
DIAGNOSIS AND TESTING (Continued) Pin Number(s) 1 2
Circuit Designation/Description Circuit 10A (G-R) Stop lamp power input Circuit 57A (B) Stop lamp ground
Normal Condition/Measurement 0 voltage, less than 5 ohms between stop lamp and brake switch 0 voltage, less than 5 ohms between stop lamp and chassis ground
C-707 Ute Cab Chassis LH Tail Lamp
Pin Number(s) 1 2
Circuit Designation/Description Circuit 10C (G-R) Stop lamp power input Circuit 57B (B) Stop lamp ground
Normal Condition/Measurement 0 voltage, less than 5 ohms between stop lamp and brake switch 0 voltage, less than 5 ohms between stop lamp and chassis ground
C-706 Ute Style Side Box RH Tail Lamp
Pin Number(s) 1 2
Circuit Designation/Description Circuit 10A (G-R) Stop lamp power input Circuit 57B (B) Stop lamp ground
Normal Condition/Measurement 0 voltage, less than 5 ohms between stop lamp and brake switch 0 voltage, less than 5 ohms between stop lamp and chassis ground
C-708 Ute Style Side Box LH Tail Lamp
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01/2003 2003.0 BA Falcon
417-01-27
Exterior Lighting
417-01-27
DIAGNOSIS AND TESTING (Continued) Pin Number(s) 1 2
Circuit Designation/Description Circuit 10C (G-R) Stop lamp power input Circuit 57D (B) Stop lamp ground
Normal Condition/Measurement 0 voltage, less than 5 ohms between stop lamp and brake switch 0 voltage, less than 5 ohms between stop lamp and chassis ground
Inspection and Verification Visual Inspection Chart Mechanical Brake switch
Electrical Junction Box (JB): fuse 7 (15A) Circuitry Stop Lamp bulbs
Symptom Chart Condition
Source
Action
Both stop lamps are inoperative
Junction Box (JB): fuse 7 (15A) Circuitry Brake switch
Go to PinPoint Test L
One or more stop lamps are inoperative
Circuitry Stop Lamp bulbs
Go to PinPoint Test M
The stop lamps are continuously on
Circuitry Brake switch
Go to PinPoint Test N
Pinpoint Tests Both headlamps are inoperative Possible causes: Circuit 10AA (G-R) open or short to ground. Brake switch C-191. Circuit 10Y (G-R) open or short to ground . PINPOINT TEST L : THE STOP LAMPS ARE INOPERATIVE Test Step L1
CHECK THE BRAKE SWITCH INPUT VOLTAGE Disconnect: brake switch C-191. Turn ON ignition. Measure the voltage between the brake switch C-191, circuit 10AA (G-R), harness side and ground. Is the voltage greater than 10 volts?
L2
Result / Action to Take
Yes
Go to L2.
No
Repair circuit 10AA (G-R). Test the system for normal operation.
CHECK THE CIRCUIT 10Y (G-R) FOR A SHORT TO GROUND Measure the resistance between the brake switch C191, circuit 10Y (G-R), harness side and ground. Is the resistance less than 5 ohms?
Yes
Repair circuit 10Y (G-R) Test the system for normal operation.
No
Go to L3.
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417-01-28
DIAGNOSIS AND TESTING (Continued) Test Step L3
Result / Action to Take
CHECK CIRCUIT 10 (G-R) FOR AN OPEN Disconnect: Inoperative tail lamp. Measure the resistance between the brake switch C191, circuit 10Y (G-R), harness side and inoperative tail lamp (one of the following): SWB Left tail lamp C-78, circuit 10A (G-R), harness side SWB Right tail lamp C-77, circuit 10B (G-R), harness side SWB High mount stop lamp C-39, circuit 10D (G-R), harness side LWB High mount stop lamp C-39, circuit 10Z (G-R), harness side Wagon Left tail lamp C-44, circuit 10A (G-R), harness side Wagon Right tail lamp C-45, circuit 10B (G-R), harness side Wagon High mount stop lamp C-39, circuit 10 (G-R), harness side Ute non-SSB Left tail lamp C-707, circuit 10C (G-R), harness side Ute non-SSB Right tail lamp C-705, circuit 10A (G-R), harness side Ute SSB Left tail lamp C-708, circuit 10C (G-R), harness side Ute SSB Right tail lamp C-706, circuit 10A (G-R), harness side Is the resistance less than 5 ohms?
Yes
Perform the brake switch testing in Section 206-06. Test the system for normal operation.
No
Repair circuit 10 (G-R). Test the system for normal operation.
One or more stop lamps are inoperative Possible causes: Circuit 10 (G-R) open. Circuit 57 (B) open.
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01/2003 2003.0 BA Falcon
417-01-29
Exterior Lighting
417-01-29
DIAGNOSIS AND TESTING (Continued) PINPOINT TEST M : ONE OR MORE STOP LAMPS ARE INOPERATIVE Test Step M1
Result / Action to Take
CHECK CIRCUIT 10 (G-R) FOR AN OPEN Disconnect: Inoperative stop lamp. Turn ON ignition. Measure the voltage between the brake switch C-191, circuit 10AA (G-R), harness side and inoperative tail lamp. SWB LH tail lamp C-78, circuit 10A (G-R), harness side SWB RH tail lamp C-77, circuit 10B (G-R), harness side SWB High mount stop lamp C-39, circuit 10D (G-R), harness side LWB High mount stop lamp C-39, circuit 10Z (G-R), harness side Wagon LH tail lamp C-44, circuit 10A (G-R), harness side Wagon RH tail lamp C-45, circuit 10B (G-R), harness side Wagon High mount stop lamp C-39, circuit 10 (G-R), harness side Ute cab chassis LH tail lamp C-707, circuit 10C (G-R), harness side Ute cab chassis RH tail lamp C-705, circuit 10A (G-R), harness side Ute style side box LH tail lamp C-708, circuit 10C (G-R), harness side Ute style side box RH tail lamp C-706, circuit 10A (G-R), harness side Is the resistance less than 5 ohms?
Yes
Perform the brake switch testing in Section 206-06. Test the system for normal operation.
No
Repair circuit 10 (G-R). Test the system for normal operation.
The stop lamps are continuously on Possible causes: Brake switch C-191 Circuit 10 (G-R) short to power PINPOINT TEST N : THE STOP LAMPS ARE CONTINUOUSLY ON Test Step N1
Result / Action to Take
CHECK THE CIRCUIT 10Y (G-R) FOR A SHORT TO POWER Disconnect: brake switch C-191. Are the stop lamps illuminated?
Yes
Repair circuit 10 (G-R). Test the system for normal operation.
No
Perform the brake switch testing in Section 206-06. Test the system for normal operation.
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01/2003 2003.0 BA Falcon
417-01-30
Exterior Lighting
417-01-30
DIAGNOSIS AND TESTING (Continued) Fog Lamps Connector Circuit Reference C-163 Power Distribution Box (PDB)
Pin Number(s) 1 2 3 4
Circuit Designation/Description Circuit 37H (Y) Battery to fog lamp relay Circuit 57AX (B) Fog lamp relay ground 477 (SB) Fog lamp switch to fog lamp relay 478A (BR-W) Fog lamp relay to fog lamps
Normal Condition/Measurement Greater than 10 volts and 10,000 between fog lamp relay and ground 0 volts, less than 5 ohms between fog lamp relay and ground 0 volts, less than 5 ohms between fog lamp switch and fog lamp relay 0 volts, less than 5 ohms between fog lamp relay and fog lamps
C-360 LH Fog Lamp
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417-01-31
Exterior Lighting
417-01-31
DIAGNOSIS AND TESTING (Continued) Pin Number(s) 1 2
Circuit Designation/Description Circuit 57AZ (B) LH fog lamp ground Circuit 478C (BR-W) LH fog lamp power input
Normal Condition/Measurement 0 volts, less than 5 ohms between LH fog lamp and ground 0 volts, less than 5 ohms between LH fog lamp and fog lamp relay
Circuit Designation/Description Circuit 57AY (B) RH fog lamp ground Circuit 478B (BR-W) RH fog lamp power input
Normal Condition/Measurement 0 volts, less than 5 ohms between RH fog lamp and ground 0 volts, less than 5 ohms between RH fog lamp and fog lamp relay
C-362 RH Fog Lamp
Pin Number(s) 1 2
C-363 Fog Lamp Switch
Pin Number(s) 1 2
Circuit Designation/Description Circuit 1045M (BR) Fog lamp switch power input from tail lamp relay Circuit 477 (SB) Fog lamp switch to fog lamp relay
Normal Condition/Measurement 0 volts, less than 5 ohms between fog lamp switch and tail lamp relay. 0 volts, less than 5 ohms between fog lamp switch and fog lamp relay
Inspection and Verification Visual Inspection Chart Mechanical Fog lamp switch.
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Electrical Power Distribution Box (PDB): Fuse 18 (20A) Relay 1 (20A) Circuitry Fog Lamp bulbs
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417-01-32
Exterior Lighting
417-01-32
DIAGNOSIS AND TESTING (Continued) Symptom Chart Condition
Source
Action
Both fog lamps are inoperative.
Power Distribution Box (PDB): Fuse 18 (20A) Relay 1 (20A) Circuitry Fog lamp switch
Go to PinPoint Test O
One fog lamp is inoperative.
Circuitry
Go to PinPoint Test P
Both fog lamps are on continuously.
Power Distribution Box (PDB): Relay 1 (20A) Circuitry Fog lamp switch
Go to PinPoint Test Q
Pinpoint Tests Both headlamps are inoperative Possible causes: Circuit 1045M (BR) open or short to ground Fog lamp switch C-363 Circuit 477 (SB) open or short to ground
Fog lamp relay Circuit 57AX (B) open Circuit 478 (BR-W) open or short to ground
PINPOINT TEST O : BOTH FOG LAMPS ARE INOPERATIVE Test Step O1
Result / Action to Take
CHECK THE FOG LAMP SWITCH TO FOG LAMP RELAY VOLTAGE Disconnect: Fog lamp relay, PDB C-163 relay 1 (20A). Turn ON fog lamps. Measure the voltage between fog lamp relay, PDB C-163 relay 1, circuit 477 (SB), harness side and ground.
Yes
Go to O5
No
Go to O2
Is the voltage greater than 10 volts?
O2
CHECK CIRCUIT 1045M (BR) VOLTAGE Disconnect: Fog lamp switch C-363.
Yes
Measure the voltage between fog lamp switch C-363, circuit 1045M (BR), harness side and ground.
No
Is the voltage greater than 10 volts?
O3
Go to O3 Repair circuit 1045M (BR)
CHECK CIRCUIT 477 (SB) FOR A SHORT TO GROUND Measure the resistance between fog lamp relay, PDB C-163 relay 1, circuit 477 (SB), harness side and ground. Is the resistance less than 5 ohms?
Yes
Repair circuit 477 (SB). Test the system for normal operation.
No
Go to O4
O4
CHECK CIRCUIT 477 (SB) FOR AN OPEN Measure the resistance between the fog lamp relay, PDB C-163 relay 1, circuit 477 (SB), harness side and fog lamp switch C-363, circuit 477 (SB), harness side. Is the resistance less than 5 ohms?
Yes
Perform the fog lamp switch testing in Section 000-00. Test the system for normal operation.
No
Refer Circuit 477 (SB). Test the system for normal operation.
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Exterior Lighting
417-01-33
DIAGNOSIS AND TESTING (Continued) Test Step O5
Result / Action to Take
CHECK CIRCUIT 37H (SB) VOLTAGE Yes
Measure the voltage between fog lamp relay, PDB C-163 relay 1, circuit 37H (SB), harness side and ground
Go to O6
Is the voltage greater than 10 volts?
No
Repair circuit 37H (SB)Test the system for normal operation.
O6
CHECK CIRCUIT 57AX (B) FOR AN OPEN Yes
Measure the resistance between fog lamp relay, PDB C-363 relay 1, circuit 57AX (B), harness side and ground.
Go to O7
Is the resistance less than 5 ohms?
No
Repair circuit 57AX (B)Test the system for normal operation.
O7
CHECK CIRCUIT 478 (BR-W) FOR A SHORT TO GROUND Measure the resistance between fog lamp relay, PDB C-363 relay 1, circuit 478A (BR-W), harness side and ground. Is the resistance less than 5 ohms?
Yes
Repair circuit 478 (BR-W). Test the system for normal operation.
No
Go to O8.
O8
CHECK CIRCUIT 478 (BR-W) FOR AN OPEN Disconnect: RH fog lamp C-362. Measure the resistance between fog lamp relay, PDB C-363 relay 1, circuit 478A (BR-W), harness side and RH fog lamp C-362, circuit 478B, harness side. Is the resistance less than 5 ohms?
Yes
Replace fog lamp relay, PDB C-163 relay 1 (20A). Test the system for normal operation
No
Repair circuit 478 (BR-W). Test the system for normal operation
One fog lamp is inoperative Possible causes: Circuit 478 (BR-W) open Circuit 57 (B) open PINPOINT TEST P : ONE FOG LAMP IS INOPERATIVE Test Step P1
Result / Action to Take
CHECK THE VOLTAGE TO THE INOPERATIVE FOG LAMP Disconnect: Inoperative fog lamp. Turn On Fog LampS.
Repair circuit 57 (B). Test the system for normal operation.
Measure the voltage between RH fog lamp C-362, circuit 478B (BR-W), harness side or LH fog lamp C-360, circuit 478C (BR-W), harness side and ground.
No
Is the voltage greater than 10 volts?
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Yes
Repair circuit 478 (BR). Test the system for normal operation.
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417-01-34
Exterior Lighting
417-01-34
DIAGNOSIS AND TESTING (Continued) Both fog lamps are on continuously Possible causes: For lamp switch C-363 Circuit 477 (SB) short to power Fog lamp relay Circuit 478 (BR-W) short to power PINPOINT TEST Q : BOTH FOG LAMPS ARE ON CONTINUOUSLY Test Step Q1
Result / Action to Take
CHECK FOG LAMP SWITCH Disconnect: Fog lamp switch C-363. Are the fog lamps illuminated?
Yes
Go to R2
No
Perform the fog lamp switch testing in Section 000-00. Test the system for normal operation.
Q2
CHECK CIRCUIT 478 A (BR=W) FOR A SHORT TO POWER Disconnect: Fog lamp Relay, PDB C-163 Relay 1. Are the fog lamps illuminated?
Yes
Repair circuit 478 (BR-W). Test the system for normal operation.
No
Go to Q3
Q3
CHECK CIRCUIT 477 A (SB) FOR A SHORT TO POWER Measure the voltage between fog lamp relay, PDB C-163 relay 1, circuit 477 (SB), harness side and ground Is the voltage greater than 10 volts?
Yes
Repair circuit 477 (SB). Test the system for normal operation.
No
Replace fog lamp relay, PDB C-163 relay 1 (20A). Test the system for normal operation.
Parking, Rear and License Lamps Connector Circuit Reference C-44 Wagon LH Tail Lamp
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01/2003 2003.0 BA Falcon
417-01-35
Exterior Lighting
417-01-35
DIAGNOSIS AND TESTING (Continued) Pin Number(s) 1 2
Circuit Designation/Description Circuit 14A (BR) LH rear lamp power input Circuit 57EJ (B) LH tail lamp ground
Normal Condition/Measurement 0 voltage, less than 5 ohms between LH rear lamp and tail lamp relay 0 voltage, less than 5 ohms between LH tail lamp and chassis ground
C-45 Wagon RH Tail Lamp
Pin Number(s) 1 2
Circuit Designation/Description Circuit 14B (BR) RH rear lamp power input Circuit 57EK (B) RH tail lamp ground
Normal Condition/Measurement 0 voltage, less than 5 ohms between RH rear lamp and tail lamp relay 0 voltage, less than 5 ohms between RH tail lamp and chassis ground
C-77 Sedan RH Tail Lamp
Pin Number(s) 1 2
Circuit Designation/Description Circuit 14B (BR) RH rear lamp power input Circuit 57EK (B) RH tail lamp ground
Normal Condition/Measurement 0 voltage, less than 5 ohms between RH rear lamp and tail lamp relay 0 voltage, less than 5 ohms between RH tail lamp and chassis ground
C-78 Sedan LH Tail Lamp
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Exterior Lighting
417-01-36
DIAGNOSIS AND TESTING (Continued) Pin Number(s) 1 2
Circuit Designation/Description Circuit 14A (BR) LH rear lamp power input Circuit 57EJ (B) LH tail lamp ground
Normal Condition/Measurement 0 voltage, less than 5 ohms between LH rear lamp and tail lamp relay 0 voltage, less than 5 ohms between LH tail lamp and chassis ground
Circuit Designation/Description Circuit 14 (BR) License lamp power input Circuit 57A (B) License lamp ground
Normal Condition/Measurement 0 voltage, less than 5 ohms between license lamp and tail lamp relay 0 voltage, less than 5 ohms between license lamp and chassis ground
C-81 License Lamp
Pin Number(s) 1 2
C-159 RH Parking Lamp
Pin Number(s) 1 2
Circuit Designation/Description Circuit 14D (BR) RH parking lamp power input Circuit 57AL (B) RH parking lamp ground
Normal Condition/Measurement 0 voltage, less than 5 ohms between RH parking lamp and tail lamp relay 0 voltage, less than 5 ohms between RH parking lamp and chassis ground
C-160 LH Parking Lamp
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Exterior Lighting
417-01-37
DIAGNOSIS AND TESTING (Continued) Pin Number(s) 1 2
Circuit Designation/Description Circuit 14A (BR) LH parking lamp power input Circuit 57AE (B) LH parking lamp ground
Normal Condition/Measurement 0 voltage, less than 5 ohms between LH parking lamp and tail lamp relay 0 voltage, less than 5 ohms between LH Parking Lamp and chassis ground
C-167 Multifunction Switch
Pin Number(s) 1
Circuit Designation/Description Normal Condition/Measurement Circuit 175 (B-Y) 0 voltage, less than 5 ohms between Multifunction switch parking lamps Multifunction switch and tail lamp relay input from tail lamp relay
C-331 Junction Box (JB)
Pin Number(s) 1
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Circuit Designation/Description Normal Condition/Measurement Circuit 175 (B-Y) 0 voltage, less than 5 ohms between tail lamp Multifunction switch parking lamps relay and Multifunction switch input from tail lamp relay
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Exterior Lighting
417-01-38
DIAGNOSIS AND TESTING (Continued) C-334 Junction Box (JB)
Pin Number(s) 1
Circuit Designation/Description Normal Condition/Measurement Circuit 14E (BR) 0 voltage, less than 5 ohms between tail lamp Parking lamp power input relay and parking, rear and license lamps
C-705 Ute Cab Chassis RH Tail Lamp
Pin Number(s) 1 2
Circuit Designation/Description Circuit 14D (BR) RH rear lamp power input Circuit 57A (B) LH tail lamp ground
Normal Condition/Measurement 0 voltage, less than 5 ohms between RH rear lamp and tail lamp relay 0 voltage, less than 5 ohms between LH tail lamp and chassis ground
C-707 Ute Cab Chassis LH Tail Lamp
Pin Number(s) 1 2
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Circuit Designation/Description Circuit 14B (BR) LH rear lamp power input Circuit 57B (B) LH tail lamp ground
Normal Condition/Measurement 0 voltage, less than 5 ohms between LH rear lamp and tail lamp relay 0 voltage, less than 5 ohms between LH tail lamp and chassis ground
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417-01-39
Exterior Lighting
417-01-39
DIAGNOSIS AND TESTING (Continued) C-706 Ute Style Side Box RH Tail Lamp
Pin Number(s) 1 2
Circuit Designation/Description Circuit 14D (BR) RH rear lamp power input Circuit 57B (B) RH tail lamp ground
Normal Condition/Measurement 0 voltage, less than 5 ohms between RH rear lamp and tail lamp relay 0 voltage, less than 5 ohms between RH tail lamp and chassis ground
C-708 Ute Style Side Box LH Tail Lamp
Pin Number(s) 1 2
Circuit Designation/Description Circuit 14B (BR) LH rear lamp power input Circuit 57D (B) LH tail lamp ground
Normal Condition/Measurement 0 voltage, less than 5 ohms between LH rear lamp and tail lamp relay 0 voltage, less than 5 ohms between LH tail lamp and chassis ground
Inspection and Verification Visual Inspection Chart Mechanical Multifunction switch
Electrical Junction Box (JB): fuse 23 (15A) relay 4 (20 A) Circuitry Parking, rear and license lamp bulbs Multifunction switch
Symptom Chart Condition The parking, rear and license lamps are inoperative
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Source Junction Box (JB): fuse 23 (15A) relay 4 (20 A) Circuitry Multifunction switch C-167
Action Go to PinPoint Test R
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DIAGNOSIS AND TESTING (Continued) Condition
Source
Action
One or more parking, rear or license lamps are inoperative
Circuitry
Go to PinPoint Test S
The parking, rear and license lamps are on continuously
Junction Box (JB): relay 4 (20 A) Circuitry Multifunction switch C-167
Go to PinPoint Test T
Pinpoint Tests The parking, rear and license lamps are inoperative Possible causes: circuit 38G (Y-R) open or short to ground Tail lamp relay, JB relay 4 (20A)
Circuit 175 (B-Y) open Multifunction switch C-167 Circuit 57CL (B) open Circuit 14 (BR) open or short to ground
PINPOINT TEST R : THE PARKING, REAR AND LICENCE LAMPS ARE INOPERATIVE Test Step R1
CHECK TAIL LAMP RELAY INPUT VOLTAGE Disconnect: Tail lamp relay, JB relay 4.
Yes
Measure the voltage between tail lamp relay, JB relay 4, circuit 38G (Y-R), harness side and ground.
No
Is the voltage greater than 10 volts?
R2
Result / Action to Take
Go to R2 Repair circuit 38G (Y-R). Test the system for normal operation.
CHECK CIRCUIT 14 (BR) FOR A SHORT TO GROUND Measure the resistance between tail lamp relay, JB C-334 relay 4, circuit 14E (BR), harness side and ground Is the resistance less than 5 ohms?
Yes
Repair circuit 14 (BR) Test the system for normal operation.
No
Go to R2
R3
CHECK CIRCUIT 14 (BR) FOR AN OPEN Disconnect: RH Headlamp park lamp C-159.
Yes
Measure the resistance between tail lamp relay, JB C-334 relay 4, circuit 14E (BR), harness side RH headlamp park lamp C-159, circuit 14D (BR), harness side.
No
Is the resistance less than 5 ohms?
R4
Repair circuit 14 (BR). Test the system for normal operation.
CHECK CIRCUIT 175 (B-Y) FOR AN OPEN Disconnect: Multifunction switch C-167.
Yes
Measure the resistance between tail lamp relay, JB C-331 relay 4, circuit 175 (B-Y), harness side and Multifunction switch C-167, circuit 175 (B-Y), harness side
No
Is the resistance less than 5 ohms?
R5
Go to R4
Go to R5 Repair circuit 175 (B-Y)) Test the system for normal operation.
CHECK MULTIFUNCTION SWITCH Perform the Multifunction switch testing in Section 211-05. Is the Multifunction switch functioning correctly?
Yes
Replace the tail lamp relay. Test the system for normal operation.
No
Replace the Multifunction switch, see Section 211-05. Test the system for normal operation.
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417-01-41
DIAGNOSIS AND TESTING (Continued) One or more parking, rear or license lamps are inoperative Possible causes: Circuit 14 (BR) open or short to ground Circuit 57 (B) open PINPOINT TEST S : ONE OR MORE PARKING, REAR OR LICENCE LAMPS ARE INOPERATIVE Test Step S1
Result / Action to Take
CHECK TAIL LAMP RELAY INPUT VOLTAGE Disconnect: Inoperative parking, rear or license lamp. Turn ON the parking lights. Measure the voltage between the inoperative lamp: LH parking lamp C-160, circuit 14A (BR), harness side RH parking lamp C-160, circuit 14D (BR), harness side Sedan LH tail lamp C-78, circuit 14A (BR), harness side Sedan RH tail lamp C-77, circuit 14B (BR), harness side Wagon LH tail lamp C-44, circuit 14A (BR) harness side wagon right tail lamp C-45, circuit 14B (BR) harness side Ute, non-SSB, LH rear lamp C-707, circuit 14B (BR) harness side Ute, non-SSB, RH rear lamp C-705, circuit 14D (BR) harness side Ute, SSB, LH rear lamp C-708, circuit 14B (BR) harness side Ute, SSB, RH rear lamp C-706, circuit 14D (BR) harness side License plate lamp C-81, circuit 14 (BR), harness sideand ground Is the voltage greater than 10 volts?
Yes
Repair circuit 57 (B). Test the system for normal operation.
No
Repair circuit 14 (BR). Test the system for normal operation.
The parking, rear and license lamps are on continuously Possible causes: Tail lamp relay Circuit 175 (B-Y) short to ground Multifunction switch C-167 Circuit 14 (BR) short to power PINPOINT TEST T : THE PARKING, REAR AND LICENCE LAMPS ARE ON CONTINUOUSLY Test Step T1
Result / Action to Take
CHECK MULTIFUNCTION SWITCH Disconnect: Multifunction switch C-167. Are the parking, rear and license lamps illuminated?
Yes
Go to T2
No
Perform the Multifunction switch testing in Section 211-05. Test the system for normal operation.
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DIAGNOSIS AND TESTING (Continued) Test Step T2
Result / Action to Take
CHECK CIRCUIT 175 (B-Y) FOR A SHORT TO GROUND Measure the resistance between Multifunction switch C-167, circuit 175 (B-Y), harness side and ground. Is the resistance less than 5 ohms?
Yes
Repair circuit 175 (B-Y). Test the system for normal operation.
No
Go to T3
T3
CHECK TAIL LAMP RELAY Disconnect: Tail lamp relay, JB C-334 relay 4. Are the parking, rear and license lamps illuminated?
Yes
Repair circuit 14 (BR). Test the system for normal operation
No
Replace the tail lamp relay. Test the system for normal operation.
Reverse Lamps Connector Circuit Reference C-12 Inhibitor switch and PRNDL switch
Pin Number(s) 1 2
Circuit Designation/Description Normal Condition/Measurement Circuit 140 (W-R) 0 voltage, less than 5 ohms between inhibitor switch and PRNDL switch and ignition relay Circuit 140X (R-B) 0 voltage, less than 5 ohms between inhibitor switch and PRNDL switch, and reverse lamps
C-26 Reverse Lamp Switch
Pin Number(s) 1 2
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Circuit Designation/Description Normal Condition/Measurement Circuit 140 (W-R) 0 voltage, less than 5 ohms between reverse lamp switch and ignition relay Circuit 140X (R-B) 0 voltage, less than 5 ohms between reverse lamp switch and reverse lamps 01/2003 2003.0 BA Falcon
417-01-43
Exterior Lighting
417-01-43
DIAGNOSIS AND TESTING (Continued) C-44 Wagon LH Tail Lamp
Pin Number(s) 1 2
Circuit Designation/Description Normal Condition/Measurement Circuit 140A (R-B) 0 voltage, less than 5 ohms between LH reverse LH reverse lamp power input lamp and either inhibitor switch and prndl switch or reverse lamp switch Circuit 57EJ (B) 0 voltage, less than 5 ohms between LH tail LH tail lamp ground lamp and chassis ground
C-45 Wagon RH Tail Lamp
Pin Number(s) 1 2
Circuit Designation/Description Normal Condition/Measurement Circuit 140B (R-B) 0 voltage, less than 5 ohms between RH reverse RH reverse lamp power input lamp and either inhibitor switch and prndl switch or reverse lamp switch Circuit 57EK (B) 0 voltage, less than 5 ohms between RH tail RH tail lamp ground lamp and chassis ground
C-77 Sedan RH Tail Lamp
Pin Number(s) 1 2
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Circuit Designation/Description Normal Condition/Measurement Circuit 140B (R-B) 0 voltage, less than 5 ohms between RH reverse RH reverse lamp power input lamp and either inhibitor switch and prndl switch or reverse lamp switch Circuit 57EK (B) 0 voltage, less than 5 ohms between RH tail RH tail lamp ground lamp and chassis ground 01/2003 2003.0 BA Falcon
417-01-44
Exterior Lighting
417-01-44
DIAGNOSIS AND TESTING (Continued) C-78 Sedan LH Tail Lamp
Pin Number(s) 1 2
Circuit Designation/Description Normal Condition/Measurement Circuit 140A (R-B) 0 voltage, less than 5 ohms between LH reverse LH reverse lamp power input lamp and either inhibitor switch and prndl switch or reverse lamp switch Circuit 57EJ (B) 0 voltage, less than 5 ohms between LH tail LH tail lamp ground lamp and chassis ground
C-705 Ute Cab Chassis RH Tail Lamp
Pin Number(s) 1 2
Circuit Designation/Description Normal Condition/Measurement Circuit 140A (R-B) 0 voltage, less than 5 ohms between RH reverse RH reverse lamp power input lamp and either inhibitor switch and prndl switch or reverse lamp switch Circuit 57A (B) 0 voltage, less than 5 ohms between RH tail RH tail lamp ground lamp and chassis ground
C-714 Ute Back Up Lamp
Pin Number(s) 1 2
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Circuit Designation/Description Normal Condition/Measurement Circuit 140 (R-B) 0 voltage, less than 5 ohms between back up LH back up lamp power input lamp and either inhibitor switch and prndl switch or reverse lamp switch Circuit 57C (B) 0 voltage, less than 5 ohms between back up LH back up lamp ground lamp and chassis ground 01/2003 2003.0 BA Falcon
417-01-45
Exterior Lighting
417-01-45
DIAGNOSIS AND TESTING (Continued) Inspection and Verification Visual Inspection Chart Mechanical Inhibitor switch and PRNDL switch Reverse lamp switch
Electrical Junction Box (JB): Fuse 15 (15A) Circuitry Reverse lamp bulbs
Symptom Chart Condition
Source
Action
The reversing lamps are inoperative
Power Distribution Box (PDB): Fuse 15 (20A) relay 4 (20 A) Circuitry Inhibitor switch and PRNDL switch Reverse lamp switch
Go to PinPoint Test U
The individual reversing lamp is inoperative
Circuitry
Go to PinPoint Test V
The reversing lamps are on continuously
Circuitry Inhibitor switch and PRNDL switch Reverse lamp switch
Go to PinPoint Test W
Pinpoint Tests The reversing lamps are inoperative
Circuit 140 (W-R) open or short to ground Circuit 57 (B) open
Possible causes: Circuit 140X (R-B) open or short to ground Inhibitor switch and PRNDL switch C-26 Reverse lamp switch C-12 PINPOINT TEST U : THE REVERSE LAMPS ARE INOPERATIVE Test Step U1
Result / Action to Take
CHECK CIRCUIT 140X (R-B) VOLTAGE Disconnect either: (manual) Reverse Lamp Switch C-26. (automatic) Inhibitor switch and PRNDL switch C-12. Turn ON ignition.
Yes
Go to U2
No
Repair circuit 140X (R-B). Test the system for normal operation.
Measure the voltage between (manual) Reverse Lamp Switch C-26, circuit 140X (R-B), harness side or (automatic) Inhibitor switch and PRNDL switch C-12, circuit 140X (R-B), harness side and ground. Is the voltage greater than 10 volts?
U2
CHECK CIRCUIT 140 (W-R) FOR A SHORT TO GROUND Yes
Measure the resistance between (manual) Reverse Lamp Switch C-26, circuit 140 (W-R), harness side or (automatic) Inhibitor switch and PRNDL switch C-12, circuit 140 (W-R), harness side and ground.
Repair circuit 140 (W-R). Test the system for normal operation.
Is the resistance less than 5 ohms?
No
Go to U3
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DIAGNOSIS AND TESTING (Continued) Test Step U3
Result / Action to Take
CHECK CIRCUIT 140 (W-R) FOR AN OPEN Disconnect: Inoperative tail lamp.
Yes
Measure the resistance between (manual) Reverse Lamp Switch C-26, circuit 140 (W-R), harness side or (automatic) Inhibitor switch and PRNDL switch C-12, circuit 140 (W-R), harness side and inoperative tail lamp, circuit 140 (R-B), harness side.
No
Go to U4 Repair circuit 140 (W-R). Test the system for normal operation.
Is the resistance less than 5 ohms?
U4
CHECK CIRCUIT 57ER (B) FOR AN OPEN Measure the resistance between inoperative tail lamp, circuit 57 (B), harness side and ground. Is the resistance less than 5 ohms?
Yes
Perform the inhibitor switch and PRNDL switch or reverse lamp switch testing in Section 307-01. Test the system for normal operation.
No
Repair circuit 57 (B). Test the system for normal operation.
The individual reversing lamp is inoperative Possible causes: Circuit 140 (W-R) open Circuit 57 (B) open PINPOINT TEST V : THE INDIVUDUAL REVERSING LAMP IS INOPREATIVE Test Step V1
Result / Action to Take
CHECK THE VOLTAGE TO THE INOPERATIVE REVERSING LAMP Set the parking brake. Key in ON position. Disconnect: inoperative reversing lamp. Select REVERSE. Measure the voltage between the: sedan left tail lamp C-78, circuit 140A (R-B) harness sidesedan right tail lamp C-77, circuit 140B (R-B) harness side
Yes
Repair circuit 57(B). Test the system for normal operation.
No
Repair circuit 140(W-R). Test the system for normal operation.
wagon left tail lamp C-44, circuit 140A (R-B) harness side. wagon right tail lamp C-45, circuit 140B (R-B) harness side. Ute, non-SSB, right tail lamp C-705, circuit 140A (R-B) harness side. Ute, non-SSB, left tail lamp C-707, circuit 140C (R-B) harness side. Ute, SSB, back up lamp C-714, circuit 140 (R-B) harness side and ground. Is the voltage greater than 10 V?
The reversing lamps are on continuously Possible causes: Inhibitor switch and PRNDL switch C-26 Reverse lamp switch C-12 Circuit 140 (W-R) short to power
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Exterior Lighting
417-01-47
DIAGNOSIS AND TESTING (Continued) PINPOINT TEST W : THE REVERSING LAMPS ARE ON CONTINUOUSLY Test Step W1
Result / Action to Take
CHECK CIRCUIT 140 (W-R) FOR A SHORT TO POWER Disconnect either: (manual) Reverse Lamp Switch C-26. (automatic) Inhibitor switch and PRNDL switch C-12. Measure the voltage between (manual) Reverse Lamp Switch C-26, circuit 140 (W-R), harness side or (automatic) Inhibitor switch and PRNDL switch C-12, circuit 140 (W-R), harness side and ground.
Yes
Repair circuit 140 (W-R). Test the system for normal operation.
No
Perform the inhibitor switch and PRNDL switch or reverse lamp switch testing in Section 307-01. Test the system for normal operation.
Is the voltage greater than 10 volts?
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Exterior Lighting
417-01-48
GENERAL PROCEDURES
Headlamp Adjustment
Driving Beam
Low Beam
1. The driving beam is fixed internally within the headlamp relative to the low beam. Whenever the low beam aim is adjusted the driving beam is also adjusted.
(Refer to diagram on following page.) 1. To adjust the headlamp aim in accordance with this specification, a flat vertical test screen as shown is required. Alternatively an approved headlamp aim testing device may be used. 2. The vehicle must have the correct tyre pressure, must be unloaded, have a fully filled tank and the hand brake must be in the fully released position. 3. The vehicle must be placed on a flat horizontal surface and carefully positioned 10 metres from the test screen. 4. Gently rock vehicle to obtain correct horizontal vehicle attitude. 5. Measure H the height of the headlamp low beam bulb centre above ground. For different lamps and vehicles this height will vary due to vehicle production tolerance. 6. Set the horizontal breakline on the test screen to a height h = H-e where e is the aim setting dimension. 7. Measure A the distance between the low beam bulb centres. Using this dimension set up the low beam aim centre C and construct the 15 inclined breakline from this point on the test screen. 8. Switch on the low beam lights and cover all lamps except the one that is being aimed. 9. Using the horizontal and vertical aim adjusting screws shift the light pattern of the headlamp on the test screen until the light/dark boundaries of the light pattern coincides with the breaklines on the test screen. The low beam pattern should now be centred on point C.
10. Repeat the above procedure to adjust the remaining headlamp. High Beam 1. The high beam aim is fixed internally within the headlamp relative to the low beam. Whenever the low beam aim is adjusted the high beam aim is also adjusted. G86734 en
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Exterior Lighting
417-01-49
GENERAL PROCEDURES (Continued)
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Exterior Lighting
417-01-50
GENERAL PROCEDURES (Continued) Fog Lamp Adjusment (XR Only) (Refer to diagram on following page.) 1. To adjust the foglamp aim in accordance with this specification, a flat vertical test screen as shown is required. 2. The vehicle must have the correct tyre pressure, must be unloaded, have a fully filled tank and the hand brake must be in the fully released position. 3. The vehicle must be placed on a flat horizontal surface and carefully positioned 5 metres from the test screen. 4. Gently rock vehicle to obtain correct horizontal vehicle attitude. 5. Measure H the height of the foglamp bulb centre above ground. For different lamps and vehicles this height will vary due to vehicle production tolerance. 6. Set the horizontal line on the test screen to a height h = H-e where e is the aim setting dimension. 7. Switch on the fog lights and cover all lamps except the one that is being aimed. 8. Using the vertical aim adjusting screw (accessible from under the bumper with an 6 mm Allen key or Phillips screw driver) shift the light pattern of the foglamp on the test screen until the centre of the of the light pattern Point C coincides with the line at h on the test screen.
9. Repeat the above procedure to adjust the remaining fog lamp.
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Exterior Lighting
417-01-51
GENERAL PROCEDURES (Continued)
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Exterior Lighting
417-01-52
REMOVAL AND INSTALLATION
Headlamp Assembly
3. Remove the rubber boot from the lamp back face.
Removal WARNING: Bulbs become hot to touch and can cause burns if not allowed to cool before handling. 1. Raise the hood. 2. Disconnect the 3 lamp wiring connectors. 3. Remove the front bumper & bumper absorber (Refer to section 501-19).
4. Release retaining spring clip and withdraw bulb. 5. Remove bulb from holder. Installation NOTE: Hold the replacement Quartz Halogen bulb with a clean cloth or tissue to prevent contact with glass. If the glass is touched, the skin’s natural oils will contaminate the bulb. Wipe the bulb clean using methylated spirits before installing. 1. Push bulb into holder. 2. Install the bulb and retain it with the spring clip. 4. Remove 4 bolts from the lamp. 5. Pull lamp slighty forward and upwards to dislodge 3. Install the rubber boot, installing the inner aperture to the bulb first, followed by the outer retainers. aperture to the lamp body. Ensure the rubber boot 6. Gently move lamp slightly inboard and rock has sealed correctly and is not deformed. forward to remove ensuring indicator bulb clears 4. Reconnect wiring to the bulb and test. fender opening. Installation Headlamp Bulb — Low Beam H4 1. Connect lamp wiring harness. Removal 2. Reverse removal procedure. 1. Switch the headlamps off and allow sufficient time 3. Check and adjust headlamp aim if necessary. to cool. Headlamp Bulb — High Beam H7 2. Disconnect wiring from bulb. 3. Remove the rubber boot from the lamp back face. Removal 1. Switch the headlamps off and allow sufficient time 4. Release retaining spring clip and withdraw bulb. Installation to cool. NOTE: Hold the replacement Quartz Halogen bulb 2. Disconnect wiring from the bulb closest to the with a clean cloth or tissue to prevent contact with centre of the vehicle. glass. If the glass is touched, the skin’s natural oils will contaminate the bulb. Wipe the bulb clean using methylated spirits before installing. 1. Install the bulb and retain it with the spring clip. 2. Install the rubber boot, installing the inner aperture to the bulb first, followed by the outer aperture to the lamp body. Ensure the rubber boot has sealed correctly and is not deformed. 3. Reconnect wiring to the bulb and test.
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Exterior Lighting
417-01-53
REMOVAL AND INSTALLATION (Continued)
Turn Signal Bulb
Installation 1. Reverse the removal procedure.
Removal 1. Turn the front wheel inward to allow access to the Auxiliary Lamp 3 lower front fender splash shield push pin rivets Removal and screw. Carefully peel back the splash shield 1. Switch the lamps off and allow sufficient time to to expose the turn signal wiring connector. cool. 2. Remove the lower air deflector from the front bumper.
Item 1 2 3 4 5
Description Fender splash shield Firtree Cip - 6.5x25mm (x2) Scrivets - 6mm (x10) Screw - 5mm (x1) Screw - 5mm (x2)
Item 1 2 3 4
Description Wiring harness Self-tapping screw Firtree clip Air deflector retaining screw
2. Turn the bayonet-style connector anti-clockwise approximately 1/8 of a turn to free the bulb holder. 3. Disconnect the wiring harness from the lamp bulb. Installation 4. Remove the three self-tapping screws used to 1. Reverse the removal procedure. retain the lamp. Installation Parklamp Bulb 1. Reverse the removal procedure. Removal 1. Switch the headlamps off and allow sufficient time Auxiliary Lamp Bulb to cool. Removal 2. Gently rotate anticlockwise and pull bulb holder NOTE: Switch the lamps off and allow sufficient time from the lamp. to cool. 1. Remove the lower air deflector from the bottom of the front bumper. 2. Disconnect the terminal. 3. Remove the bulb retainer by rotating in an anti-clockwise direction. 4. Remove the bulb from the bulb by pulling outwards. Installation 1. Install the new bulb. 2. Refit the bulb retainer into the lamp housing and rotate 1/8 turn clockwise until the bulb retainer is fully positioned. Note that the bulb retainer will 3. Remove bulb from the holder by pulling outwards. only fit correctly in one position. 3. Connect the terminal to the bulb retainer. G86741 en
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REMOVAL AND INSTALLATION (Continued) 4. Refit the lower air deflector.
Tail Lamp Assembly — Sedan
Fog Lamp
Removal
Removal 1. Switch the foglamps off and allow sufficient time to cool. 2. Remove the air lower air deflector. 3. Push the lamp inward with your palm. 4. Disconnect the lamp wiring. 5. Remove the lamp assembly from the car. Installation 1. Reverse the removal procedure.
Fog Lamp Bulb Removal 1. Remove the foglamp assembly from the bumper as above.
2. Unclip retaining clip and remove bulb. Installation NOTE: Hold the replacement Quartz Halogen bulb with a clean cloth or tissue to prevent contact with glass. If the glass is touched, the skin’s natural oils will contaminate the bulb. Wipe the bulb clean using methylated spirits before installing. 1. Install the bulb and retain it with the spring clip. 2. Test. 3. Clip lamp insert into the lamp assembly.
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1. Open decklid. 2. Remove interior quarter trim. 3. Disconnect wiring connector to tail lamp and squeeze rubber grommet through hole. 4. Remove two retaining screws on the inboard side of tail lamp assembly. 5. Insert a thin flat head screwdriver or similar object having a flat blade to the forward side of the outboard stud and gently prise it off the plastic retainer, being careful to protect any paint from damage. 6. Remove the lamp assembly. 7. Discard mating ball stud insert. Installation 1. Replace plastic ball stud insert. 2. Pull the wiring assembly in and ensure the rubber grommet is correctly seated to body panel. 3. Install lamp into vehicle ensuring locating tab is over the sheetmetal tab. 4. Install the two retaining screws. 5. Connect the wiring connector and refit the rear quarter interior trim. 6. Close the decklid.
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Exterior Lighting
417-01-55
REMOVAL AND INSTALLATION (Continued)
Tail Lamp Assembly — Wagon Removal 1. Open the liftgate.
2. Remove the rear quarter interior trim. 3. Disconnect wiring connector to tail lamp and squeeze rubber grommet through hole. 4. Remove the two retained screws, one on the inboard side and another one on the top of the tail lamp assembly. 5. Insert a thin flat head screwdriver or similar object having a flat blade to the forward side of the outboard stud and gently prise it off the plastic retainer, being careful to protect any paint from damage. 6. Remove the tail lamp assembly. Installation 1. Pull the wiring assembly in and ensure the rubber grommet is correctly seated to body panel. 2. Insert the locating peg to the upper inboard square hole on the body panel and push the outboard stud into the plastic retainer. 3. Install the two retained screws. 4. Connect the wiring connector and refit the rear quarter interior trim. 5. Close the liftgate.
Tail Lamp, Reverse Lamp and Rear Indicator Bulb — Sedan And Wagon Removal 1. Follow steps 1, 4, 5 of Tail Lamp Assembly Removal and Installation procedure, so that lamp assembly is free from vehicle. It is not necessary to disconnect the electrical wiring from vehicle.
2. Remove bulb holder from socket by rotating holder anti-clockwise approximately 1/8th turn until free from socket. Stop and tail lamp - (clear twin filaments bulb) Indicator lamp - (amber bulb) Reverse lamp - (clear bulb) 3. Remove bulb from holder by rotating anti-clockwise approximately 1/8th turn. Installation 1. Install bulb in holder by gently pushing bulb into holder and rotating bulb clockwise. 2. Insert bulb and holder assembly into socket. Note: the holder cannot be inserted into the incorrect socket. Rotate holder clockwise until firm in socket. 3. Follow the procedure given in this section for installation of the tail lamp assembly.
Tail Lamp Assembly — Style Side Box Removal 1. Open tailgate. 2. Remove two bolts on taillight edge.
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Exterior Lighting
417-01-56
REMOVAL AND INSTALLATION (Continued) 3. Remove lamp, pulling away at 45 degrees.
2. Carefully insert the tail lamp assembly, snapping the two retaining tabs into place. 3. Install the two bolts.
Reverse Light Replacement — Style Side Box Removal 1. Remove the two bolts attaching the reverse light.
Item 1 2 3 4
Description Bolt (x2) Tail lamp wiring Tail lamp pin location guide Tail lamp assembly
4. Disconnect wiring. Installation 1. Reverse removal procedure.
Rear Light Bulbs Replacement — Style Side Box Removal 1. Remove the two bolts from the inside of the tailgate. 2. Carefully pull the tail lamp assembly from the liftgate pillar by releasing the two retaining tabs.
Item 1
Description Reverse lamp
2. Carefully insert a flat blade under the lens. 3. Disconnect the bulb connector. 4. Remove the bulb to be replaced. Installation 1. Insert a new bulb and replace the wiring connector. 2. Replace the lens and install the two bolts.
Tail Lamp Assembly — Tray Removal 1. Remove M6 nuts from lamp mounting bracket.
Item 1 2
Description Brake/Tail lamp Indicator lamp
3. Disconnect the wiring connector. 4. Carefully pull out the bulb to be replaced. Installation 1. Insert the new bulb and replace the wiring connector. G86747 en
Item 1 2
Description Tail lamp assembly Nut - M6
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Exterior Lighting
417-01-57
REMOVAL AND INSTALLATION (Continued)
Rear Light Bulbs Replacement — Cable/Chassis and Tray Removal 1. Release the retaining clip and swivel aside the plastic frame that secures the lens.
Item 1 2 3 4
Item 1 2 3 4 5
Description Bolt Nut - M6 Tail lamp assembly Ute chassis Mointing bracket
Installation 1. Reverse the removal procedure.
G86752 en
Description Reversing lamp Indicator lamp Tail lamp Brake lamp
2. Remove the lens from the lamp assembly. 3. Remove the blown bulb by gently pressing the bulb down and turning it anti-clockwise. Installation 1. Insert a new bulb, replace the lens and close the plastic frame with the retaining clip.
Licence Plate Lamp Assembly Removal 1. Gently insert a flat blade or similar object under one side of lamp assembly and gently press on the locking tab. 2. Lift the lamp assembly out of the bumper or applique. 3. Disconnect the wiring connector.
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Exterior Lighting
417-01-58
REMOVAL AND INSTALLATION (Continued) Installation 1. Connect the wiring connector. 2. Position lamp assembly and push into bumper or applique until locking tabs engage.
Licence Plate Bulb
Rear Licence Plate Lamp Replacement — Chassis/Cab and Tray Removal and Installation 1. Push off the rubber band and pull off the cap.
Removal 1. Remove lamp assembly as above leaving the wiring connected. 2. Turn bulb holder approximately 1/8th turn anti-clockwise until it is free. 3. Pull bulb out from socket. Installation NOTE: Tabs prevent the bulb holder from being inserted into the lamp assembly at the incorrect orientation. Do not apply force. 1. Reverse the removal procedure.
Rear Licence Plate Lamp Replacement — Style Side Box Removal and Installation 1. Carefully insert a flat blade under one side of the lamp assembly. Press gently on the locking tab.
Item 1 2
Description Retaining bolt Licence plate housing
2. Remove the bulb by gently pressing it down and turning it anti-clockwise. 3. Insert a new bulb and replace the cap in the rubber band.
Side Indicator Lamps Removal 1. Turn front wheel outward. 2. Remove front splash shield fixings behind wheel, and peel splash shield back.
2. Lift the lamp assembly out of the bumper. 3. Disconnect the wiring connector. 4. Turn the bulb holder approximately 1/8th turn anti-clockwise until it is free. Pull the bulb from the socket. 5. Replace the bulb and bulb holder, connect the wiring connector and push the lamp assembly into the bumper until the locking tabs engage. Item 1 2 3 4 5
G86752 en
Description Fender splash shield Firtree Cip - 6.5x25mm (x2) Scrivets - 6mm (x10) Screw - 5mm (x1) Screw - 5mm (x2)
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Exterior Lighting
417-01-59
REMOVAL AND INSTALLATION (Continued) 3. Remove bulb holder by turning anti-clockwise about 45 degrees. 4. Remove bulb from holder by pulling straight out. Installation 1. Reverse the removal procedure.
2. Disconnect wiring connector to stop lamp.
High Mount Stop Lamp — Sedan (Except LWB) Removal 1. From inside the luggage compartment remove the bulb holder from the base of the lamp. 2. From inside the vehicle remove the parcel shelf trim. 3. Unscrew lamp assembly from spoiler. Installation NOTE: Lamp is a sealed unit and must be replaced as a complete assembly. 1. Reverse the removal procedure.
High Mount Stop Lamp Bulb — Wagon Removal 1. Raise the liftgate and detach the clip-on cover from the lamp. 2. Detach the bulb holder from the lamp. 3. Gently prise the lamp from the panel, dislodging the front legs first. Installation 1. Slot rear hooks of lamp into panel, then snap in front legs. 2. Replace the trim. 3. Install the bulb holder in the lamp. NOTE: There is no bulb fitted to holder when a spoiler mounted HMSL is fitted.
High Mount Stop Lamp — XR Series Sedan Removal 1. Unbolt rear spoiler and lift from bootlid.
Item 1 2 3 4 5 6
Description High mount stop lamp Screw receptacle Screw High mount brake light lens High mount brake light housing Tail gate
3. Remove the wedge base bulb from the bulb holder. Installation 1. Install the bulb in the bulb holder. 2. Install the bulb holder in the lamp. 3. Install the cover on the lamp. G86760 en
01/2003 2003.0 BA Falcon
417-01-60
Exterior Lighting
417-01-60
REMOVAL AND INSTALLATION (Continued)
High Mount Stop Lamp — LWB Removal 1. Remove the rear clips holding the roof trim from inside the vehicle. 2. Disconnect lamp wiring.
3. Remove the two screws connecting the lamp to the vehicle roof. Installation 1. Reverse the removal procedure. NOTE: Lamp is a sealed unit and must be replaced as a complete assembly.
Twilight Sensor/Sun Load Sensor For removal and installation of twilight sensor/sun load sensor, refer to section 412-04.
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01/2003 2003.0 BA Falcon
417-02-1
Interior Lighting
417-02-1
SECTION : 417-02 Interior Lighting VEHICLE APPLICATION : 2003.0 BA Falcon CONTENTS
PAGE
DESCRIPTION AND OPERATION Interior Lighting .....................................................................................................................417-02-2 DIAGNOSIS AND TESTING Interior Lighting .....................................................................................................................417-02-3 Principles of Operation .........................................................................................................417-02-3 Visual Inspection Chart ........................................................................................................417-02-3 Symptom Chart ....................................................................................................................417-02-3 Pinpoint Tests ......................................................................................................................417-02-4 REMOVAL AND INSTALLATION Interior Lamp .........................................................................................................................417-02-7 Map Reading Lamp ...............................................................................................................417-02-7 Front Vanity Lamp .................................................................................................................417-02-7 Luggage Compartment Lamp — Wagon ..............................................................................417-02-7 Luggage Compartment Lamp — Sedan ...............................................................................417-02-8 Console Lamp (Lo Series) ....................................................................................................417-02-8 Console Lamp (High Series) .................................................................................................417-02-8
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Interior Lighting
417-02-2
DESCRIPTION AND OPERATION
Interior Lighting The interior lighting consists of the following: Interior lamp Console lamp Map reading lamp and bulb Luggage compartment lamp Vanity mirror lamp Interior lamp switch Illuminated entry module
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Interior Lighting
417-02-3
DIAGNOSIS AND TESTING Visual Inspection Chart
Interior Lighting
Normal Condition
Principles of Operation The interior lamps are supplied positive power from the BEMs battery saver circuit. This positive supply turns off 15 minutes after the ignition is turned off or door/ lamp activity ceases. Operating the Audio with ignition off also activates the battery saver power supply to energise the on glass antenna amplifier. Pressing the remote entry unlock button or courtesy lamp switch, opening the boot, wagon liftgate or any of the doors will also activate the battery saver power supply. The negative side of the courtesy lamps are also supplied from the BEM - refer to circuit diagrams for details. These can be switched by the BEM using the WDS tool. Reading lamps and glove box lamps are switched to regular ground through their respective switches. For sedan, the luggage compartment lamp is switched to ground through the decklid latch ajar switch.
Possible cause of abnormality Fuse Not blown Extra accessories added drawing more current. Wiring short circuit Faulty switch (if applicable) Globe filament in tact Bulb life exceeded Vibration damage Switch turns circuit on Physical damage or heat and off damage Ensure air can circulate around lamp Lens, housing etc are not Physical damage or heat damaged damage Ensure air can circulate around lamp
Symptom Chart Symptom Chart Condition Courtesy Lamp button on ICC not working
Courtesy Lamps not turning on when doors opened
Reading lamps not working
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Source
Action
Blown Globe
Check globe
Function disabled
Press courtesy lamp switch for five second to reactivate function - see owners manual
Internal ICC Fault
Diagnose button functionality - refer ICC diagnostics Section 413-08
BEM Fault
Check BEM switches lamp on and off refer BEM diagnostics Section 419-10
Damaged Lamp Unit
Check for damage to terminal and connections
Damaged Wiring
Check continuity of wiring to BEM
Blown Globe
Check globe
Function disabled
Press courtesy lamp switch for five second to reactivate function - see owners manual
Internal ICC Fault
Diagnose button functionality - refer ICC diagnostics Section 413-08
BEM Fault
Check BEM door inputs and that it switches lamp on and off - refer BEM diagnostics Section 419-10
Damaged Lamp Unit
Check for damage to terminal and connections
Damaged Wiring
Check continuity of wiring from lamp to BEM
Blown Globe
Check globe
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Interior Lighting
417-02-4
DIAGNOSIS AND TESTING (Continued) Condition
Source
Glove Box lamp not working
Luggage Compartment Lamp not working
Action
BEM Fault
Check BEM door inputs and that it switches lamp on and off - refer BEM diagnostics Section 419-10
Damaged Lamp Unit
Check for damage to terminal and connections
Damaged Wiring
Check continuity of wiring to BEM
Blown Globe
Check globe
BEM Fault
Check BEM door inputs and that it switches lamp on and off - refer BEM diagnostics Section 419-10
Damaged Lamp Unit
Check for damage to terminal and connections
Damaged Wiring
Check continuity of wiring to BEM
Blown Globe
Check globe
BEM Fault
Check BEM door inputs and that it switches lamp on and off - refer BEM diagnostics Section 419-10
Damaged Lamp Unit
Check for damage to terminal and connections
Damaged Wiring
Check continuity of wiring to BEM
Pinpoint Tests PINPOINT TEST A : LUGGAGE COMPARTMENT LAMP Test Step A1
Result / Action to Take
INITIAL CHECK Open Boot. Does the Luggage compartment lamp illuminate?
Yes
Functioning correctly
No
Continue
A2
FILAMENT CONDITION Remove globe and check filament (use multi-meter if necessary). Is the filament OK ?
Yes
Continue
No
Change globe and recheck
A3
WDS CHECK Use WDS and turn lamps on (See BEM diagnostics for switch input status).
Yes
Does the lamp turn on?
No
Continue
Go to A6
A4
WDS CHECK Cont. Check latch switch using WDS (See BEM diagnostics for switch input status).
Yes
Is switch functioning OK?
No
Functioning correctly.
Continue
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Interior Lighting
417-02-5
DIAGNOSIS AND TESTING (Continued) Test Step A5
WIRING CONDITION Disconnect wiring from boot latch and check switch function with multi-meter by latching and unlatching the unit. Refer wiring schematic for connection detail.
Yes
Check wiring to boot latch switch. Refer wiring circuits and diagnostics.
No
Is switch OK ?
A6
Result / Action to Take
Replace latch
CIRCUIT INTEGRITY Check integrity of wiring (including fuse and globe) from BEM to lamp. Are fuse, wiring and globe OK ?
Yes
Refer BEM diagnostics.
No
Replace fuse, globe or wiring as required and recheck system.
PINPOINT TEST B : GLOVE BOX / READING LAMP Test Step B1
Result / Action to Take
VISUAL CHECK Open Glove Box / switch on reading lamp. Does the Glove Box / reading lamp illuminate?
Yes
Functioning correctly
No
Continue
B2
FILAMENT CONDITION Remove globe and check filament (use multi-meter if necessary). Is the filament OK ?
Yes
Continue
No
Change globe and recheck.
B3
WIRING CONDITION Yes Disconnect wiring from glove box / reading switch and check switch function with multi-meter. Refer wiring schematic for connection detail. Check wiring to switch / globe. Refer wiring circuits and diagnostics. Is switch OK ? No
Replace switch.
PINPOINT TEST C : COURTESY LAMPS Test Step C1
Result / Action to Take
ICC CONTROLLED FUNCTIONALITY
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Refer to ICC section of owners manual (a five second press of the courtesy lamp switch will toggle modes)
Yes
Is the courtesy lamp function controlled by the Interior Command Centre enabled?
No
Continue
Enable function by pressing the courtesy lamp switch on ICC for longer than five seconds. Recheck operation
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Interior Lighting
417-02-6
DIAGNOSIS AND TESTING (Continued) Test Step C2
Result / Action to Take
VISUAL CHECK Open Doors. Do the courtesy lamps illuminate?
Yes
Functioning correctly.
No
Continue - to check lamps that do not illuminate.
C3
WDS SELF – TEST Use WDS and turn courtesy lamps on (See Body Electronics Module diagnostics).
Yes
Do the lamps turn on?
No
Continue
Go to C5
C4
WDS SELF – TEST Cont. Check door switch using WDS (See BEM diagnostics for switch input status).
Yes
Is switch functioning OK?
No
System is operating - recheck system
Continue with BEM diagnostics to check door inputs to BEM
C5
CIRCUIT INTEGRITY Check integrity of wiring (including fuse and globe) from BEM to lamp. Are fuse, wiring and globe OK?
Yes
Refer BEM diagnostics.
No
Replace fuse, globe or wiring as required and recheck system.
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Interior Lighting
417-02-7
REMOVAL AND INSTALLATION
Interior Lamp Removal 1. Unclip the interior lamp lens.
Item 1 2 Item 1 2 3 4
Description Roof Trim Panel Bezel Bulb Lens
2. Remove the bulb. Installation 1. Install lamp bulb. 2. Refit the interior lamp lens.
Map Reading Lamp
Description Bezel Roof Trim Panel
2. Remove the bulb from the lamp. Installation 1. Install the bulb into the lens. 2. Refit the lens into the bezel, inserting the knob end first.
Front Vanity Lamp Removal Refer to Map Reading Lamp removal. Installation Refer to Map Reading Lamp installation.
Luggage Compartment Lamp — Wagon
Removal 1. Unclip the lens from the bezel using a screwdriver Removal on the end of the lens opposite the knob. 1. Refer to Map Reading Lamp removal. Installation 1. Refer to Map Reading Lamp installation.
Item 1 2
Description Bezel Roof Trim Panel
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01/2003 2003.0 BA Falcon
417-02-8
Interior Lighting
417-02-8
REMOVAL AND INSTALLATION (Continued)
Luggage Compartment Lamp — Sedan Removal 1. Remove lamp as shown.
Item 1 2 3 4 5 6
Description Black Insulator (earth) Negative earth Negative Positive Positive Insulator Red Insulator (feed)
Installation 1. Reverse removal procedure.
Console Lamp (Lo Series) Removal 1. Remove console lamp as shown in figure.
Installation 1. Reverse removal procedure.
Console Lamp (High Series) Refer to Section 501-05.
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01/2003 2003.0 BA Falcon
418-00-1
Module Communications Network
418-00-1
SECTION : 418-00 Module Communications Network VEHICLE APPLICATION : 2003.0 BA Falcon CONTENTS
PAGE
SPECIFICATIONS Specifications ........................................................................................................................418-00-2 DESCRIPTION AND OPERATION Communications Network .....................................................................................................418-00-3 DIAGNOSIS AND TESTING Communications Network .....................................................................................................418-00-4 Principles of Operation .........................................................................................................418-00-4 Inspection and Verification ...................................................................................................418-00-4 Symptom Chart ....................................................................................................................418-00-4 Connector Circuit Reference ................................................................................................418-00-5 Pinpoint Tests ......................................................................................................................418-00-9 GENERAL PROCEDURES Communication Circuit Wiring Repair .................................................................................418-00-22
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418-00-2
Module Communications Network
418-00-2
SPECIFICATIONS General Specifications Description Heat shrink tube overlap mm (inch) Wire insulation removal length (twist side) mm (inch) Wire insulation removal length (receiving side) mm (inch) Raychem SCT® Heat Shrink Tubing, Motorcraft part number WT-5627
G86726 en
Specification 12.7 (0.5) 37.2 (1.5) 19.5 (0.75) ESB-M99D56-A2
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418-00-3
Module Communications Network
418-00-3
DESCRIPTION AND OPERATION
Communications Network The module communications network consists of the following items: High Speed Controller Area Network (HS-CAN) communications network. International Standards Organization (ISO) 9141 communications network Anti-lock Braking System and Traction Control System (ABS/TCS) {*or ABS Module} Interior Command Centre (ICC) {*or ACM} Body Electronics Module (BEM) HVAC Integrated Module (HIM) Instrument Cluster (IC) {*or Cluster} Parking Aid Module (PAM) {*or Sonar Module} Powertrain Control Module (PCM) {*or EEC-B} Restraints Control Module (RCM) {*or ARS} Data Link Connector (DLC) NOTE: The abbreviations shown in { } may also be shown on wiring diagrams.
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Module Communications Network
418-00-4
DIAGNOSIS AND TESTING The following modules are linked to the HS-CAN communication network: Refer to Wiring Diagram Section 418-00 for schematic Anti-lock Braking System and Traction Control and connector information. System ABS/TCS - Operation only, diagnostics via ISO9141 Special Tool(s) Audio Control Module (ACM) 73III Automotive Meter Body Electronics Module (BEM) 105-R0057 or equivalent HVAC Integrated Module (HIM) Instrument Cluster (IC) Powertrain Control Module (PCM) The HS-CAN network is terminated at one end by the PCM, with the other end terminated by the IC. Additionally, the DLC and the remaining HS-CAN Worldwide Diagnostic System modules are connected to this bus. (WDS) For information on operation of individual modules please refer to the relevant sections.
Communications Network
Inspection and Verification 1. Verify the customer concern. 2. Visually inspect for obvious signs of electrical damage. Principles of Operation Visual Inspection Chart The vehicle has two module communications Electrical networks. Wiring harness The High Speed Controller Area Network (HS-CAN), Electrical connectors which is an unshielded twisted pair cable (data bus Central junction box (CJB) Fuses plus, CAN High, circuit 914 [BR-Y] and data bus Modules: minus, CAN Low, circuit 915 [P-L]); and the International Standards Organization (ISO) 9141 ABS/TCS module network which is a single wire (circuit 70 [SB-W]). The ABS/EVAC FILL module diagnostic tool can connect to both networks through ACM the Data Link Connector (DLC). This makes diagnosis and testing of these systems easier by allowing one BEM smart tester to be able to diagnose and control any HIM module on the two networks from one connector. IC The ISO 9141 communication network does not PAM permit inter-module communication. When the PCM diagnostic tool communicates to modules on the ISO 9141 communication network, the diagnostic tool must RCM ask for all information; the modules cannot initiate 3. If the concern remains after the inspection, communications. connect the diagnostic tool to the Data Link The ISO 9141 communication network will not Connector (DLC) and select the vehicle to be function if the wire is shorted to ground or battery tested from the diagnostic tool menu. If the voltage. Also, if one of the modules on the ISO 9141 diagnostic tool does not communicate with the communication network loses power or shorts vehicle: internally, communications to that module will fail. 1. Check that the program card is correctly The following modules are linked to the ISO9141 installed. communication network (for diagnostics only): 2. Check the connections to the vehicle. Anti-lock Braking System and Traction Control 3. Check the ignition switch position is in RUN. System (ABS/TCS) - Diagnostics only, If the diagnostic tool still does not communicate with operation via HS-CAN the vehicle, go to Pinpoint Test M. ABS/EVAC FILL module 4. Go to Pinpoint Test A. Parking Aid Module (PAM) (if equipped) Restraints Control Module (RCM)
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01/2003 2003.0 BA Falcon
418-00-5
Module Communications Network
418-00-5
DIAGNOSIS AND TESTING (Continued) Symptom Chart Condition
Source
Action
ABS/TCS module does not respond to the diagnostic tool (WDS)
Circuit or connection on ISO-9141 communication network. ABS/TCS module. Power and ground circuits.
Go to PinPoint Test B .
ABS/EVAC FILL module does not respond to the diagnostic tool (WDS)
Circuit or connection on ISO-9141 communication network. ABS/EVAC FILL module. Power and ground circuits .
Go to PinPoint Test J .
RCM does not respond to the diagnostic tool (WDS)
Circuit or connection on ISO-9141 communication network. RCM. Power and ground circuits .
Go to PinPoint Test C.
PAM does not respond to the diagnostic tool (WDS)
Circuit or connection on ISO-9141 communication network. PAM. Power and ground circuits.
Go to PinPoint Test D .
IC does not respond to the diagnostic tool (WDS)
Circuit or connection on CAN communication network. IC. Power and ground circuits.
Go to PinPoint Test E .
PCM does not respond to the diagnostic tool (WDS)
Circuit or connection on CAN communication network. PCM. Power and ground circuits .
Go to PinPoint Test F .
ACM does not respond to the diagnostic tool (WDS)
Circuit or connection on CAN communication network. ACM. Power and ground circuits.
Go to PinPoint Test G .
BEM does not respond to the diagnostic tool (WDS)
Circuit or connection on CAN communication network. BEM. Power and ground circuits.
Go to PinPoint Test H .
HIM does not respond to the diagnostic tool (WDS)
Circuit or connection on CAN communication network. HIM. Power and ground circuits.
Go to PinPoint Test I .
No ISO 9141 network communication
Circuit or connection on the ISO 9141 network. ISO 9141 network modules.
Go to PinPoint Test K .
No HS-CAN network communication
Circuit or connection on the HS-CAN network. HS-CAN network modules.
Go to PinPoint Test L .
No module/network communication no power to the diagnostic tool
Data link connector (DLC). Central junction box (CJB) Fuse (Courtesy Lamp). Circuits. Diagnostic tool.
Go to PinPoint Test M .
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Module Communications Network
418-00-6
DIAGNOSIS AND TESTING (Continued) Connector Circuit Reference NOTE: Connector view is looking into the front of the connector (wiring half). Data Link Connector (DLC) - C174
Pin Number(s) 70C 914K 915K
Circuit Designation/Description (SB-W) — ISO Communications ( BR-Y) — HS-CAN Communications (High) ( P-L) — HS-CAN Communications (Low)
Normal Condition/Measurement
In-line connector - C119
Pin Number(s) 70 70A 914P 915P
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Circuit Designation/Description (SB-W) ISO Communications (SB-W) ISO Communications ( BR-Y) HS-CAN Communications (High) ( P-L) HS-CAN Communications (Low)
Normal Condition/Measurement — — — —
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418-00-7
Module Communications Network
418-00-7
DIAGNOSIS AND TESTING (Continued) Connector C364 (ICC, Section 413-08)
Pin Number(s) 914M 915M 914N 915N
Circuit Designation/Description (BR-Y) HS-CAN Communications (High) ( P-L) HS-CAN Communications (Low) (BR-Y) HS-CAN Communications (High) ( P-L) HS-CAN Communications (Low)
Normal Condition/Measurement — — — —
Connector C150 (ABS, Section 206-09)
Pin Number(s) 70 914H 915H
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Circuit Designation/Description (SB-W) — ISO Communications (BR-Y) — HS-CAN Communications (High) (P-L) — HS-CAN Communications (Low)
Normal Condition/Measurement
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418-00-8
Module Communications Network
418-00-8
DIAGNOSIS AND TESTING (Continued) Connector C386 (ABS, Section 206-09)
Pin Number(s) 70
Circuit Designation/Description (SB-W) — ISO Communications
Normal Condition/Measurement
Connector C189 (Occupant Restraints, Section 501-20B)
Pin Number(s) 70B
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Circuit Designation/Description (SB-W) ISO Communications
Normal Condition/Measurement
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418-00-9
Module Communications Network
418-00-9
DIAGNOSIS AND TESTING (Continued) Pinpoint Tests PINPOINT TEST A : DATA LINK DIAGNOSTICS NETWORK TEST Test Step A1
Result / Action to Take
DATA LINK DIAGNOSTICS NETWORK TEST
Yes
Key in ON position. Run the data link diagnostics network test. Is SYSTEM PASSED obtained?
Test passed. RETURN to the Symptom Chart of the section for the module in question.
No
If no response from the diagnostic tool, Go to PinPoint Test H If CKT70, CKT914, or CKT915 = SOME ECUS NO RESP/NOT EQUIP, REFER to the Symptom Chart. If CKT70 = ALL ECUS NO RESP/NOT EQUIP, Go to PinPoint Test K If CKT914 = ALL ECUS NO RESP/NOT EQUIP, Go to PinPoint Test L If CKT915 = ALL ECUS NO RESP/NOT EQUIP, Go to PinPoint Test L If module in question is NO RESPONSE/NOT EQUIPPED, REFER to the Symptom Chart. If module in question is NO RESPONSE ON CKT914 (BUS+) or NO RESPONSE ON CKT915 (BUS-), REFER to Symptom Chart.
PINPOINT TEST B : ABS/TCS MODULE DOES NOT RESPOND TO THE DIAGNOSTIC TOOL (WDS) Test Step B1
CHECK ABS/TCS C150 CIRCUIT 70 (SB-W) FOR DAMAGE Key in OFF position. Disconnect ABS/TCS C150. Inspect ABS/TCS C150 for damage. Is the ABS/TCS C150 OK?
B2
Result / Action to Take
Yes
Go to B2
No
REPAIR the ABS/TCS C150. CARRY OUT the DATA LINK DIAGNOSTICS test.
CHECK CIRCUIT 70 (SB-W) BETWEEN DLC C174 AND ABS/TCS C150 FOR OPEN
Yes
Measure the resistance between ABS/TCS C150, circuit 70 (SB-W), harness side and DLC C174, circuit 70C (SB-W), harness side.
Go to B3
Is the resistance less than 5 ohms?
No
REPAIR the circuit(s) as necessary. CARRY OUT the DATA LINK DIAGNOSTICS test.
B3
CHECK FOR CORRECT ABS/TCS OPERATION Disconnect all ABS/TCS connectors. Check for: Corrosion Pushed-out pins Connect all ABS/TCS connectors and make sure they seat correctly. Operate the system and verify the concern is still present. Is the concern still present?
G86728 en
Yes
INSTALL a new ABS/TCS module. Refer to Section 206-09. CARRY OUT the DATA LINK DIAGNOSTICS test.
No
The system is operating correctly at this time. Concern may have been caused by a loose, or a corroded connector. CLEAR the DTCs. REPEAT the self-test.
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418-00-10
Module Communications Network
418-00-10
DIAGNOSIS AND TESTING (Continued) PINPOINT TEST C : RCM MODULE DOES NOT RESPOND TO THE DIAGNOSTIC TOOL (WDS) NOTE: For connector circuit information on C189, refer to chapter 501-20b. Test Step C1
Result / Action to Take
CHECK RCM C189 CIRCUIT 70B (SB-W) FOR DAMAGE
Yes
Key in OFF position. Deactivate the air bag system. Refer to Section 501-20b. Disconnect RCM C189. Inspect RCM C189 for damage.
Go to C2
No
REPAIR the RCM C189. CARRY OUT the DATA LINK DIAGNOSTICS test.
Is the RCM C189 OK?
C2
CHECK CIRCUIT 70B (SB-W) BETWEEN DLC C174 AND RCM C189 FOR OPEN
Yes
Measure the resistance between RCM C189, circuit 70B (SB-W), harness side and DLC C174, circuit 70C (SB-W), harness side.
Go to C3
Is the resistance less than 5 ohms?
No
REPAIR the circuit(s) as necessary. CARRY OUT the DATA LINK DIAGNOSTICS test.
C3
CHECK FOR CORRECT RCM OPERATION Disconnect all RCM connectors.
Yes
INSTALL a new RCM module. Refer to Section 501-20b. CARRY OUT the DATA LINK DIAGNOSTICS test.
Check for: Corrosion Pushed-out pins Connect all RCM connectors and make sure they seat correctly. Operate the system and verify the concern is still present. Is the concern still present?
No
The system is operating correctly at this time. Concern may have been caused by a loose, or a corroded connector. CLEAR the DTCs. REPEAT the self-test.
PINPOINT TEST D : PAM MODULE DOES NOT RESPOND TO THE DIAGNOSTIC TOOL (WDS) NOTE: For connector circuit information on C369, refer to module connector diagram in chapter 413-13. Test Step D1
CHECK PAM C369 CIRCUIT 70 (SB-W) FOR DAMAGE Key in OFF position. Disconnect PAM C369. Inspect PAM C369 for damage. Is the PAM C369 OK?
D2
Result / Action to Take
Yes
Go to D2
No
REPAIR the PAM C369. CARRY OUT the DATA LINK DIAGNOSTICS test.
CHECK CIRCUIT 70 (SB-W) BETWEEN DLC C174 AND PAM C369 FOR OPEN
Yes
Measure the resistance between PAM C369, circuit 70 (SB-W), harness side and DLC C174, circuit 70C (SB-W), harness side.
Go to D3
Is the resistance less than 5 ohms?
No
REPAIR the circuit(s) as necessary. CARRY OUT the DATA LINK DIAGNOSTICS test.
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Module Communications Network
418-00-11
DIAGNOSIS AND TESTING (Continued) Test Step D3
Result / Action to Take
CHECK FOR CORRECT PAM OPERATION Disconnect all PAM connectors.
Yes
INSTALL a new PAM module. Refer to section 413-13. CARRY OUT the DATA LINK DIAGNOSTICS test.
Check for: Corrosion Pushed-out pins Connect all PAM connectors and make sure they seat correctly. Operate the system and verify the concern is still present. Is the concern still present?
No
The system is operating correctly at this time. Concern may have been caused by a loose, or a corroded connector. CLEAR the DTCs. REPEAT the self-test.
PINPOINT TEST E : IC MODULE DOES NOT RESPOND TO THE DIAGNOSTIC TOOL (WDS) NOTE: For connector circuit information on C171, refer to module connector diagram in chapter 413-01. Test Step E1
CHECK IC C171 CAN CIRCUITS 914L (BR-Y) and 915L (P-L) FOR DAMAGE Key in OFF position. Disconnect IC C171. Inspect IC C171 for damage. Is the IC C171 OK?
E2
Result / Action to Take
Yes
Go to E2
No
REPAIR IC C171. CARRY OUT the DATA LINK DIAGNOSTICS test.
CHECK CAN HIGH AND CAN LOW CIRCUITS 914L (BR-Y) AND 915L (P-L) BETWEEN DLC C174 AND IC C171 FOR OPEN
Yes
Measure the resistance between IC module C171, circuit 914L (BR-Y), harness side and DLC C174, circuit 914K (BR-Y), harness side.
Go to E3
Measure the resistance between IC module C171, circuit 915L (P-L), harness side and DLC C174, circuit 915K (P-L), harness side.
REPAIR the circuit(s) in question. CARRY OUT the DATA LINK DIAGNOSTICS test.
No
Are the resistances less than 5 ohms?
E3
CHECK FOR CORRECT IC OPERATION Disconnect all IC connectors. Check for: Corrosion Pushed-out pins Connect all IC connectors and make sure they seat correctly. Operate the system and verify the concern is still present. Is the concern still present?
G86728 en
Yes
INSTALL a new IC module. Refer to section 413-01. CARRY OUT the DATA LINK DIAGNOSTICS test.
No
The system is operating correctly at this time. Concern may have been caused by a loose, or a corroded connector. CLEAR the DTCs. REPEAT the self-test.
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Module Communications Network
418-00-12
DIAGNOSIS AND TESTING (Continued) PINPOINT TEST F : PCM MODULE DOES NOT RESPOND TO THE DIAGNOSTIC TOOL (WDS) NOTE: For connector circuit information on C301, refer to module connector diagram in chapter 303-14. Test Step F1
CHECK PCM C301 CAN CIRCUITS 914G (BR-Y) AND 915G (P-L) FOR DAMAGE
Yes
Key in OFF position. Disconnect PCM C301. Inspect PCM C301 for damage. Is the PCM C301 OK?
F2
Result / Action to Take
Go to F2
No
REPAIR PCM C301. CARRY OUT the DATA LINK DIAGNOSTICS test.
CHECK CAN HIGH AND CAN LOW CIRCUITS 914G (BR-Y) AND 915G (P-L) BETWEEN DLC C174 AND PCM C301 FOR OPEN
Yes
Measure the resistance between PCM module C301, circuit 914G (BR-Y), harness side and DLC C174, circuit 914K (BR-Y), harness side.
Go to F3
Measure the resistance between PCM module C301, circuit 915G (P-L), harness side and DLC C174, circuit 915K (P-L), harness side.
REPAIR the circuit(s) in question. CARRY OUT the DATA LINK DIAGNOSTICS test.
No
Are the resistances less than 5 ohms?
F3
: CHECK FOR CORRECT PCM OPERATION Disconnect all PCM connectors.
Yes
INSTALL a new PCM module. Refer to section 303-14. CARRY OUT the DATA LINK DIAGNOSTICS test.
Check for: Corrosion Pushed-out pins Connect all PCM connectors and make sure they seat correctly. Operate the system and verify the concern is still present. Is the concern still present?
No
The system is operating correctly at this time. Concern may have been caused by a loose, or a corroded connector. CLEAR the DTCs. REPEAT the self-test.
PINPOINT TEST G : ICC MODULE DOES NOT RESPOND TO THE DIAGNOSTIC TOOL (WDS) NOTE: For connector circuit information on C364, refer to module connector diagram in chapter 413-08. Test Step G1
Result / Action to Take
CHECK ACM C364 CAN CIRCUITS 914M (BR-Y) AND 915M (P-L) FOR DAMAGE Key in OFF position. Disconnect ACM C364. Inspect ICC C364 for damage. Is the ICC C364 OK?
G86728 en
Yes
Go to G2
No
REPAIR ICC C364. CARRY OUT the DATA LINK DIAGNOSTICS test.
01/2003 2003.0 BA Falcon
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Module Communications Network
418-00-13
DIAGNOSIS AND TESTING (Continued) Test Step G2
Result / Action to Take
CHECK CAN HIGH AND CAN LOW CIRCUITS 914M (BR-Y) AND 915M (P-L) BETWEEN DLC C174 AND ICC C364 FOR OPEN
Yes
Measure the resistance between ICC module C364, circuit 914M (BR-Y), harness side and DLC C174, circuit 914K (BR-Y), harness side.
Go to G3
Measure the resistance between ICC module C364, circuit 915M (P-L), harness side and DLC C174, circuit 915K (P-L), harness side.
REPAIR the circuit(s) in question. CARRY OUT the DATA LINK DIAGNOSTICS test.
No
Are the resistances less than 5 ohms?
G3
CHECK FOR CORRECT PCM OPERATION Disconnect all ACM connectors.
Yes
INSTALL a new ACM module. Refer to section 413-08. CARRY OUT the DATA LINK DIAGNOSTICS test.
Check for: Corrosion Pushed-out pins Connect all ICC connectors and make sure they seat correctly. Operate the system and verify the concern is still present. Is the concern still present?
No
The system is operating correctly at this time. Concern may have been caused by a loose, or a corroded connector. CLEAR the DTCs. REPEAT the self-test.
PINPOINT TEST H : BEM MODULE DOES NOT RESPOND TO THE DIAGNOSTIC TOOL (WDS) NOTE: For connector circuit information on C173, refer to module connector diagram in chapter 419-10. Test Step H1
CHECK BEM C173 CAN CIRCUITS 914N (BR-Y) AND 915N (P-L) FOR DAMAGE Key in OFF position. Disconnect BEM C173. Inspect BEM C173 for damage. Is the BEM C173 OK?
H2
Result / Action to Take
Yes
Go to H2
No
REPAIR BEM C173. CARRY OUT the DATA LINK DIAGNOSTICS test.
CHECK CAN HIGH AND CAN LOW CIRCUITS 914 (BR-Y) AND 915 (P-L) BETWEEN DLC C174 AND BEM C173 FOR OPEN
Yes
Measure the resistance between BEM module C173, circuit 914N (BR-Y), harness side and DLC C174, circuit 914K (BR-Y), harness side.
Go to H3
Measure the resistance between BEM module C173, circuit 915N (P-L), harness side and DLC C174, circuit 915K (P-L), harness side.
REPAIR the circuit(s) in question. CARRY OUT the DATA LINK DIAGNOSTICS test.
No
Are the resistances less than 5 ohms?
H3
CHECK FOR CORRECT BEC OPERATION Disconnect all BEM connectors. Check for: Corrosion Pushed-out pins Connect all BEM connectors and make sure they seat correctly. Operate the system and verify the concern is still present. Is the concern still present?
G86728 en
Yes
INSTALL a new BEM module. Refer to Section 419-10. CARRY OUT the DATA LINK DIAGNOSTICS test.
No
The system is operating correctly at this time. Concern may have been caused by a loose, or a corroded connector. CLEAR the DTCs. REPEAT the self-test.
01/2003 2003.0 BA Falcon
418-00-14
Module Communications Network
418-00-14
DIAGNOSIS AND TESTING (Continued) PINPOINT TEST I : HIM MODULE DOES NOT RESPOND TO THE DIAGNOSTIC TOOL (WDS) NOTE: For connector circuit information on C376, refer to module connector diagram in chapter 412-04. Test Step I1
CHECK HIM C376 CAN CIRCUITS 914P (BR-Y) AND 915P (P-L) FOR DAMAGE
Yes
Key in OFF position. Disconnect HIM C376. Inspect HIM C376 for damage. Is the HIM C376 OK?
I2
Result / Action to Take
Go to I2
No
REPAIR HIM C376. CARRY OUT the DATA LINK DIAGNOSTICS test.
CHECK CAN HIGH AND CAN LOW CIRCUITS 914 (BR-Y) AND 915 (P-L) BETWEEN DLC C174 AND HIM C376 FOR OPEN
Yes
Measure the resistance between HIM module C376, circuit 914P (BR-Y), harness side and DLC C174, circuit 914K (BR-Y), harness side.
Go to I3
Measure the resistance between HIM module C376, circuit 915P (P-L), harness side and DLC C174, circuit 915K (P-L), harness side.
REPAIR the circuit(s) in question. CARRY OUT the DATA LINK DIAGNOSTICS test.
No
Are the resistances less than 5 ohms?
I3
: CHECK FOR CORRECT HIM OPERATION Disconnect all HIM connectors.
Yes
INSTALL a new HIM module. Refer to Section 412-04. CARRY OUT the DATA LINK DIAGNOSTICS test.
Check for: Corrosion Pushed-out pins Connect all HIM connectors and make sure they seat correctly. Operate the system and verify the concern is still present. Is the concern still present?
No
The system is operating correctly at this time. Concern may have been caused by a loose, or a corroded connector. CLEAR the DTCs. REPEAT the self-test.
PINPOINT TEST J : ABS/EVAC FILL MODULE DOES NOT RESPOND TO THE DIAGNOSTIC TOOL (WDS) NOTE: For connector circuit information on C386, refer to module connector diagram in chapter 206-09. Test Step J1
CHECK ABS/EVAC FILL C386 CIRCUIT 70 (SB-W) FOR DAMAGE Key in OFF position. Disconnect ABS/EVAC FILL C386. Inspect ABS/EVAC FILL C386 for damage. Is the ABS/EVAC FILL C386 OK?
J2
Result / Action to Take
Yes
Go to J2
No
REPAIR ABS/EVAC FILL C386. CARRY OUT the DATA LINK DIAGNOSTICS test.
CHECK CIRCUIT 70 (SB-W) BETWEEN DLC C174 AND ABS/EVAC FILL C386 FOR OPEN Measure the resistance between ABS/EVAC FILL C386, circuit 70 (SB-W), harness side and DLC C174, circuit 70C (SB-W), harness side. Is the resistance less than 5 ohms?
G86728 en
Yes
Go to J3
No
REPAIR the circuit(s) as necessary. CARRY OUT the DATA LINK DIAGNOSTICS test.
01/2003 2003.0 BA Falcon
418-00-15
Module Communications Network
418-00-15
DIAGNOSIS AND TESTING (Continued) Test Step J3
Result / Action to Take
: CHECK FOR CORRECT ABS/EVAC FILL OPERATION Disconnect all ABS/EVAC FILL connectors.
Yes
INSTALL a new ABS/EVAC FILL module. Refer to Section 206-09. CARRY OUT the DATA LINK DIAGNOSTICS test.
Check for: Corrosion Pushed-out pins Connect all ABS/EVAC FILL connectors and make sure they seat correctly. Operate the system and verify the concern is still present.
No
The system is operating correctly at this time. Concern may have been caused by a loose, or a corroded connector. CLEAR the DTCs. REPEAT the self-test.
Is the concern still present?
PINPOINT TEST K : NO MODULE / NETWORK COMMUNICATION- ISO 9141 NETWORK Test Step K1
Result / Action to Take
CHECK THE SCAN TOOL FOR DAMAGE Inspect scan tool tester circuit 70 pin for dam-age. Is the scan tool OK?
Yes
Go to K2
No
REPAIR the scan tool tester as necessary. CARRY OUT the DATA LINK DIAGNOSTICS test.
K2
CHECK THE DLC C174 FOR DEMAGE Key in OFF position. Inspect DLC C174 circuit 70C (SB-W). Is DLC C174 OK?
K3
Disconnect PAM C369.
Is the resistance less than 5 ohms?
No
REPAIR the DLC C174. CARRY OUT the DATA LINK DIAGNOSTICS test.
Yes
Go to K4
No
REPAIR circuit 70 (SB-W) between the DLC C174 and PAM C369. CARRY OUT the DATA LINK DIAGNOSTICS test.
CHECK CIRCUIT 70 (SB-W) FOR SHORT TO GROUND AND POWER - PAM MODULE DISCONNECTED Key in ON position. Enter the following diagnostic mode on the diagnostic tool: DATA LINK DIAGNOSTICS Test. Did the diagnostic tool indicate SYSTEM PASSED?
K5
Go to K3
CHECK PAM CIRCUIT 70 (SB-W) FOR OPEN
Measure the resistance between PAM C369, circuit 70 (SB-W), harness side and DLC C174, circuit 70C (SB-W).
K4
Yes
Yes
Go to K10
No
Go to K9
CHECK RCM CIRCUIT 70B (SB-W) FOR OPEN Key in OFF position. Disconnect RCM C189. Measure the resistance between RCM C189, circuit 70B (SB-W), harness side and DLC C174, circuit 70C (SB-W). Is the resistance less than 5 ohms?
G86728 en
Yes
Go to K6
No
REPAIR circuit 70 (SB-W) between the DLC C174 and RCM C189. CARRY OUT the DATA LINK DIAGNOSTICS test.
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Module Communications Network
418-00-16
DIAGNOSIS AND TESTING (Continued) Test Step K6
CHECK CIRCUIT 70 (SB-W) FOR SHORT TO GROUND AND POWER - RCM DISCONNECTED Key in ON position. Enter the following diagnostic mode on the diagnostic tool: DATA LINK DIAGNOSTICS Test. Did the diagnostic tool indicate SYSTEM PASSED?
K7
Disconnect ABS/TCS C150.
Is the resistance less than 5 ohms?
Go to K11
No
Go to K7
Yes
Go to K8
No
REPAIR circuit(s) 70 (SB-W) between the DLC C174 and ABS/TCS C150. CARRY OUT the DATA LINK DIAGNOSTICS test.
CHECK CIRCUIT 70 (SB-W) FOR SHORT TO GROUND AND POWER-ABS/TCS MODULE DISCONNECTED Key in ON position. Enter the following diagnostic mode on the diagnostic tool: DATA LINK DIAGNOSTICS Test. Did the diagnostic tool indicate SYSTEM PASSED?
K9
Yes
CHECK ABS/TCS CIRCUIT 70 (SB-W) FOR OPEN
Measure the resistance between ABS/TCS C150, circuit 70 (SB-W), harness side and DLC C174, circuit 70C (SB-W).
K8
Result / Action to Take
Yes
Go to K12
No
Go to K9
CHECK THE EVAC AND FILL C386 FOR DAMAGE Key in OFF position. Inspect the EVAC and fill C386 circuit 70 (SB-W). Is DLC C174 OK?
Yes
REPAIR the circuit between the ABS/TCS module C150, EVAC and fill C386 and the DLC C174. CARRY OUT the DATA LINK DIAGNOSTICS test.
No
REPAIR the EVAC and fill C386. CARRY OUT the DATA LINK DIAGNOSTICS test.
K10
CHECK FOR CORRECT PAM OPERATION Disconnect all PAM connectors. Check for: Corrosion Pushed-out pins Connect all PAM connectors and make sure they seat correctly. Operate the system and verify the concern is still present. Is the concern still present?
K11
Yes
INSTALL a new PAM module. Refer to Section 413-13. CARRY OUT the DATA LINK DIAGNOSTICS test.
No
The system is operating correctly at this time. Concern may have been caused by a loose or corroded connector. CLEAR the DTCs. REPEAT the self-test.
CHECK FOR CORRECT RCM OPERATION Disconnect all RCM connectors. Check for: Corrosion Pushed-out pins Connect all RCM connectors and make sure they seat correctly. Operate the system and verify the concern is still present. Is the concern still present?
G86728 en
Yes
INSTALL a new RCM module. Refer to Section 501-20b. CARRY OUT the DATA LINK DIAGNOSTICS test.
No
The system is operating correctly at this time. Concern may have been caused by a loose or corroded connector. CLEAR the DTCs. REPEAT the self-test.
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Module Communications Network
418-00-17
DIAGNOSIS AND TESTING (Continued) Test Step K12
Result / Action to Take
CHECK FOR CORRECT ABS/TCS OPERATION Disconnect all ABS/TCS connectors.
Yes
INSTALL a new ABS/TCS module. Refer to Section 206-09. CARRY OUT the DATA LINK DIAGNOSTICS test.
Check for: Corrosion Pushed-out pins Connect all ABS/TCS connectors and make sure they seat correctly. Operate the system and verify the concern is still present. Is the concern still present?
No
The system is operating correctly at this time. Concern may have been caused by a loose or corroded connector. CLEAR the DTCs. REPEAT the self-test.
PINPOINT TEST L : NO MODULE / NETWORK COMMUNICATION - HS-CAN NETWORK Test Step L1
Result / Action to Take
CHECK DIAGNOSTIC TOOL TESTER CIRCUITS 914 AND 915 FOR DAMAGE Inspect diagnostic tool tester circuits 914 and 915 for damage. Is the diagnostic tool tester OK?
Yes
Go to L2
No
REPAIR the diagnostic tool. CARRY OUT the DATA LINK DIAGNOSTICS test.
L2
CHECK DLC C174 CIRCUITS 914K AND 915K FOR DAMAGE Key in OFF position. Inspect DLC C174 circuits 914K and 915K. Check the pins and the wires for damage. Is the DLC C174 OK?
L3
Yes
Go to L3
No
REPAIR DLC C174. CARRY OUT the DATA LINK DIAGNOSTICS test.
CHECK CIRCUITS 914 (BR-Y) AND 915 (P-L) FOR SHORT TO BATTERY AND SHORT TO GROUND WITH PCM C301 DISCONNECTED Key in OFF position. Disconnect PCM C301. Key in ON position. Enter the following diagnostic mode on the diagnostic tool: DATA LINK DIAGNOSTICS Test.
Yes
Go to L10
No
Go to L4
Did the diagnostic tool indicate SYSTEM PASSED?
L4
CHECK CIRCUITS 914 (BR-Y) AND 915 (P-L) FOR SHORT TO BATTERY AND SHORT TO GROUND WITH ABS/TCS C150 DISCONNECTED Key in OFF position. Connect PCM C301. Disconnect ABS/TCS C150. Key in ON position.
Yes
Go to L11
No
Go to L5
Enter the following diagnostic mode on the diagnostic tool: DATA LINK DIAGNOSTICS Test. Did the diagnostic tool indicate SYSTEM PASSED?
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01/2003 2003.0 BA Falcon
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Module Communications Network
418-00-18
DIAGNOSIS AND TESTING (Continued) Test Step L5
Result / Action to Take
CHECK CIRCUITS 914 (BR-Y) AND 915 (P-L) FOR SHORT TO BATTERY AND SHORT TO GROUND WITH HIM C376 DISCONNECTED Key in OFF position. Connect ABS/TCS C150. Disconnect HIM C376. Key in ON position.
Yes
Go to L12
No
Go to L6
Enter the following diagnostic mode on the diagnostic tool: DATA LINK DIAGNOSTICS Test. Did the diagnostic tool indicate SYSTEM PASSED?
L6
CHECK CIRCUITS 914 (BR-Y) AND 915 (P-L) FOR SHORT TO BATTERY AND SHORT TO GROUND WITH THE IN-LINE C119 DISCONNECTED Key in OFF position. Connect HIM C376. Disconnect In-line C119. Key in ON position. Enter the following diagnostic mode on the diagnostic tool: DATA LINK DIAGNOSTICS Test.
Yes
REPAIR the circuit in question between in-line C119 and HIM C376. REFER to Communication Circuit Wiring Repair in this section. CARRY OUT the DATA LINK DIAGNOSTICS test.
No
Go to L7
Did the diagnostic tool indicate SYSTEM PASSED?
L7
CHECK CIRCUITS 914 (BR-Y) AND 915 (P-L) FOR SHORT TO BATTERY AND SHORT TO GROUND WITH BEM C173 DISCONNECTED Key in OFF position. Connect In-line C119. Disconnect BEM C173. Key in ON position.
Yes
Go to L13
No
Go to L8
Enter the following diagnostic mode on the diagnostic tool: DATA LINK DIAGNOSTICS Test. Did the diagnostic tool indicate SYSTEM PASSED?
L8
CHECK CIRCUITS 914 (BR-Y) AND 915 (P-L) FOR SHORT TO BATTERY AND SHORT TO GROUND WITH ICC C364 DISCONNECTED Key in OFF position. Connect BEM C173. Disconnect ICC C364. Key in ON position.
Yes
Go to L15
No
Go to L9
Enter the following diagnostic mode on the diagnostic tool: DATA LINK DIAGNOSTICS Test. Did the diagnostic tool indicate SYSTEM PASSED?
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01/2003 2003.0 BA Falcon
418-00-19
Module Communications Network
418-00-19
DIAGNOSIS AND TESTING (Continued) Test Step L9
CHECK CIRCUITS 914 (BR-Y) AND 915 (P-L) FOR SHORT TO BATTERY AND SHORT TO GROUND WITH IC C171 DISCONNECTED Key in OFF position. Connect ICC C364. Disconnect IC C171. Key in ON position. Enter the following diagnostic mode on the diagnostic tool: DATA LINK DIAGNOSTICS Test. Did the diagnostic tool indicate SYSTEM PASSED?
L10
Result / Action to Take
Yes
Go to L16
No
Check all circuits 914 (BR-Y) and 915 (P-L) for short to battery and short to ground. REPAIR the circuit(s) as necessary. REFER to Communication Circuit Wiring Repair in this section. CARRY OUT the DATA LINK DIAGNOSTICS test.
CHECK FOR CORRECT PCM OPERATION Key in OFF position. Disconnect all PCM connectors. Check for: Corrosion Pushed-out pins Connect all PCM connectors and make sure they seat correctly. Operate the system and verify the concern is still present.
Yes
INSTALL a new PCM module. Refer to Section 303-14. CARRY OUT the DATA LINK DIAGNOSTICS test.
No
The system is operating correctly at this time. Concern may have been caused by a loose or corroded connector. CLEAR the DTCs. REPEAT the self-test.
Is the concern still present?
L11
CHECK FOR CORRECT ABS/TCS OPERATION Key in OFF position. Disconnect all ABS/TCS connectors. Check for: Corrosion Pushed-out pins Connect all ABS/TCS connectors and make sure they seat correctly. Operate the system and verify the concern is still present.
Yes
INSTALL a new ABS/TCS module. Refer to Section 206-09. CARRY OUT the DATA LINK DIAGNOSTICS test.
No
The system is operating correctly at this time. Concern may have been caused by a loose or corroded connector. CLEAR the DTCs. REPEAT the self-test.
Is the concern still present?
L12
CHECK FOR CORRECT HIM OPERATION Key in OFF position. Disconnect all HIM connectors. Check for: Corrosion Pushed-out pins Connect all HIM connectors and make sure they seat correctly. Operate the system and verify the concern is still present.
Yes
INSTALL a new HIM module. Refer to Section 412-04. CARRY OUT the DATA LINK DIAGNOSTICS test.
No
The system is operating correctly at this time. Concern may have been caused by a loose or corroded connector. CLEAR the DTCs. REPEAT the self-test.
Is the concern still present?
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01/2003 2003.0 BA Falcon
418-00-20
Module Communications Network
418-00-20
DIAGNOSIS AND TESTING (Continued) Test Step L13
CHECK CIRCUITS 914P (BR-Y) AND 915P (P-L) FOR SHORT TO BATTERY AND SHORT TO GROUND WITH BEM C173 AND IN-LINE C119 DISCONNECTED Key in OFF position.
Yes
Disconnect In-line C119.
Connect In-line C119. Go to L14
Check circuits 914P and 915P for short to battery and short to ground between BEM C173 and In-line C119
No
Do the circuits 914P and 915P PASS?
L14
Result / Action to Take
REPAIR the circuit in question between BEM C173 and In-line C119. REFER to Communication Circuit Wiring Repair in this section. Connect BEM C173 and In-line C119. CARRY OUT the DATA LINK DIAGNOSTICS test.
CHECK FOR CORRECT BEM OPERATION Key in OFF position. Disconnect all BEM connectors. Check for: Corrosion Pushed-out pins Connect all BEM connectors and make sure they seat correctly. Operate the system and verify the concern is still present.
Yes
INSTALL a new BEM module. Refer to Section 419-10. CARRY OUT the DATA LINK DIAGNOSTICS test.
No
The system is operating correctly at this time. Concern may have been caused by a loose or corroded connector. CLEAR the DTCs. REPEAT the self-test.
Is the concern still present?
L15
CHECK FOR CORRECT ICC OPERATION Key in OFF position. Disconnect all ICC connectors. Check for: Corrosion Pushed-out pins Connect all ICC connectors and make sure they seat correctly. Operate the system and verify the concern is still present.
Yes
INSTALL a new ACM module. Refer to Section 413-08. CARRY OUT the DATA LINK DIAGNOSTICS test.
No
The system is operating correctly at this time. Concern may have been caused by a loose or corroded connector. CLEAR the DTCs. REPEAT the self-test.
Is the concern still present?
L16
CHECK FOR CORRECT IC OPERATION Key in OFF position. Disconnect all IC connectors. Check for: Corrosion Pushed-out pins Connect all IC connectors and make sure they seat correctly. Operate the system and verify the concern is still present.
Yes
INSTALL a new IC module. Refer to Section 413-01. CARRY OUT the DATA LINK DIAGNOSTICS test.
No
The system is operating correctly at this time. Concern may have been caused by a loose or corroded connector. CLEAR the DTCs. REPEAT the self-test.
Is the concern still present?
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01/2003 2003.0 BA Falcon
418-00-21
Module Communications Network
418-00-21
DIAGNOSIS AND TESTING (Continued) PINPOINT TEST M : NO MODULE/NETWORK COMMUNICATION - NO POWER TO THE DIAGNOSTIC TOOL Test Step M1
Result / Action to Take
CHECK DIAGNOSTIC TOOL CONNECTOR Inspect diagnostic tool pins for damage. Are the pins OK?
Yes
Go to M2
No
REPAIR the diagnostic tool connector. TEST the system for normal operation.
M2
CHECK DATA LINK CONNECTOR (DLC) C174 FOR DAMAGE Key in OFF position. Inspect DLC C174 pins for damage. Are the pins OK?
M3
Yes
Go to M3
No
REPAIR DLC C174. TEST the system for normal operation.
CHECK VOLTAGE CIRCUIT 956 (OG/LG) TO DIAGNOSTIC TOOL
Yes
Measure the voltage between DLC C174 pin 16, circuit 956 (OG/LG), and ground.
Go to M4
Is the voltage greater than 10 volts?
No
REPAIR the circuit. TEST the system for normal operation.
M4
CHECK THE DLC GROUND CIRCUIT 57 (BK) AND CIRCUIT 570 (BK/WH) Measure the resistance between DLC C174 pin 4, circuit 57 (BK); C174 pin 5, circuit 570 BK/WH, and ground. Is the resistance less than 5 ohms?
Yes
REPAIR the diagnostic tool. TEST the system for normal operation.
No
REPAIR the circuit(s) in question. TEST the system for normal operation.
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01/2003 2003.0 BA Falcon
418-00-22
Module Communications Network
418-00-22
GENERAL PROCEDURES
Communication Circuit Wiring Repair Special Tool(s) Heat Gun 107-R0300 or equivalent
4. Bend the wires back in a straight line. NOTE: Wait for the solder to cool before moving the wires.
1. Disconnect the battery ground cable. Refer to Section 414-01. 2. Strip the wires.
5. Position the (A) heat shrink tube over the (B) wire repair. Overlap the heat shrink tube on both wires.
3. Solder the wires. 1. Install the heat shrink tube. 2. Twist the wires together. 3. Solder the wires together. NOTE: Use rosin core mildly activated (RMA) solder, not acid core solder.
6. Use the heat gun to heat the repaired area until adhesive flows out both ends of the heat shrink tube.
7. Reconnect the battery ground cable.
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01/2003 2003.0 BA Falcon
419-07-1
Satellite Navigation
419-07-1
SECTION : 419-07 Satellite Navigation VEHICLE APPLICATION : 2003.0 BA Falcon CONTENTS
PAGE
SPECIFICATIONS Specifications .........................................................................................................................419-07-2 DESCRIPTION AND OPERATION Satellite Navigation ................................................................................................................419-07-3 GPS (Global Positioning System) ........................................................................................419-07-3 Component Layout ...............................................................................................................419-07-3 DIAGNOSIS AND TESTING Satellite Navigation ................................................................................................................419-07-5 Symptom Chart ....................................................................................................................419-07-5 Pinpoint Tests ......................................................................................................................419-07-6 REMOVAL AND INSTALLATION Navigation System Module ..................................................................................................419-07-14 Navigation System Antenna .................................................................................................419-07-14 Navigation System Display Module .....................................................................................419-07-14
01/2003 2003.0 BA Falcon
419-07-2
Satellite Navigation
419-07-2
SPECIFICATIONS Torque Specifications Description Module mounting bracket
G88869 en
Nm 8.0 ± 1.5
01/2003 2003.0 BA Falcon
419-07-3
Satellite Navigation
419-07-3
DESCRIPTION AND OPERATION Unfavorable satellite constellations in conjunction with the mounting position of the GPS antenna (in this case GPS reception may be obstructed for a How does the system work? longer period of time) The movement of the vehicle is measured by sensors In valleys and in mountainous regions that are integrated in the navigation computer. The distance driven is recorded by an electronic signal If the GPS antenna has been properly installed, from the speedometer and the rotary movements of sufficient GPS reception should be present about 95% bends by the gyroscope (a rotary measurement of the driving time. If interference in the reception system). The information from these sensors is, occurs more frequently, improper mounting of the however, not always exact. Measurements could be GPS antenna may be the cause. In this case, we affected by skidding of the wheels, varying tyre recommend you contact your Authorised Ford Dealer. pressure due to changes in temperature, etc. By However, the navigation system is able to comparison of these signals with the digitized compensate reception problems over a period of a CD-ROM map it is possible to correct any few minutes without functional interference. inaccuracies of the sensors and to determine the Component Layout position of the vehicle quite precisely. In order to correct the data, a signal from the GPS satellites is The navigation system comprises of four main required for a period of several minutes. components.
Satellite Navigation
GPS (Global Positioning System)
Remote Control
The GPS System is based on the reception of navigation signals from a total of 27 GPS satellites orbiting the earth at a height of 21,000 kilometers, once every 12 hours. To determine a 3D position (with longitude, latitude and height), signals from at least 4 satellites must be received. This allows an accuracy of about 30m to 100m which is further improved by other sensors.
The remote control is required for activation/deactivation of the system and the utilization of the navigation functions. The remote control utilizes an Infra-Red (IR) transmitter with the corresponding IR receiver located on top of the display. To achieve best results point the remote control toward the display when activiating any functions.
Start-up Behavior When the vehicle is parked for a long period of time, the satellites move on during this period. Therefore, when the ignition is turned on again it can take a few minutes before the navigation system can pick up enough satellites and evaluate the received signals. When starting up, the navigation system may tell you: ’You are leaving the digitized area’. The navigation system supposes the vehicle is in an off-road position. If there are other roads in this position, the system may send an inappropriate message. This means that the navigation system supposes the vehicle is on one of the other roads. When the vehicle has been at a standstill for a longer period of time, the navigation function may be temporarily inhibited. The system will operate reliably again once the GPS reception is G.P.S Antenna available in sufficient quality. The GPS antenna (located under the rear package Limited GPS Reception tray cover) is used to receive signals transmitted by GPS satellites. For optimum performance of the Functional disturbance may also occur if GPS navigation system, do not place objects on the right reception is interrupted or interference occurs over a hand side of the rear package tray. Metallic distance of several kilometers. compound window tinting can also obstruct GPS GPS reception may be interrupted or interference signal reception and is not recommended for could occur: installation on the rear windscreen. In between high buildings Processor In multiple story car parks or garages, in tunnels The processor (located inside the boot compartment and under bridges under the rear package tray cover) controls the In forests or tree-lined streets navigation related functions including screen display During heavy rain showers output. The map DVD (map database) is located G88870 en
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Satellite Navigation
419-07-4
DESCRIPTION AND OPERATION (Continued) inside the navigation processor. The map DVD can be removed and inserted using the front panel switch (ignition switch must be in the ’ACC’ or ’ON’ positions).
Display The display (located on the instrument panel) is shared between the GPS, Audio and Climate Control systems.
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Satellite Navigation
419-07-5
DIAGNOSIS AND TESTING
Satellite Navigation Symptom Chart Does not start with ACC ON Condition
Source
Action
Dark screen (nothing appears on screen).
ICC Display
Go to PinPoint Test A
The display does not show navigation screen even though ON/OFF button is pressed.
ICC Display Navigation Remote Control
Go to PinPoint Test B
The respective screens do not appear when AUDIO A/C buttons are pressed.
ICC display
Go to PinPoint Test B
The navigation screen does not appear and no audio sounds are produced.
ICC display Navigation Audio
Go to PinPoint Test B
The screen appears abnormal Condition
Source
Action
The screen does not change to night screen mode.
ICC display
Go to PinPoint Test C
The navigation screen becomes out of sync.
ICC display
Go to PinPoint Test D
The colours of the navigation screen are abnormal (RGB signal abnormal).
ICC display Navigation
Go to PinPoint Test E
The menu becomes dark when MAP, MENU or DEST button is pressed.
ICC display Navigation Remote Control
Go to PinPoint Test B
The sound is abnormal Condition
Source
Action
Only the sounds from the audio system can be output from the speakers.
Audio
Go to PinPoint Test F
Only the front speaker cannot output the audio system sounds.
Navigation Audio
Go to PinPoint Test F
Only the rear speaker cannot output the audio system sounds.
Audio
Go to PinPoint Test F
The navigation functions are abnormal Condition
Source
Action
A map disc cannot be loaded.
Navigation
Go to PinPoint Test B
The screen does not display a map when the MAP button is pressed (only the "Disc Caution" screen is shown).
Navigation
Go to PinPoint Test G
The map turns white or blue (the switches and the vehicle’s current position mark are shown).
Navigation
Go to PinPoint Test H
The screen does not change to the night screen mode.
ICC display Navigation
Go to PinPoint Test I
The vehicle’s current position mark deviates considerably.
GPS antenna
Go to PinPoint Test J
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Satellite Navigation
419-07-6
DIAGNOSIS AND TESTING (Continued) Condition
Source
Action
The GPS mark does not appear on the display.
GPS antenna
Go to PinPoint Test K
There is no voice guidance.
Navigation Audio
Go to PinPoint Test L
The vehicle’s current position mark turns on its own (the map turns on its own).
Navigation GPS antenna
Go to PinPoint Test M
The direction of travel and the movement of the vehicle’s current position mark are opposite of each other.
Navigation Speed Sensor
Go to PinPoint Test N
Pinpoint Tests List of Caution Messages Caution Message Disk player error. Have vehicle serviced. Disk read error. Check disk. Disk temp high.
Incorrect disk format. No disk detected. Please close disk cover before using system. Program disk is inserted.
Description Appears when there is an error in communication with the DVD player. Appears if a type of DVD disc that differs from a map disc is used. Appears when the DVD has reached a high temperature.
Action Turn the ignition switch from OFF to ON.*¹ Load a correct type of disc.
Move the vehicle to a cool place in the shade and turn the ignition switch OFF. After the navigation ECU and the map disc has cooled down sufficiently, turn the ignition switch back ON. Appears when a DVD of a different Load a correct type of disc. system is loaded. Appears when no DVD is loaded. Load a correct type of disc. Appears when the DVD cover is Close the cover. open. Appears when a program DVD Load a correct type of disc. disc is inserted.
*¹ If the same caution screen appears after the ignition switch is turned back ON, replace the navigation ECU. PINPOINT TEST A : DARK SCREEN (NOTHING APPEARS ON SCREEN) Test Step
Result / Action to Take
A1 Is the B+ or ACC on the vehicle the correct capacity?
Yes
Replace the fuse with one with the specified capacity.
No
Go to A2
A2 Measure the voltage B+, ACC, GND. Is the power system to the CDU display normal?
Yes
Repair the CDU display.
No
Inspect the wiring harnesses and connectors.
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Satellite Navigation
419-07-7
DIAGNOSIS AND TESTING (Continued) PINPOINT TEST B : THE DISPLAY DOES NOT SHOW THE NAVIGATION SCREEN EVEN THOUGH THE ON/OFF BUTTON (ON THE REMOTE CONTROL) IS PRESSED (THE SCREEN DOES NOT CHANGE) Test Step
Result / Action to Take
B1 Apply the parking brake and turn the ignition switch to ACC or IG. Measure the voltage B+, ACC, GND. Is the power system to the navigation ECU normal?
Yes
Go to B2
No
Inspect the wiring harnesses and connectors.
B2 Measure the voltage of the wires Red, Green, Blue, Video Return and Videa Ground. Are the connections and the continuity of the wiring harnesses and connectors between the CDU display and the navigation ECU normal?
Yes
Go to B3
No
Inspect the wiring harnesses and connectors.
B3 Yes
Measure the voltage of the wires Red, Green, Blue, Video Return and Videa Ground on Navigation ECU.
Repair the CDU display.
Are the video output signals of the navigation ECU normal?
No
Repair the navigation ECU.
NOTE: To recheck the symptom after inspecting the wiring harnesses and connectors, turn the ignition switch OFF. Then, turn it back ON and start troubleshooting from the beginning. PINPOINT TEST C : THE SCREEN DOES NOT OPERATE IN THE DIM OR NIGHT MODE Test Step
Result / Action to Take
C1 Is TAIL signal normal in the vehicle signal check of the service check screen?
Yes
Repair the Navigation Unit display.
No
Inspect the wiring harnesses and connectors. Area to inspect: TAIL
PINPOINT TEST D : THE NAVIGATION SCREEN BECOMES OUT OF SYNC Test Step
Result / Action to Take
D1 Measure the voltage B+, ACC, GND. Is the power system of the navigation ECU normal?
Yes
Go to D2
No
Inspect the wiring harnesses and connectors.
D2 Measure the voltage across Video Synchronisation Signal, Video Return, Video Ground. Are the connections and the continuity of the wiring harnesses and connectors between the CDU display and the navigation ECU normal?
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Yes
Go to D3
No
Inspect the wiring harnesses and connectors.
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Satellite Navigation
419-07-8
DIAGNOSIS AND TESTING (Continued) Test Step
Result / Action to Take
D3 Yes
Measure the voltage Video Synchronisation Signal, Video Return, Video Ground on Navigation ECU.
Check the display.
Are the video output signals of the navigation ECU normal?
No
Repair the CDU display.
PINPOINT TEST E : THE COLORS OF THE NAVIGATION SCREEN ARE ABNORMAL Test Step
Result / Action to Take
E1 Are the colors abnormal on the screens other than the navigation Yes Go to E2 screen?
No
Repair the navigation ECU.
E2 Are the colors normal in the navigation color bar check of the service check screen?
Yes
Check the CDU display.
No
Go to E3
E3 Measure the voltage B+, ACC, GND. Is the power system of the navigation ECU normal?
Yes
Go to E4
No
Inspect the wiring harnesses and connectors.
E4 Measure the voltage of the wires Red, Green, Blue, Video Return and Videa Ground. Are the connections and the continuity of the wiring harnesses and connectors between the display and the navigation ECU normal?
Yes
Go to E5
No
Inspect the wiring harnesses and connectors.
E5 Measure the voltage of the wires Red, Green, Blue, Video Return and Videa Ground on Navigation ECU. Are the video output signals of the navigation ECU normal?
Yes
Check the CDU display.
No
Repair the navigation ECU.
PINPOINT TEST F : ONLY THE SOUNDS FROM THE AUDIO SYSTEM ARE OUTPUT FROM THE SPEAKERS Test Step
Result / Action to Take
F1 Measure the voltage B+, ACC, GND. Is the power system of the navigation ECU normal?
Yes
Go to F2
No
Inspect the wiring harnesses and connectors.
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Satellite Navigation
419-07-9
DIAGNOSIS AND TESTING (Continued) Test Step
Result / Action to Take
F2 Measure the voltage AUO+, AUO-, MUTE. Are the connections and the continuity of the wiring harnesses and connectors between the navigation and the power amplifier normal?
Yes
Repair the audio system. Repair navigation ECU.
No
Inspect the wiring harnesses and connectors.
PINPOINT TEST G : THE SCREEN DOES NOT DISPLAY A MAP WHEN THE "I AGREE" BUTTON IS PRESSED (ONLY THE "DISCCAUTION"SCREEN IS SHOWN) Test Step
Result / Action to Take
G1 Apply the parking brake and turn the ignition switch to ACC or ON.
Yes
Does the same caution screen appear even if actions have been taken for the respective caution screen as described in the table below?
No
Replace the map disc. Repair the navigation ECU. Normal
PINPOINT TEST H : THE MAP SCREEN TURNS WHITE OR BLUE (THE SWITCHES AND THE VEHICLE’S CURRENT POSITION MARK ARE NOT SHOWN) Test Step
Result / Action to Take
H1 Does the map appear if the map display scale is set to the widest Yes Correct the vehicle’s current position and range? recheck.
No
Go to H2
H2 Using a soft cloth, wipe the map disc, and insert the disc in the player. Yes Determine that the condition is normal (the Then, turn the ignition switch from OFF to ON. cause was the dirty disc). Is the system okay?
No
Replace the map disc. Repair the navigation ECU.
PINPOINT TEST I : THE SCREEN DOES NOT CHANGE TO THE NIGHT SCREEN MODE Test Step
Result / Action to Take
I1 Is the picture quality adjustment set to the Day Screen mode?
Yes
The Day Screen mode will not show the Night Screen mode.
No
Go to I2
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Satellite Navigation
419-07-10
DIAGNOSIS AND TESTING (Continued) Test Step
Result / Action to Take
I2 Does the screens other than the navigation screen appear in the night mode when the tailight switch is ON?
Yes
Check the display.
No
Go to I3
I3 Does it make a beep sound when each of the switches is pressed Yes Repair the navigation ECU. on the navigation remote control?
No
Inspect the connections the continuity of the wiring harnesses and connectors between the navigation ECU and the CDU display. Areas to inspect : Remote
PINPOINT TEST J : THE REMOTE CONTROL IS NON-OPERATIONAL (ONLY ON THE NAVIGATION SCREEN) Test Step
Result / Action to Take
J1 Areas to inspect : Remote Are the connections the continuity of the wiring harnesses and connectors between the navigation ECU and the CDU display normal?
Yes
Repeair the navigation ECU.
No
Inspect the wiring harnesses and connectors.
PINPOINT TEST K : THE VEHICLE’S CURRENT POSITION MARK DEVIATES CONSIDERABLY Test Step
Result / Action to Take
K1 Does the GPS mark appear on the screen?
Yes
Go to K2
No
Inspect the wiring harness and connectors.
K2 Does it occur in a particular location?
Yes
The current position mark could deviate in an area in which the vehicle’s actual location is difficult to determine. (Immediately after leaving a parking area, etc. Parallel running roads, high-rise roads, loop roads, etc.)
No
Go to K3
K3 Is the system currently undergoing a distance correction? (Does the AUTO CORRECTION button appear green on the distance correction screen?)
Yes
Wait and see until the correction is completed (for 10km or more). The AUTO CORRECTION button will turn blue upon completing the correction.
No
Go to K4
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Satellite Navigation
419-07-11
DIAGNOSIS AND TESTING (Continued) Test Step
Result / Action to Take
K4 Is SPD (vehicle speed) normal in the vehicle signal check of the navigation check menu on the service check screen?
Yes
Go to K5
No
Inspect the wiring harnesses and connectors. Areas to inspect: SPD
K5 Correct the current position. Drive the vehicle for a while with the Yes Okay. GPS mark shown and observe the display for a while.
No
Repair the navigation ECU.
PINPOINT TEST L : THE GPS MARK DOES NOT APPEAR ON THE DISPLAY Test Step
Result / Action to Take
L1 Move the vehicle to an area with an unobstructed view. (The signals from the satellites cannot be received at times in an area that is surrounded by buildings.)
Yes
Go to L2
No
Is the GPS antenna connected securely? Check whether the wiring harness is being pinched or is kinked sharply.
Securely connect the GPS antenna. Repair any abnormal conditions of the wiring harness.
Are there any retrofit accessories such as theft-deterrent devices?
Go to L3
L2 Yes
No
Replace the GPS antenna. Replace the navigation ECU.
L3 The GPS mark appears on the display when the power (including backup power) to a retrofit accessory is turned OFF. Is the system okay?
Yes
The reception sensitivity of the GPS could be affected if a retrofit accessory that receives radiowave signals is installed. In this case, change the position in which the retrofit accessory is installed.
No
Replace the GPS antenna. Replace the navigation ECU.
NOTE: Use a ground plate if the GPS antenna is mounted inside the vehicle. The reception sensitivity of the GPS could become affected if a ground plate is not used. In addition, the GPS reception sensitivity could become affected if a film is affixed to the glass. In that case, mount the GPS antenna on the outside of the vehicle.
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Satellite Navigation
419-07-12
DIAGNOSIS AND TESTING (Continued) PINPOINT TEST M : THERE IS NO VOICE GUIDANCE Test Step
Result / Action to Take
M1 When the volume in the volume setting of the menu screen is turned to maximum, is there a voice announcement that says "The guidance will be given at this volume"?
Yes
Voice guidance cannot be given in the cases listed below. Check again. A destination has not been set. The vehicle is not being driven along the route. (The remaining distance does not appear at the bottom left area of the current position screen.) The "Guidance in other modes" has not been set. (No voice guidance will be given at this time on a screen other than the map screen.)
No
Go to M2
M2 Measure the voltage AUO+, AUO-.
Yes
Go to M3
Are the connections the continuity of the wiring harnesses and connectors between the navigation ECU and the speaker wiring harness normal?
No
Does the sound of the audio unit (radio, CD, etc.) come out from the speakers?
Repair the navigation ECU.
Inspect the wiring harnesses and connectors.
M3 Yes
No
Inspect the Audio unit.
PINPOINT TEST N : THE VEHICLE’S CURRENT POSITION MARK TURNS ON ITS OWN (THE MAP TURNS ON ITS OWN) Test Step
Result / Action to Take
N1 Has the ignition switch been turned to ACC or IG when the vehicle is placed on a turntable?
Yes
If the ignition switch is turned to ACC or IG while the vehicle is turned around, the turning speed at that time is stored in memory as a reference value. With the vehicle stopped, turn the ignition switch from OFF to ACC or IG and recheck the condition.
No
Go to N2
N2 On the service check screen, does the vehicle signal of navigation check show the SPD to be normal?
Yes
Repair the navigation ECU.
No
Inspect the wiring harnesses and connectors. Areas to inspect: SPD
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Satellite Navigation
419-07-13
DIAGNOSIS AND TESTING (Continued) PINPOINT TEST O : THE DIRECTION OF TRAVEL AND THE MOVEMENT OF THE VEHICLE’S CURRENT POSITION MARK ARE OPPOSITE OF EACH OTHER Test Step
Result / Action to Take
O1 On the service check scree, does the vehicle signal of navigation Yes Repeair the navigation ECU. check show the REV to be normal?
No
Inspect the wiring harnesses and connectors. Areas to inspect : REV
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Satellite Navigation
419-07-14
REMOVAL AND INSTALLATION
Navigation System Module
5. Remove mounting bracket from processor, four bolts.
Removal and Installation 1. Remove Parcel Shelf as described in Section 501-05 Interior Trim and Ornamentation. 2. Remove Navigation Bracket mounting bolts (x3). Tightening torque 8Nm. NOTE: Navigation bracket is held in position by guide tabs.
Navigation System Antenna Removal and Installation 1. Remove Parcel Shelf as described in Section 501-05 Interior Trim and Ornamentation. 2. Disconnect antenna and remove. 3. Remove map DVD. NOTE: Ignition must be "ON" position, then push the front panel switch on the processor.
Navigation System Display Module Removal and Installation Refer to section 413-08 for instructions.
4. Slide processor and bracket assembly out. NOTE: Disconnect main connector and G.P.S antenna lead wire.
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Cellular Phone
419-08-1
SECTION : 419-08 Cellular Phone VEHICLE APPLICATION : 2003.0 BA Falcon CONTENTS
PAGE
SPECIFICATIONS Specifications ........................................................................................................................419-08-2 DESCRIPTION AND OPERATION Mobile Telephone Wiring ......................................................................................................419-08-3 Mobile Telephone Platform ...................................................................................................419-08-3 DIAGNOSIS AND TESTING Cellular Phone .......................................................................................................................419-08-4 Connector Circuit Reference ................................................................................................419-08-4 REMOVAL AND INSTALLATION Mobile Telephone Platform ...................................................................................................419-08-5 Mobile Telephone Kit ............................................................................................................419-08-5
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Cellular Phone
419-08-2
SPECIFICATIONS Torque Specifications Description Bracket to console mounting screw
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Cellular Phone
419-08-3
DESCRIPTION AND OPERATION
Mobile Telephone Wiring
2. Storage of the hands free phone system in the console whilst not in use.
All Falcon models are supplied with mobile telephone wiring to facilitate installation of mobile telephones including a mute function to interrupt the radio. All models have wiring to facilitate mobile phone audio interface to the radio. This feature enables the phone audio to operate through the vehicles speakers. The two connectors are located behind the fuse panel on the right hand side of the instrument panel.
Mobile Telephone Platform The cellular phone attaches to the centre console through the phone platform to allow: 1. Access to the phone, suitable for hands free use.
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Cellular Phone
419-08-4
DIAGNOSIS AND TESTING
Cellular Phone Connector Circuit Reference Mobile Phone C-192
Pin Number(s) 297 57CS 37A 823
Circuit Designation/Description Accessory +VE Ground Battery 12V Mute
Normal Condition/Measurement — — — —
Mobile Phone C-204
Pin Number(s) 724 725
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Circuit Designation/Description Audio Input — — Audio Input + —
Normal Condition/Measurement
01/2003 2003.0 BA Falcon
419-08-5
Cellular Phone
419-08-5
REMOVAL AND INSTALLATION
Mobile Telephone Platform
4. Screw the bracket into the console body.
Removal and Installation 1. Join the front and back plates together by using the screw bosses as a guide.
5. Replace the console bump stops currently fitted with new larger bumps stops provided. 6. To remove, unscrew bracket mounting to console. 2. Screw plates together.
Mobile Telephone Kit Removal and Installation 1. Fit presenter arm to console (with phone holder attached as per the above instructions). 2. Drill hole (diameter 25mm), using template provided (see overleaf), in base of console directly in line of presenter arm mounting.
3. Assemble the arm to the mounting bracket using the pin provided.
3. Move passenger seat forward and remove bolt at rear of console, clipping in console wing LHS. 4. Unclip and remove "T" bar surround then unscrew and remove left and right console wings and tissue box holder.
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Cellular Phone
419-08-6
REMOVAL AND INSTALLATION (Continued) 5. Loosen hardware as indicated to allow flexibility in the console side panel.
6. Feed wiring through the drilled hole in the console floor (concealing hole made under carpet) to reach under console side. Feed wiring forward to front of console.
7. Conceal wiring under console side. 8. Feed wiring through to wiring connector C192 & C204 as shown in Wiring - General Information Component location views 700-06-00-1.
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Template for drilling hole in console base: 1. Fold paper at dotted line and fit into console in place of carpet with arrow facing forwards 2. Drill 25mm hole at point marked
Facing toward front of console
DRILL HERE
419-10-1
Body Electronics Module (BEM)
419-10-1
SECTION : 419-10 Body Electronics Module (BEM) VEHICLE APPLICATION : 2003.0 BA Falcon CONTENTS
PAGE
DESCRIPTION AND OPERATION Body Electronics Module ......................................................................................................419-10-2 DIAGNOSIS AND TESTING Body Electronics Module ......................................................................................................419-10-9 Inspection and Verification ...................................................................................................419-10-9 Symptom Chart ..................................................................................................................419-10-13 Connector Circuit Reference ..............................................................................................419-10-19 Pinpoint Tests ....................................................................................................................419-10-24 GENERAL PROCEDURES Remote Key Teaching ........................................................................................................419-10-30 Receiver Resynchronization ...............................................................................................419-10-30 Dealer DST Ignition Key Teach Mode ................................................................................419-10-30 Customer DST Ignition Key Teach .....................................................................................419-10-30 Lost Keys ............................................................................................................................419-10-30 Customer Key Erasure ........................................................................................................419-10-30 PCM Parameter Reset ........................................................................................................419-10-30 Cabin Temperature Sensor Calibration Factor ...................................................................419-10-30 Changing BEM ....................................................................................................................419-10-31 REMOVAL AND INSTALLATION The BEM and Remote Receiver .........................................................................................419-10-32
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419-10-2
Body Electronics Module (BEM)
419-10-2
DESCRIPTION AND OPERATION delay determined by the vehicle road speed and the position of the wipe potentiometer. As the vehicle speed increases above 8km/h, the dwell time will be General Description The Body Electronics Module, hereafter referred to as reduced. When the vehicle speed is decreased then BEM, combines a transponder Challenge /Response the wiper dwell time will extend. immobilisation system with the Body electronics Vehicle speed information is sent to the BEM via the functions. The BEM interfaces with a Integrated CAN BUS. Command Centre (ICC). There are two levels of BEM; When the wiper dwell potentiometer is fitted to the a High series and a Low series; these are identified wiper switch, five dwell positions can be selected. as BEM/H and BEM/L. Over the speed range zero to 80 km/h 11 increments of 8 km/h adjust the wiper dwell time. When the All current, resistance, frequency figures are ± 10% unless specified otherwise. All voltage readings will be vehicle accelerates from zero to 8km/h the next wipe will be brought forward to provide a Wipe On Take Off as specified. function. With no speed information to the BEM from the CAN BUS the wiper dwell time will be as follows: Position 1, 4.1 secs. Position 2, 6.6 secs. Position 3, 9.1 secs. Position 4, 11.1 secs. Position 5, 14.1 secs.
Body Electronics Module
Front Wipe After Wash Control, Low Series When activating the wash switch with the ignition turned on, there will be a small delay of 0.4 seconds before the wipers operate until the washer switch is released. A further three wipes will be performed before parking at the bottom of the windscreen. If intermittent wipe function is active, it will be Accessories Line Status suspended whilst the wash function is in progress and The BEM reports the status of the Accessories line via resume once the wash switch is deactivated. the CAN BUS. The Accessories line is high when the Wash function will also be suspended if the engine is ignition switch is in the Accessories and Ignition being started. positions and open in the Start position. Switching the ignition switch to the off position will cancel the wash function. Heated Backlight Timer The Heated back light may be activated when the Front Wipe After Wash Control, (High Series) ignition switch is in the Ignition or accessories Activating the front washer switch momentarily with position. Pressing the heated backlight switch momentarily is reported over the CAN BUS. Once the the ignition switch in the on position on a high series message is received by the BEM, the Backlight relay vehicle will activate the washers for a period of 1.2 seconds. If a longer period is required than this then is activated by pin J2/10 (cct 686 violet) being hold the washer switch in the on position for the switched low. The relay will remain energised for 15 minutes or until the backlight switch is activated again desired period of time, after the washer motor is activated 0.4 seconds the wipers will perform or the ignition switch is turned to the off position. approximately three wipes then park. If the During the engine starting process the timer will be intermittent wipe function is active, it will be suspended, once the engine is started, the timer will suspended whilst the wash function is in progress and resume the timed period. resume once the wash switch is deactivated. Front Intermittent Wiper Timer Wash function will be cancelled if the engine is being Vehicles may be fitted with Variable Dwell; Speed started. Dependant Wiper and Wipe on take off functions. If Switching the ignition switch to the off position will the wiper dwell potentiometer is not connected then also cancel the wash function. the wiper dwell will be fixed to a period of 7 seconds. Switching the front intermittent wiper switch to the Washer Fluid level (High series) intermittent position whenever the ignition switch is With the ignition switch in the Accessories, Ignition or turned on will enable the intermittent function. Start position; the status of the washer bottle is Whenever the intermittent function is enabled, the front wiper output will be activated for a period of 0.8 updated via the CAN bus. For a change of state to be seconds to initiate a single wipe. This is followed by a G43560 en
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Body Electronics Module (BEM)
419-10-3
DESCRIPTION AND OPERATION (Continued) observed, the condition must be present for a period longer than 20 seconds. Power Window Control With the ignition switch in the accessories or ignition position, the power window relay is switched low. Switching the ignition switch to the start position will deactivate the relay. Switching the ignition switch to the off position will allow the power window relay to remain activated for a period of 1 hour. If a door is opened, the time will be reduced to 40 seconds from the time the door is opened to comply with Australian design rule 42. Remote key unlock press will activate power supply pressing on lock button will activate.
overridden by any of the following actions, a door opened, ignition turned from off to the on position or a remote key activation.
With the ignition key in the off position and activating the panic function, the courtesy lamps will be turned on. Activation of remote door unlock, boot release or deactivation of the panic function will cause an entry delay to occur. (20 seconds on, 6.4 seconds fade to off). Whilst the ignition is in the off position and a door lock command is executed with all doors closed, the courtesy lamp will be immediately deactivated. If no remote key has been taught, then the courtesy lamp will deactivate in a shorter time than usual ie. 3 minutes when the doors are opened regardless of the ignition key position. The courtesy lamp will turn on in Analogue Clock Interface (High Series) 1 second remain on for 3 minutes then fade out in 1 The BEM provides battery power for the analogue second. clock at all times and connects to the Clock’s The courtesy lamp can be turned on and off via CAN illumination line to the graphics illumination signal diagnostics. from the cluster. A police blackout mode is available to turn off the Cabin Temperature Module (High Series) battery saver circuit. To enter or exit this mode, hold With the ignition key in the ignition or start position, the courtesy manual switch for longer than 10 the BEM provides power to the fan motor of the cabin seconds. This function has been added to discourage temperature module. With the ignition switch in the wiring modifications for the emergency services. ignition position the BEM reads the analogue temperature signal from the module and converts the Battery Saver Supply analogue data into degrees Centigrade and transmits When the battery saver is active it provides power to this data on the CAN bus to the climate control the courtesy lamps, boot lamp and glove box lamp system. Note: DTC’s will not be logged for invalid circuits. It also supplies power to the sunload/twilight data when the ignition switch is in the off or sensor, Audio antenna amplifier and the transceiver accessories position. Calibration factor is programmed light ring illumination. into the BEM using diagnostic command. The battery saver is activated with any of the following actions: Sunload / Twilight Sensor Module (High Series) The ignition key in the accessories, ignition or Activation of the battery saver supply (J3/3) provides start position. power to the sunload/twilight sensor module. With the ignition on and the battery saver supply active, the Operating the remote key door unlock, lock, boot BEM reads the signals from the sensor. The BEM and panic. transmits the sunload data over the CAN bus to the The battery saver function has a number of climate control module. This sensor also controls the operational modes, these are tabulated below. Auto Headlight on function. Refer to Auto Headlight section. Normal Mode Battery Saver ON, Courtesy OFF NOTE: DTC’s will not be available for invalid data Saver Mode Battery Saver OFF, signalled with the ignition switch in either the Courtesy OFF accessories or the start position. The output voltage from the sunload sensor is available at pin J2/1; it is in Courtesy Mode Battery Saver ON, the range of five to zero volts. Courtesy ON Dash Mode Battery Saver ON, Courtesy Lamp operation with illuminated Entry Courtesy ON and Exit Delays EXIT Mode Battery Saver ON, With the ignition in the Accessories, Ignition or Start Courtesy ON, 20 sec position, and if, any door is open then the courtesy delay, 6.4 sec fade lamp will be on. With all doors closed, the courtesy Police Mode Battery Saver OFF, lamp will be off. With the ignition in the off position Courtesy OFF and any door open, the Courtesy lamp will be on until Audio Keyless Play Battery Saver ON, the battery saver times out at 15 minutes. If in the Courtesy OFF meantime the door is closed then the courtesy lamp will remain on for 20 seconds then fade to off over a period of 6.4 seconds. The delay period will be G43560 en
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Body Electronics Module (BEM)
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DESCRIPTION AND OPERATION (Continued) Normal Mode (Battery Saver On, Courtesy Off) The battery saver circuit will be in normal mode; when the BEM is powered up or reset, by removing and replacing the BEM fuse; it will be in Normal Mode. Normal mode will be entered from saver mode if the ignition key is turned from off to the accessories, ignition or start position, a door is opened then closed, operating the remote key door or boot functions. Saver Mode (Battery Saver Off, Courtesy Off) The BEM will go into saver mode after 15 minutes with the ignition in the off position as long as the last event of opening and closing a door has occurred. It may also enter saver mode 15 minutes after pressing the door lock button, unlock button, panic button or boot button whichever occurred last. Courtesy Mode (Battery Saver on, Courtesy On) The transition from normal mode to courtesy mode can occur with ignition key out of the lock, Door opened. Remote key unlock command, boot unlock, panic or dash switch with a one second fade in. The transition back to normal mode from Courtesy mode can occur after remote key lock command, Ignition key from off to Ignition, Accessories or start position or the dash switch with a one-second fade out. If the BEM is in courtesy mode due to a boot open command, when the doors are closed and the ignition is off the BEM will enter Exit mode.
Door and Boot Ajar Status The BEM will report the ajar status of the four Doors and Boot individually via the CAN bus. Manual Boot/Tailgate Release The manual boot/tailgate release switch is enabled when any door is unlocked or battery saver is active. The switch is disabled 10 minutes after ignition off if all doors locked. When pressed the BEM will output a 12 Volt pulse to the release solenoid for a period of 0.8 seconds. No output is available if the vehicle speed exceeds 12 km/h. If no CAN speed data is available then the BEM will default to 0kmh and the release function will be enabled. Remote key Boot /Tailgate Release Pressing the boot release button the BEM will output a 12 volt pulse of 0.8 seconds in duration to the release solenoid. It will also cause the hazard lamps to flash once for a duration of 1.6 seconds. The courtesy lamp will illuminate for 20 seconds then fade for 6.4 seconds. Central Locking Manual Central Locking Functions Manual central locking can be initiated by the following actions:
Pressing the central door-locking switch once will lock the doors if unlocked, pressing the switch again will Dash Mode (Battery Saver on, Courtesy On) unlock the doors. Inserting the mechanical key into The courtesy lamp may be turned on via the CAN bus the driver’s door exterior lock will unlock only the by holding the dash switch in the on position for 1 driver’s door. To open the passenger doors press the second. To turn off hold the dash switch for 1 second central locking switch with the driver’s door open. If with the door closed, a one-second fade will occur the drivers door is closed after a manual unlock then when the BEM returns to Normal Mode. pressing the central locking switch will first lock the drivers door then a second press will unlock all doors. Exit Mode (Battery Saver On, Courtesy On, Exit If the soldier button is pressed downwards then all Delay 20 secs. 6.4 Secs Fade) doors will lock. If drivers door opens when soldier This mode is entered from courtesy mode with the button pressede all doors will unlock the soldier action of closing the boot or closing the doors with the button. Opening the interior door handle half way will ignition off. The BEM will return to courtesy mode if unlock the driver’s door. Unlocking any passenger during the delay or fade period a door is opened, a interior door lock handle will unlock all doors. If the door is unlocked or a remote key (except lock) driver’s door is slammed when in the locked mode, command is received. On completion of the exit the BEM will command a driver’s door unlock. mode, the BEM will resume normal mode. In the event of a crash signal being received by the Door Trigger Disable Mode, Courtesy off) BEM from the airbag system via the CAN bus, an unlock all doors will be actioned. During a power up or This mode may be entered from any other mode by reset, the status of the doors will be unchanged to holding the dome dash switch for a period of 5 seconds. It does not require any wiring modifications avoid a lock out action. to be undertaken. To restore normal operations again Remote Central Locking Functions with Boot hold the dome dash switch for 5 seconds. Release and Panic Alarm NOTE: Police and Taxi Mode can be set under Remote entry and panic functions only operate with personalised settings in WDS. the ignition switch in the off position. Two modes of These settings control horn (control by BEM) courtesy operation are possible, Two stage unlocking or single lamp enabling, battery saver control, & taximode of stage unlocking. This feature may be activated or door locks. deactivated for each remote key programmed to the vehicle. To toggle between these modes hold the lock G43560 en
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Body Electronics Module (BEM)
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DESCRIPTION AND OPERATION (Continued) and unlock buttons down simultaneously for a period of 3 seconds. In two stage unlock, pressing the unlock button once will unlock the driver’s door, the hazards will flash once, a second press or holding down button for 3 sec. will unlock the remaining doors and again flash the hazards once. In single stage unlocking, pressing the unlock button, will unlock all doors and flash the hazards once. In both modes pressing the lock button, will lock all doors and flash the hazards twice. Pressing the panic button will activate the panic alarm for a period of 30 seconds, unless the ignition is turned on or the panic button is pressed a second time. The hazards will flash and the horn will sound at a frequency of 5 Hz while the panic function is active. Pressing the boot/tailgate, release button will output a 12 volt pulse for 0.8 seconds. A hazard flash of 1.0 second is enabled via the CAN bus. A confirmation of door lock is possible by pressing the remote lock button; if locked the horn will bip 0.016 sec and a hazard Flash of 0.5 secs. When a door is open then a door ajar will be detected or a transponder key is detected in the ignition, a door lock attempt will result in the horn issuing a door ajar warning of 8 pulses in rapid succession. The BEM will action a door unlock, the hazards will flash two long and two short pulses, the Cluster smartshield warning jewel will be turned on and the courtesy lamp will be on. If a successful lock is achieved then the system will revert to normal operation. Automatic Door Relock If a remote key is used to unlock the doors and no door is opened, the ignition is not turned on. The doors will automatically relock after 45 seconds. RF Remote Key The RF remote key signals are received by the RF receiver module all the time. The data is only passed to the BEM, when the ignition is in the off position, and the remote key has been trained to the BEM. If the Receiver receives a number of invalid transmissions, it is possible for the receiver to resynchronise to a single remote key. If a remote key has not been used for a long time, the receiver may not respond, should this happen, press the remote key button 3 times in succession and it will be resynchronised to the receiver. RF Remote Key Teach (up to 8 keys) To enter teach mode turn the ignition switch from off to accessories and within 5 seconds press the rear demist switch 3 times; remote key teach mode will be entered. When the mode is entered then the door locks will change state. Once the mode is entered then all the remote keys will be erased. To teach the keys press any remote keys button; to acknowledge the new key has been stored in memory the door locks will change state G43560 en
then change back again. Then teach the next key and so on. As each key is taught, the door locks will cycle. Turning the ignition switch to off or on position will exit teach mode. Again the door locks will change state to indicate the mode has been exited. NOTE: it is important that all keys that are to be taught to the system are taught in the same teach sequence. Seat Memory and Priority Key Control (High Series) On the high series vehicle, the priority key control is activated when the driver’s door is unlocked with a remote key. The BEM is able to identify the remote key by the order they were taught to the BEM. When the BEM identifies the key used it sends data to the seat module via pins J2/22 (seat memory data) and J2/23 (seat memory enable). Data stored in the seat memory is acted upon according to the remote key number. Automatic Headlamps with Twilight Sensing and Delayed Turn-Off Setting the headlamp switch to the automatic position allows the BEM to control the headlamp relay from ambient light information from the twilight sensor, ignition switch and the driver’s door. The headlamp switch is ignored in automatic mode. To avoid the headlamps being turned on and off by sudden changes in light level ie moving trees, moving cars etc, The BEM uses a combination of hysteresis and delay strategies. When the ignition switch is in the accessories or ignition on position, the BEM headlamp relay output driver is controlled by changes in ambient light level. The BEM also controls the relay to provide a headlamp delay when the ignition is turned from on to off and it is dark. If the driver’s door is opened within the delay period then the time is shortened. Case
Twilight Sensor status Light Light to Dark Dark to Light
Ignition / Driver Accessory Door
4 5
Light Dark
On to Off On to Off
6
Dark
On to Off
7
Light
Off
1 2 3
On On On
BEM Headlamp Relay Output N/A Off N/A Delayed On to Off 2 secs N/A Delayed Off to On 15 secs N/A Off Closed Delayed On to Off 120 secs Open Delayed On to Off 20 secs N/A Off
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Body Electronics Module (BEM)
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DESCRIPTION AND OPERATION (Continued) Case
Twilight Sensor status Light to Dark Dark
Ignition / Driver Accessory Door
BEM the light condition is BRIGHT the BEM will respond by Headlamp setting a delayed turn off. Relay Output Electronic Immobilisation 8 Off N/A Off The immobilisation interfaces with four systems in the vehicle, the associated components are as follows: 9 Off Closed If already on, to then delay Ignition key with embedded Digital Signature Open 20 secs from Transponder (DST). The ignition key also has a On to Off mechanical encoded key and electronic transponder technology. The ignition key is the 10 Dark Off N/A Off authority to start and drive the vehicle. For the 11 Dark to Off N/A Off BEM to respond the ignition key must be inserted Light into the ignition lock and the transceiver antenna 12 Light Off to On N/A Off field. The Auto headlamp control has a number of inbuilt Transceiver Ignition lock assembly (TILA): The safety features to ensure that the headlamps remain TILA in addition to the steering lock, ignition and operational even if a connector is disconnected whilst starter functions interfaces the ignition key (DST) running. and the BEM through the transceiver circuit. The It is possible to adjust the Auto Headlamp Transitions TILA consists of a transceiver and a transmit and from Off to On in Diagnostics Mode from the factory receive antenna attached to the lock barrel. The default setting. Adjustment of the on to Off transition antenna is used to transmit to and receive date can also be selected in diagnostics mode. from the transponder. Body Electronics Module (BEM): The BEM is There are 8 possible setting available in each mode. responsible for verifying that the DST ignition key The System performs diagnosis of the twilight sensor is valid by issuing a challenge and the receiving a and the output circuitry via a dedicated feedback. response; this received data is then compared Diagnostics runs independently of the main Auto with the values stored in the BEM memory. If a Headlamp circuitry. match is made the BEM will mobilise. The BEM When the auto headlamp feature is selected and the will then receive a challenge from the Power ignition is in the run or accessories position, Control module (PCM) over the CAN bus. The diagnostics of the Auto Headlamps and twilight sensor BEM will then respond to the PCM also over the will occur every time auto headlamps are required to CAN bus. turn on. Diagnostics will also run if the headlamps are Power Control Module (PCM): The PCM is required to turn off. responsible for allowing the vehicle to start, sends a challenge to the BEM, once a valid response Twilight Sensor Diagnostics has been received from the BEM allows the An error message out of range DTC will be displayed engine to continue to run. If not, the engine will be if the PWM frequency is above 420 Hz for the darkest stalled. condition or below 1 to 47Hz for the lightest condition. If no PWM signal is received, the error message will read Open or Short circuit to ground and DTC will be displayed. The Auto Headlamp output has a failsafe mechanism in that the relay output will be maintained should an output driver fail. If the Twilight Sensor fails and Auto Headlamps is selected then the BEM will default to a failsafe strategy as follows. When the Ignition or accessories are turned on, the headlamps will be on and when the ignition is off the Headlamps will turn off. Whenever an Auto headlamp output failure is detected, a warning buzzer (from the cluster) will sound for a limited time when the ignition is turned from on to off and next time the ignition is turned from off to on. The buzzer will sound on the ignition transitions until the fault is rectified. During a power reset and Twilight Sensor data is not available the BEM will assume a dark condition and turn the Auto headlamps on until sufficient twilight sensor data is available. Once the data is available if G43560 en
Transceiver Lock assembly (TILA)
The TILA comprises a Transceiver with an ignition key light ring, steering lock and ignition starter switch that will perform the following functions: 01/2003 2003.0 BA Falcon
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Body Electronics Module (BEM)
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DESCRIPTION AND OPERATION (Continued) The Transceiver provides an electrical/RF interface between the BEM and the transponder housed in the ignition key head. The transceiver generates a low frequency field that is radiated by the integrated antenna, and used to transmit and receive signals from the transponder. The transceiver may be removed by loosening the retaining screw and sliding the assembly off the lock housing. When replacing the transceiver it is important that the tightening torque for the retaining screw is observed. This is 19.5 Nm Max for the original screw. The Ignition Key light Ring illuminates as part of the courtesy lamp function with illuminated entry and exit delays. The Steering Lock Assembly is part of the steering column and cannot be removed. The lock assembly provides mechanical security by locking the steering column by way of a locking bolt that engages once the ignition key is removed from the lock and the steering column rotated. A lock barrel is located in the lock housing and when the ignition key is inserted allows the ignition switch to be turned to Accessories, Ignition and start positions.
provide an interface between the RF remote Keys and the BEM. The receiver is a superheterodyne design that converts the AM encoded signals from the RF remote keys into data that is validated by the BEM. Once validated the command sent to the receiver is acted upon by the BEM. Ie lock or unlock etc. The range of the remote keys may be reduced by the use of aftermarket window tinting, heavy rain, snow, hail, close proximity to trees. Strong RF signals on or near the frequency of the receiver may cause de-sensitisation. The receiver obtains battery power from the BEM fuse all the time. The receiver detects any valid signals from any remote key. If a signal is detected, the receiver will be turned on. After the signal has been received, the receiver will resume polling to await the next transmission. Refer to WDS tests for fault finding. The receiver unit is a servicable item. If faulty refer to ICC section of service manual for procedure for removal and replacement.
Cabin Temperature Sensor (CTS) The CTS is located behind the instrument fascia panel CAUTION: As an added security feature the as part of the ICC. The CTS takes temperature lock bolt will fire into the locked position and readings via a DC operated fan motor drawing air remain permanently locked if the lock is turned from the car interior through the grill and across a with the barrel removed, if this happens the whole thermistor. When there is a change in temperature, steering column must be removed and replaced. the value of resistance changes giving a change in voltage output. This change is read by the BEM where To replace the lock barrel, insert the barrel into the it is translated into a CAN message that is read by the lock until the pin locks into the housing. HIM. The Ignition Starter Switch provides electrical contact of the battery supply to the accessories, ignition and starter circuits. In the start position, a lamp proofing circuit is provided with a ground. The start position is spring loaded to return to the ignition position. The switch mechanism cannot be removed and is not serviceable. The TILA wiring harness also provides an interface to the pedal height motor assembly. Remote Receiver Module
The CTS is not a servicable item. If the CTS is faulty the complete ICC should be replaced as per procedure for ICC replacement, after prior approval gained. WDS to be used to program and check calibration factor loaded into BEM. This calibration factor should be the same as the calibration factor identified on the CTS ID label.
The RF receiver module is mounted inside the passenger compartment at the top of the ICC to G43560 en
P & A BEM The P & A BEM is programmed in an immobilised state. To install a new P & A BEM, DST ignition key 01/2003 2003.0 BA Falcon
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Body Electronics Module (BEM)
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DESCRIPTION AND OPERATION (Continued) teach, CTS calibration factor loading and PCM parameter reset functions need to be performed. BEM and PCM security status can be identified by the BEM’s mobilisation status and current status of the PCM communications PID’s respectively. CTS calibration factor can be read by the WDS. If a calibration factor has not been loaded then DTC will be set on the BEM until a valid calibration factor is loaded. Normal Operation — BEM Mobilisation With the ignition switch in the off position, the BEM will be in the armed state. Turning the ignition key to the accessories, ignition or start position will cause the BEM to commence a challenge of the ignition key’s Digital Signature Transponder (DST). Each time a new challenge is made the old challenges are flagged as used. If the response is known by the BEM then it will mobilise. Failure of the challenge will result in the mobilisation state changing to immobilised and a transponder DTC will be logged to identify the type of error. If an incorrect response is received a new challenge will begin, this will be repeated until a correct response is received or the ignition is turned off. If an attempt is made to scan the BEM, it will shut down for a set period, after this time the BEM will resume with a new random challenge. Once a valid response is received and the BEM mobilised then the challenges will stop. Normal Operation PCM Enabling Once the ignition switch is in the accessories, ignition or start position, the BEM will look for a pre-challenge request from the PCM, and respond with a challenge request message. Any challenges from the PCM will cause the BEM to respond with a not ready, reading transponder message. Once the BEM has mobilised, it will request a challenge from the PCM and wait for the challenge message from the PCM to appear on the CAN bus. The BEM will calculate a response from information learnt from the PCM and transmit a response code. A challenge acknowledgment message from the PCM shall indicate to the BEM that the response has been accepted. PCM communication status may be monitored using BEM diagnostics. Dealer DST Key Teach Mode This mode is used by dealers to teach new DST keys to a replacement BEM. The mode can also erase DST keys. To enter this mode using the WDS tester ensure that the ignition is turned to the off position. Entry into the mode and deletion of the PCM ID is confirmed by a mode acknowledgment. Select the anti-theft status screen, and then select Transponder Dealer Teach Mode. Insert DST key 1 into the ignition lock, then turn to the ignition on position. For each DST key, the BEM will record the DST unique identification number and program the DST with its own encryption code key. G43560 en
Acknowledgment of a successfully taught first key will be by cycling the door locks once, twice for the second key and so on. Acknowledgment will normally occur within 2.5 seconds of inserting the key and turning to the ignition on position. Turn the ignition to the off position and remove the key, immediately insert the next key to be taught and turn to the ignition on position. If a key cannot be programmed then no acknowledgment will be received. Dealer teach mode will be terminated by the following conditions: Interruption to the BEM power. Leaving the ignition in the off position for 10 seconds. Turning the ignition to the on position with a DST key that has been programmed; once more than two keys have been taught. Once eight keys have been taught. Exiting the Dealer teach mode will be confirmed by a door lock cycle. Customer Spare DST Key Teach Mode The customer key teach mode allows the owner limited teach and delete key function. To enter customer key teach mode, the owner must have two valid keys that are already taught to the BEM. Insert one of the trained keys into the ignition lock and turn to the accessories position, turn to off and remove the key. Within 5 seconds insert the second key and turn to the ignition on position. At this point the door locks should cycle to indicate the teach mode has been entered. To teach additional keys to the BEM, insert the new key and turn to the ignition position, if successful the door lock cycling will indicate the number of keys taught. Once acknowledgment has occurred turn the key to off and insert the next key to be taught. Up to additional 6 keys may be taught in this way. For key deletion only the keys that are not taught to the BEM will be deleted. The two known keys used to enter teach mode plus any additional keys taught will be valid, all other keys will be erased. To exit teach mode leave the ignition on for longer than 10 seconds. An acknowledgment will be received when the BEM exits teach mode. PCM Parameter Reset A PCM parameter reset will be required if either a BEM or a PCM are replaced in the field or a dealer DST ignition key teach is performed. If PCM parameter reset invoked by WDS it will also require the entry of a CTS calibration factor. The BEM must be mobilised by turning the ignition to the on position using a taught DST Key. Using the WDS tester select PCM parameter reset function, complete the steps indicated on the WDS screen.
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Body Electronics Module (BEM)
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DIAGNOSIS AND TESTING Boot shut Glovebox open Inspection and Verification Do not sit in the Drivers seat During this test, it is important to make visual On Demand Self Test observations. Using the WDS Tester it is possible to conduct an on The total time for the test is 14 seconds the following demand self test. table gives the order and function being tested. The pre-conditions for this test are as follows: NOTE: We can categorise the tests as visible and Ignition key in the ignition switch and turned to the invisible to the operator. The following is a table of ignition on position tests/operations to be performed. It will do different Headlamp switch in Auto position tasks at 1 second intervals.
Body Electronics Module
Time (second) 0 (start)
Visible Tests Door Lock
1
Memory Seat #1
2
Driver Door Unlock
4
Horn Relay
5
Front wash motor
6
Battery Saver
7
8
G43561 en
Front wiper motor
Boot Release
Invisible Tests Driver Door Lock feedback Seat Module Data line Open circuit* Short to battery Driver Door Lock feedback Memory Test* Horn Relay line Open circuit* Short to battery
Transceiver TX Data Line Open circuit* Short to battery TILA Challenge TILA - Key ID unknown TILA - Faulty transponder TILA disconnected TILA - Faulty or fixed code transponder Wiper Feedback Front wiper switch potentiometer* Out of Range Circuit Failure Boot Release feedback
Precondition
!!!Do not sit on the seat
Comments Relay energised for 200ms High series only DTC may be set if option is not fitted. Relay energised for 200ms 100ms On, 100ms Off,100ms on, 400ms off, 100ms on, 100ms Off,100ms on, Off High series only
Key in ignition position Leave open "glove Battery Saver left on box" or turn on "map for rest of test lamp" to observe Battery Saver active. Battery Saver activeKey in ignition position
Key in ignition position Key in ignition position
1 wipe (Turn on for 700ms) High series only
Boot needs to be shutBattery Saver must be active
Relay energised for 800ms DTC will be set on utes.
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Body Electronics Module (BEM)
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DIAGNOSIS AND TESTING (Continued) Time (second)
9
Visible Tests
Heated Backlight
11
Power Windows
12
Dome Lamp
14 (end)
G43561 en
Precondition Key in ignition position
Comments Must follow TILA challenge
All Door Unlock
10
13
Invisible Tests Immobilisation transfer* – message not sent from PCM (missing message)
Auto Headlamp
Cabin Temperature Sensor* Circuit Open Circuit short to battery Circuit short to ground Driver Sunload Sensor* Circuit Open Circuit short to battery Circuit short to ground Passenger Sunload Sensor* Circuit Open Circuit short to battery Circuit short to ground Heated Backlight Relay Open circuit* Short to battery Power Window Relay Open circuit* Short to battery Twilight Sensor* Circuit Open Circuit short to battery Circuit short to ground Auto headlamp feed back CAN PCM data out of range (speed)* CAN battery voltage - signal out of range from cluster*
Relay energised for 200ms High series only
Key in ignition position
Key in ignition position
High series only
Key in ignition position
High series only
Key in ignition position
Look at dash board to observe indicator
Hold button to observe window operation No fade in/out Battery Saver active High series only
Headlamp switch in "auto" position Key in ignition position Key in ignition position
High series only
Dome flashes (300ms on) to indicate self test complete.
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Body Electronics Module (BEM)
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DIAGNOSIS AND TESTING (Continued) BEM Diagnostic Trouble Code (DTC) index DTC C1943
Description Airbag Deployment Indication Input Fault
B1213
Anti-Theft Number of Programmed Keys Is Below Minimum Air Temperature Internal Sensor Circuit Failure
B1250
B1251
Air Temperature Internal Sensor Circuit Open
B1253
Air Temperature Internal Sensor Circuit Short To Ground
B1259
Solar Radiation Sensor Circuit Open
B1261
Solar Radiation Sensor Circuit Short To Ground Power Door Lock Circuit Failure
B1300
B1342
ECU Is Faulted
B1348
Heated Backlite Relay Circuit Open Heated Backlite Relay Short To Battery Wiper Park Sense Circuit Failure
B1349 B1446
B1458 B1548
G43561 en
Wiper Washer Pump Motor Relay Circuit Failure Power Window Master Circuit Open
Precondition Airbag Deployed CAN bit received. Status read during self tests. Number of programmed keys is less than 2.
Action Airbag deployed. No action Program more Keys
Out of range. Will be set if Check ICC wiring. If input is between 0.32V wiring OK then replace and 0.47V Cabin Temperature Sensor. Input floats > 4.56V Check resistance of CTS. If O/C then change CTS. If not O/c then check ICC wiring. Input < 0.32V, External Check resistance of CTS. Fault If S/C then change CTS. If not S/c then check ICC wiring. Circuit open or short to Check Driver’s Sunload battery, Input greater then Sensor and Wiring. 4.78V, External Fault Input held at less than Check Driver’s Sunload 0.17V, External Fault Sensor and Wiring. Door Lock Motor Error / Pinpoint tests G and N. Driver’s door lock feedback did not change after lock action, External Fault EEPROM /TEMIC are ECU Failure - Replace continuous only, but if set Module. the DTC will be reported as part of self test. ROM / RAM DTC can be set after BEM power reset (continuous DTC) or during self test. Internal Fault O/C or S/C to Ground, Check Heated Backlite External Fault and wiring S/C to Battery, External Check Heated Backlite Fault and wiring Feedback does not Check Wiper motor, change / park circuit wiring and switch failure, External Fault Confirm DTC with Self Test Front wash motor error, Check Washer motor, External Fault wiring and switch Power Window Relay driver O/C or S/C to Ground, External Fault
Check Power window relay and wiring
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Body Electronics Module (BEM)
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DIAGNOSIS AND TESTING (Continued) DTC B1549
Description Power Window Master Circuit Short To Battery
B1600
PATS Ignition Key Transponder Signal Is Not Received
B1601
PATS Received Incorrect Key-Code From Ignition Key Transponder PATS Received Invalid Format Of Key-Code From Ignition Key Transponder Autolamp On Circuit Failure
B1602
B1693
B1790
Autolamp Sensor Input Circuit Failure
B1791
Autolamp Sensor Input Circuit Open
B1982
B2072 B2073 B2074 2075 B2103
B2141 B2431
G43561 en
Precondition Power Window Relay driver S/C to Battery, External Fault TILA RF receiver error
Key ID unknown or Incorrect challenge Faulty or fixed code transponder Autoheadlamps Driver Circuit Failure, External Fault. Twilight sensor input circuit failure
Twilight sensor input circuit open, External Fault Driver’s Door Unlock Driver’s door unlock is Relay Circuit Failure not successful / Driver’s door lock feedback did not change after unlock action Seat Memory Module S/C to Battery, External Data Line Short to Battery Fault Seat Memory Module Data Line Open or Short to Ground Seat Memory Module Enable Line Short to Battery B Seat Memory Module Enable Line Open or Short to Ground Antenna Not Connected
NVM Configuration Failure Transponder Programming Failed
Action Check Power window relay and wiring Check power available on J1/4 & earth on J1/3. Check continuity from BEM J1/7 to TILA J6/1. Check TILA. Check programmed key is used. Reprogram keys if required. Program correct transponder Key Twilight sensor Headlamp switch must be in Auto position. Check Wiring and headlamp switch and headlamp relay. Check operation of battery saver. Check Twilight sensor and wiring Check Twilight sensor and wiring Pinpoint tests G and N.
Check Seat memory module and wiring J2/22 Check option is fitted O/C or S/C to Ground, Check Seat memory External Fault module and wiring J2/22 Check option is fitted S/C to Battery, External Check Seat memory Fault module and wiring J2/23 Check option is fitted O/C or S/C to Ground, Check Seat memory External Fault module and wiring J2/23 Check option is fitted TILA antenna not Check power available on connected, External Fault J1/4 & earth on J1/3. Check continuity from BEM J1/7 to TILA J6/1. Check TILA. No PCM ID Stored Conduct a parameter reset Key programming failed Program new key. If this fails try new transponder. If this still fails try a new TILA.
01/2003 2003.0 BA Falcon
419-10-13
Body Electronics Module (BEM)
419-10-13
DIAGNOSIS AND TESTING (Continued) DTC B2477 B2511 B2682
Description Module Configuration Failure Horn Output Relay Circuit Short to Battery PCM (PCM) Communication Fault
Precondition Calibration factor is not configured S/C to Battery, External Fault Immobilisation Message Invalid
B2849
Horn Output Relay Circuit O/C or S/C to Ground, Open External Fault
B2891
Front Wiper Switch Potentiometer Circuit Failure Decklid Release Circuit Failure
B2894
B2929 B2930 U1900
U2197
Action Program CTS calibration factor Test wiring J2/9 and horn relay Conduct a parameter reset. If this fails check the PCM. Check Horn relay and wiring J2/9 Continious DTC not valid. On demand DTC is valid. Check wiper dwell pot and wiring J2/19 to J2/8
Potentiometer is missing, External Fault (O/C or S/C) Boot is not ajar after boot Boot release solenoid release, External Fault error, Test boot ajar switch and listen for activation of solenoid. If not heard then check wiring and boot solenoid. DTC not valid on utes. Transmit Data Line Short S/C to Battery, External Check continuity from to Battery Fault BEM J1/8 to TILA J6/9. Check wiring and TILA. Transmit Data Line Open O/C or S/C to Ground, Check continuity from Circuit or Short to Ground External Fault BEM J1/8 to TILA J6/9. Check wiring and TILA. CAN Communication Bus CAN Network failure Check PID B902 for Fault - Receive Error (Missing Messages) modules whose messages where missed. Check relevant module and CAN wiring. Invalid ’Vehicle Speed’ CAN bytes for vehicle BEM default speed data data speed is read as $FF used is Zero. Test PCM. from PCM
Symptom Chart Condition
Source
Action
No Clock illumination
BEM related No Graphics Illumination Feedthrough No park lamp supply feedthrough from park lamp relay Incorrect BEM fitted Cluster fault Wiring fault Clock fault
Check for open circuit J1/1 to J4/12 and J1/2 to J4/10 Check for 12v at J1/2 when park lamps on Check other possible causes on symptom chart Check correct level BEM fitted
No TILA light Ring Illumination
BEM related Courtesy lamp driver Battery BEM fuse blown Cluster fault Wiring fault TILA fault O/C globe
Check 12v at J1/4 and J6/3 Check BEM battery fuse Test continuity J6/10 to J6/3 Go to pinpoint test A Check other possible causes on symptom chart
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01/2003 2003.0 BA Falcon
419-10-14
Body Electronics Module (BEM)
419-10-14
DIAGNOSIS AND TESTING (Continued) Condition
Source
Action
No Demist Function
BEM related Relay driver failure DTC’s logged Backlight fuse 40A blown BEM accessories fuse Blown Radio 2 fuse (7.5A) blown External Relay failure Demist Element fault Demist switch failure (ICC) Audio fault Wiring fault No accessories feed to BEM CAN line failure
BEM does not mobilise
BEM related PCM/BEM comms not working BEM/TILA comms not working More than one key in the TILA antenna field. Transponder does not validate. Wrong type of transponder key eg Ford Transit. Magnetic badge on key ring. Vehicle parked close to magnetic scanner. PCM fault Wiring fault (CAN) TILA fault Transponder key fault
Connect WDS Turn Ignition On and Run On Demand Self Test. Record any DTC’s logged. Refer DTC chart for relevant pinpoint tests – Note TILA Status Record any DTC’s logged. Low frequency security scanners may interfere with TILA read process. Check other possible causes on symptom chart.
Customer Cannot Teach Transponder Keys
BEM related Customer Key teach mode not enabled. BEM programmed to disable customer key teach. Ignition not turned to accessories position. Low Battery Voltage. More than one key in antenna field Wiring fault TILA fault Transponder key fault
Check programmed keys mobilise car. Pinpoint test C If pinpoint test C OK check other probable causes on symptom chart.
BEM/PCM Training Failure
BEM Related BEM has not learnt Ignition Key. BEM does not learn PCM key or loses Key (System Noise) BEM validation failure (dealer used Dealer Teach Mode causing code erasure) Low battery prevents Training. Power interrupted during training. Wiring fault. Water in PCM connector (No codes Logged) PCM fault Wiring fault
Use WDS to check vehicle anti theft status PID THEFTS Use WDS to check if ignition keys have been trained (>1) PID N_KEYCODE If training fails retry parameter reset. If pinpoint test C OK check other probable causes on symptom chart.
Auto Headlamps do not turn on at low light level
BEM related Setting values Incorrect. Low series BEM fitted to Vehicle. Open circuit wiring Sunload sensor to BEM. Twilight sensor fault Wiring fault Headlamp switch fault
Check setting values PID ON_THOLD and DTC’s B1693, B1790, B1791 with WDS. Control headlamp drivers using WDS PID AUTOOUTST#. Check other possible causes on symptom chart.
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Check relevant fuses Check DTC B1348/49. If present go to Pinpoint Test B. If not present check ICC, wiring, Element, external relay.
01/2003 2003.0 BA Falcon
419-10-15
Body Electronics Module (BEM)
419-10-15
DIAGNOSIS AND TESTING (Continued) Condition
Source
Action
No Automatic Delay of Headlamps
BEM related Faulty Headlamp Drivers Low Series BEM Fitted. No Park input to Cluster or BEM Pin J2/12 or J1/10 remains high at Ignition Off. Incorrect Headlamp switch fitted. Headlamp switch fault Wiring fault
Check setting values PID ON_THOLD and DTC’s B1693, B1790, B1791 with WDS. Control headlamp drivers using WDS PID AUTOOUTST#. Go to Pinpoint Test D Check other possible causes.
Wipers do not Park in Off position
BEM Related Feedback circuit faulty J3/1, J3/2 Wiring fault Wiper motor fault Wiper switch fault
Operate wipers and monitor wiper park switch status using WDS and monitor pin J3/1. If J3/1 does not follow status of PID WFLUID Byte 1 Bit 0 then change BEM else. Check other possible causes on symptom chart.
Wipers do not Operate in Intermittent Mode.
BEM Related No accessories input to BEM BEM wiper relay faulty Wiring fault Wiper motor fault Wiper switch fault
Do all tests in Wiper does not park, if ok proceed. Using WDS read wiper switch status PID WP_STAT by selecting each position with intermittent selected. Pin J2/19 should vary between 0 - 2.5V as intermittant position is changed. If voltage varies and PID WP_STAT does not reflect change then replace BEM. Else check other possible causes.
No Variable Speed Dependant Wipers
BEM Related No accessories input to BEM BEM wiper relay faulty No Speed data or invalid data from PCM Wiring faulty (CAN)
Functional test for missing CAN messages Check for existence of DTC U2917 (invalid speed data) using WDS. If present check PCM else Check other possible causes.
Intermittent Dwell Time cannot be changed
BEM Related BEM potentiometer input faulty. BEM wiper motor driver faulty (relay or relay drive circuit) Wiper dwell pot switch faulty Wiper stalk switch faulty Wiring faulty
No Wash Function or timed wash or wipe after wash
BEM Related BEM output driver faulty BEM wash input faulty Washer bottle empty No accessories supply to BEM Faulty wash motor Faulty wiring Faulty washer switch
Check washer level warning jewel on cluster. If showing then add water to wahser bottle. Using WDS monitor status of washer switch (PID WASH_SW) when activating switch. If not OK check voltage level at pin J3/10. If PID status and voltage levels do not match, then change BEM. If signal does not change then check wiring. If OK then Using WDS activate and deactivate washer motor output (PID WASH_SW). If no operation of washer motor, check wiring and motor. If wiring and motor OK then change BEM. Check other possible causes.
Power Windows not Working
BEM related Faulty BEM power window supply output Wiring faulty Power window switch faulty Power window motor faulty
Go to Pinpoint test E Check other possible causes.
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Use WDS to Monitor Wiper dwell positions 1 to 5 (PID WP_STAT) while changing position of dwell pot. – If not OK then test dwell pot. If WDS check OK then check Check other possible causes
01/2003 2003.0 BA Falcon
419-10-16
Body Electronics Module (BEM)
419-10-16
DIAGNOSIS AND TESTING (Continued) Condition
Source
Action
Power windows do not time out 45 seconds after door opened
BEM related BEM power window supply output faulty BEM door ajar inputs faulty Faulty door ajar switch. Wiring fault
Go to Pinpoint Test E Go to pinpoint test M Check other possible causes
Doors will not lock, Horn beeps
BEM related Door Ajar input faulty Door open Ignition key in ignition lock. Transponder in vicinity of ignition Faulty Door actuator Wiring fault Water ingress into connectors of door circuits.
Check if key in ignition Check if transponder in vicinity of ignition Check cluster door ajar indicator if not accurate then Go to pinpoint test M Go to doors will not lock/unlock Check other possible causes
Doors will not Lock/unlock
BEM related BEM door lock driver circuit faulty BEM door ajar inputs faulty BEM door lock status input faulty PCM mistakenly reports a crash (lock only) Remote key not trained Remote key battery Flat Poor range due to aftermarket window tint High local RF field. Faulty door feedback circuit Ignition turned on Blown Door Fuse Remote receiver fault Wiring fault Door lock motor fault ICC switch fault
Check all doors are closed Using WDS ensure BEM is not in taxi mode. PID TAXI_MODE Byte 1 Bit 7 should =0. If not then change status of bit. Check for DTC B1300. Action DTC’s Go to Pinpoint Test C Following test should be called up from DTC chart: Check door lock output status with WDS (PID D_LCKO#) Monitor status of door lock feedback (PID DLOCK_ST) while activating locks manually. Go to pinpoint test M Go to Pinpoint Test F Check other possible causes
Door Locks Change State randomly
BEM related Door lock feedback circuit faulty Door lock output faulty Wiring fault (Ground shift). Turning on high current loads such as headlamps can cause the feedback reference at pin J2/24 to move upwards. ICC faulty
Using WDS check for DTC B1300. Action DTC Check earth connections for door actuators, main battery to body earth G1. Refer to earth path, Door actuator to G2 or G3 Check other possible causes
No Response from Remote Keys all Buttons
BEM related: Comms line with Receiver not working Ignition and/or Accessories not low at key off Remote key not trained. Two remotes operating at the same time Remote key lost sychronisation. Remote key battery Flat.(<3.2V) Poor range due to aftermarket window tint. High local RF field Remote Receiver not operating.
Resynchronise keys. Replace remote key battery if required. Retrain all keys. Go to Pinpoint Test F Go to Pinpoint Test D Relocate vehicle and test remote keys.
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01/2003 2003.0 BA Falcon
419-10-17
Body Electronics Module (BEM)
419-10-17
DIAGNOSIS AND TESTING (Continued) Condition
Source
Boot will not open using Instrument Panel Switch
BEM Related: Input to BEM faulty BEM output faulty Vehicle speed above 8km/h. Vehicle Locked and Battery Saver Timed out Wiring faults Switch fault. Solenoid fault
Press decklid switch, Ignition On. Monitor decklid switch status, PID DECKLIDOS# If PID does not change state then check J1/9 goes low when boot release pressed Press decklid switch, Ignition On. Monitor decklid output status, PID DECKLIDOS# If PID does not change state Activate PID DECKLIDOS# Listen for activation of solenoid. If not OK then test J3/7 with a test light to ground press boot release switch a short pulse should be observed. Test solenoid and wiring to boot solenoid. Check other possible causes
Battery Saver Circuit Not Functioning Remote key will not turn on dome lamp.
BEM related: Incorrect Personalised settings. Battery saver timed out. Faulty Battery Saver Output Blown Courtesy Fuse. Fault in wiring
Cycle ignition switch. Does battery saver turn on? If not proceed as follows. Use PID BATSAVRLY# to turn on battery saver Go To Pinpoint Test H. Check other possible causes
Dome lamp not functioning
BEM Related: Personalized settings incorrect No 12 V Input at J3/6 Low Side Driver Failure(J3/12) Door ajar input faulty Remote Receiver did not receive unlock signal Ignition On Blown Globe
Go to Pinpoint Test I Pinpoint test H Pinpoint test M and monitor dome lamp operation Check other possible causes
Dome lamp will not go out
BEM Related: Shorted Low Side Driver Faulty Wiring Can message not being received from ICC Short circuit on TILA
Press dome lamp button on ICC, if dome lamps do not turn off then Test for shorts on J3/12 to dome lamps, check wiring from BEM to Light ring for shorts to ground. Select PID ILLENTRLY#, and monitor status while pressing dome lamp switch. If not changing state then check ICC and CAN wiring. If PID is changing state then check wiring. If wiring OK then control PID ILLENTRLY#. IF wiring OK, CAN comms OK and PID will still not turn off dome lamp then change BEM. Check other possible causes
No Hazard Acknowledgment of Remote Key
BEM Related: BEM/receiver comms not operating BEM not sending CAN message BEM CAN global wake up line faulty Wiring fault (CAN line or Can wake up line faulty) Faulty cluster Faulty receiver
Confirm other remote functions are operating correctly With ignition on check the CAN communication between BEM and cluster by opening and closing a door to check if door ajar status is correctly shown on cluster. If status is not correctly shown then check CAN wiring. If status is correctly shown then proceed Leave car in ignition off status for more than 2 minutes, then press remote key. Check pin J2/21 (CAN global wake up) goes low for 2 minutes after remote key is pressed Check other possible causes
NOTE: The following functions will not
operate: Dome lamps, Glove box lamps, Boot lamp, Sunload/Twilight sensor, Power Antenna, Antenna amplifier, TILA Light Ring.
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Action
01/2003 2003.0 BA Falcon
419-10-18
Body Electronics Module (BEM)
419-10-18
DIAGNOSIS AND TESTING (Continued) Condition
Source
Action
Low Washer Fluid not detected
BEM related Faulty washer fluid level input circuit CAN comms not working Wiring O/C Faulty Level switch Cluster fault
Monitor Washer Fluid level PID WFLUID Remove the lid from the washer bottle so that the switch closes. Did Status of PID change? A low should be present on J1/20. Check earthing of switch. Check BEM to cluster CAN comms by opening and closing a door with the ignition on. Cluster should indicate door ajar status Check other possible causes.
BEM does not have Accessories input. (CCT297)
If 12V is not available at the BEM the following functions will be affected: No wash function No intermittent wipe No power windows No rear demist No ICC operation Fuse blown Wiring fault BEM input faulty
Check the 10A fuse is not blown Check wiring If fuse OK and wiring OK then change BEM
BEM Accessories line remains high at key off resulting in No remote entry No battery saver function No boot release time out Rear demist time out not cancelled
BEM related Internal short on BEM External wiring problem This fault is often due to the fitment of other accessories holding the accessories line high. Audio amplifiers or mobile phones can have high supply line capacitance that keeps the voltage high after key off
Remove all non standard accessories and see if problem persists If problem persists without the accessories then check wiring. If wiring OK then change the BEM
No Ignition input to BEM in ignition or start position resulting in No Headlamp failure chime
BEM related Ignition input on BEM faulty Wiring fault Blown fuse No global can make up
Tila fault Check fuse Check wiring Check TILA Using WDS check PID IGN_SW correctly reflects ignition switch position. If it does not and wiring and fuse and TILA are OK then change BEM.
No Clock illumination
BEM related Feedthrough circuit/s faulty Faulty cluster Faulty wiring
Check continuity between pins J1/1 and J4/12 Check continuity between pins J1/2 and J4/10 If continuity checks above are not OK then change BEM. If they are OK then check other possible causes.
Cannot Teach Transponder Keys
BEM related Customer Key teach mode not enabled BEM/TILA communication circuit faulty Faulty TILA Faulty wiring Faulty transponder Low Battery Voltage
Confirm correct procedure has been used to enter transponder key teach mode Using already trained key check that key out/dome on function works. If this does not work there is a problem with TILA/BEM system and al possible causes should be checked. If TILA, wiring, and transponder are OK then change BEM
Headlamps do not go on when light level is low (dark conditions) with Ignition on and Auto Selected
BEM related Low series BEM in a High series car. Twilight level settings incorrect No connection between J1/6, J2/1 and the headlamp switch Faulty Headlamp switch Low series Headlamp switch fitted in high series car Faulty twilight sensor Faulty wiring
Check other possible causes Using WDS control using PID AUTOOUTST# to turn headlamps on and off (with headlamp switch in auto position). If this does not work then change BEM. If this works then Check twilight level settings using WDS and interrogating PID ON_THOLD & OFF_THOLD. Adjust these thresholds using block write $0F if required
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01/2003 2003.0 BA Falcon
419-10-19
Body Electronics Module (BEM)
419-10-19
DIAGNOSIS AND TESTING (Continued) Condition
Source
Action
No Wipe on take off
BEM related Speed signal not received on CAN from PCM Faulty PCM Faulty CAN line
Using WDS Check for $D900 DTC. This, in conjunction with PID PCM_MSG will indicate if there have been issues with CAN comms to PCM Check other possible causes
Wipers do not Park in Off position
BEM related Wiper interface circuit on BEM faulty Ignition turned off before wipers parked Faulty wiper motors Faulty park switch
Use WDS to determine if park switch is in parked position. PID WPRPRKSTS Test continuity between J3/1 and J3/2, wiper off. Tests internal relay contacts. Test continuity between J3/2 and 28 of wiper switch Test continuity between J3/1 and wiper park switch Inspect wiper park switch Check Adjustment
Wipers do not operate in intermittent mode
BEM related Faulty wiper interface circuitry Faulty wiper dwell pot input circuit Wiper motor drivers not working Faulty wiper motor Faulty wiper dwell pot Faulty wiring
Do all tests in Wipers do not park in Off position, if ok proceed Using WDS read wiper switch status PID WP_STAT by selecting each position with intermittent selected Test wiring between J1/19 and wiper switch. Goes low when intermittent selected Check Wiper switch grounding Check other possible causes
No Timed Wash Function or Wipe after Wash
BEM related Wash input circuit faulty Wiring fault Wiper switch fault
If washer motor runs but no timed feature, check wiring between J3/10 and wiper switch (CCt 941) Check 12 V available at J2/12 and J1/10 with ignition on
No Headlamp Fail Chime
BEM related Ignition input circuit faulty CAN communication to cluster not working BEM thinks its in auto mode No Ignition Input to BEM Cluster faulty Wiring faulty Headlamp switch faulty
Check headlamp switch is in auto position Check BEM communications to cluster by opening and closing a door when ignition is on and confirming the cluster is correctly displaying door ajar status Check other possible causes Test 12V available at J1/10 when in ignition position, and 0V when ignition is off
Connector Circuit Reference BEM
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01/2003 2003.0 BA Falcon
419-10-20
Body Electronics Module (BEM)
419-10-20
DIAGNOSIS AND TESTING (Continued) Pin Number(s) J1/1 J1/2 J1/3 J6/2 J6/3 J1/5 J1/7 J6/1 J1/8 J6/9 J1/9 J1/10 J6/5 J1/11 J1/12 J1/13 J1/14 J1/15 J1/16 J1/17 J1/18 J1/19 J1/20
G43561 en
Circuit Designation/Description Normal Condition/Measurement 19J (BL/RD) De-energised: 0-2.2 Graphics illumination feed Energised: 8.0-12.0 Level: H 14KC (BR) De-energised: 0-2.2 Park lamp Fuse Energised: 8.0-12.0 Level: H & L 25 (GR/VLT) De-energised: Transceiver ground Energised: 12-1.0 Level: H & L 23 (RD/YLW) De-energised: Less than 1.0 Transceiver Supply Energised: Greater than 10.0 Level: H & L 57CP (BLK) De-energised: 0 Auto Headlamp relay ground Energised: 0 Level: H 24 (BL/ORG) De-energised: <5.2 Transceiver RX Data Energised: >11 Level: H & L 340 (BLK/LT GR) De-energised: Data Transceiver TX Data Energised: Data Level: H & L 170 (RD) De-energised: <5.2 Boot/Tailgate release switch Energised: >11 Level: H & L 16HB 16C (RD/GR) De-energised: <2.2 BEM Tila Energised: >8.0 Level: H & L 627 (BLK/ORG) De-energised: <5.2 Rear right hand passenger door Energised: >11 ajar switch Level: H & L 630 (BLK/RD) De-energised: <5.2 Rear left hand passenger door ajar Energised: >11 switch Level: H & L 629 (WHT/RD) De-energised: <5.2 Front passenger door ajar switch Energised: >11 Level: H & L 628 (WHT) De-energised: <5.2 Front drivers door ajar switch Energised: >11 Level: H & L Digital spare 1 Level: Optional 341 (ORG) Level: H & L, Optional Digital spare 2 26 (WHT) De-energised: <5.2 Boot/Tailgate ajar switch Energised: >11 Level: H & L 234D (WHT/BLU) De-energised: <5.2 Twilight sensor PWM Energised: >11 Level: H 590C (GR/WHT) De-energised: <5.2 Front intermittent wiper switch Energised: >11 Level: H & L 82 (PNK/YLW) De-energised: <5.2 Washer fluid level switch Energised: >11 Level: H 01/2003 2003.0 BA Falcon
419-10-21
Body Electronics Module (BEM)
419-10-21
DIAGNOSIS AND TESTING (Continued) Pin Number(s) J2/1 J2/2 J2/3 J2/4 J2/5 J2/6 J2/7 J2/8 J2/9 J2/10 J2/11 J2/12 J6/12 J2/13 J8/6 J2/14 J2/15 J2/16 J2/17 J2/18 J2/19 J2/20 J2/21 J2/22 J2/23
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Circuit Designation/Description Normal Condition/Measurement 2903A (ORG/RD) De-energised: <1.5 Auto headlamp relay plug 2 Energised: >11 Level: H Output spare 2 Level: Optional Output spare 1 Level: Optional 1324 (BLK/LT GR) Level: H & L, Optional Output spare 3 Not used 234E (BL/WHT) Level: H Solar twilight sensor return Analogue spare return Level: Optional 589 (ORG) Level: H & L Variable intermittent wipe Pot rtn 1A (BL) De-energised: <2 Horn relay Energised: >11 Level: H & L 686 (VLT) De-energised: <2 Heated backlight relay Energised: >11 Level: H & L 513 (BR) De-energised: <2 Power window relay Energised: >11 Level: H & L 297B, 37F (BLK/YLW, YLW) De-energised: <2.2 Accessories Energised: >8 Level: H & L 914N (BR/YLW) De-energised: <3.0 min 2.0 CAN data link high Energised: >3.0 max 4.5 Level: H & L 914P (BR/YLW) De-energised: <3.0 min 2.0 CAN data link high Energised: >3.0 max 4.5 Level: H & L 915N (PNK/BL) De-energised: <1.75 CAN data link low Energised: >2 max 3.0 Level: H & L 915P (PNK/BL) De-energised: <1.75 CAN data link low Energised: >2 max 3.0 Level: H & L 788 (RD/WHT) Level: H Solar sensor link output Analogue spare 1 993 (BR/WHT) Level: H & L Variable intermittent wipe Pot Analogue spare 2 489B (PNK/BLK) De-energised: Data CAN global wakeup request Energised: Data Level: H & L 268 (BLK/ORG) De-energised: <2.0 Seat memory data Energised: >11.0 Level: H 267 (BR) De-energised: <2.0 Seat memory enable Energised: >11.0 Level: H
01/2003 2003.0 BA Falcon
419-10-22
Body Electronics Module (BEM)
419-10-22
DIAGNOSIS AND TESTING (Continued) Pin Number(s) J2/24 J3/1 J3/2 J3/3 J3/4 J3/5 J3/6 J3/7 J3/8 J3/9 J3/10 J3/11 J3/12 J6/10 J4/1 J9/1 J4/2 J9/4 J4/3 J9/3 J4/4 J9/2 J4/5 J4/6 J4/7 J10/3 J4/8 J10/1 J4/9 J10/2 G43561 en
Circuit Designation/Description Normal Condition/Measurement 122 (YLW) De-energised: <5.2 Driver central door lock status Energised: >11.0 Level: H & L 8A (BLK/ORG) 2De-energised: <1.5 Front wiper park switch Energised: >3.5 Level: H & L 28 (BLK/ORG) De-energised:>3.8 Front wiper motor Energised: <0.3 Level: H & L 54B (GR/YLW) Level: H & L Battery saver supply Tailgate/boot release option De-energised: open Energised: >11.7 Level: Optional Spare Level: Optional 55B (BLK/PNK) Energised: 12.0 Courtesy lamp fuse Level: H & L 84 (VLT) De-energised: open Boot/Tailgate release solenoid Energised: >11.7 Level: H & L Spare Level: Optional 1329 (YLW) De-energised: <0.3 Drivers door unlock motor Energised: >11.7 Level: H & L 941B (GRY/BLK) De-energised: <5.2 Front wash motor switch Energised: >11.0 Level: H & L 38BA (YLW/BLK) Level: H & L BEM battery fuse 53G/53D (BLK/BL) De-energised: <1.5 Courtesy lamp transceiver return Energised: >11.0 Level: H & L C11 (GR/WHT) Level: H & L RF receiver supply C8 (RD/WHT) De-energised: <5.2 RF receiver data Energised: >11.0 Level: H & L C9 (GRY) De-energised: <0.5 RF receiver polling Energised: >11.7 Level: H & L C10 (BL/WHT) De-energised: 0 RF receiver return Level: H & L C1 (YLW/BLK) Level: H Analogue clock supply C2 (BLK/LT. GR) De-energised: 0 Analogue clock return Level: H C6 (GR) De-energised: <1.5 Cabin temperature sensor fan Energised: >11.0 supply Level: H C4 (WHT) Level: H Cabin temperature sensor thermistor C5 (BL) Level: H Cabin temperature sensor return 01/2003 2003.0 BA Falcon
419-10-23
Body Electronics Module (BEM)
419-10-23
DIAGNOSIS AND TESTING (Continued) Pin Number(s) J4/10 J4/11 J10/4 J4/12 J5/1
Circuit Designation/Description 14 (BR) Analogue clock supply C7 (YLW) Cabin temperature sensor fan return C3 (BLK) Analogue clock illumination return 118A (RD/YLW) Central door unlock motor
J5/2
117A (YLW/BLK) Central door lock motor
J5/3
134 (WHT) Central door locking fuse 57CN (BLK) High current ground
J5/4
Normal Condition/Measurement Level: H De-energised: 0 Level: H De-energised: 0 Level: H De-energised: <0.3 Energised: >11.7 Level: H & L De-energised: <0.3 Energised: >11.7 Level: H & L Energised: 12.0 Level: H & L De-energised: 0 Level: H & L
TILA 16 pin connector
Pin Number(s) J6/1 J6/2 J6/3 J6/4 J6/5 J6/6 J6/7 J6/8 J6/9 J6/10 J6/11
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Circuit Designation/Description (BLK/Lt GR) TILA Receive (BLK) TILA Ground (RD/YLW) TILA Supply (YLW) Battery ignition circuit (RD/GR) Ignition circuit (BLK) Ground (YLW) Pedal circuit Battery + (LT BL/ORG) Pedal circuit motor (DK GR/VLT) TILA Transmit (BLK/BL) Illumination return (VLT/WHT) Brake fail circuit
Normal Condition/Measurement
01/2003 2003.0 BA Falcon
419-10-24
Body Electronics Module (BEM)
419-10-24
DIAGNOSIS AND TESTING (Continued) Pin Number(s) J6/12 J6/13 J6/14 J6/15 J6/16
Circuit Designation/Description (WHT) Accesory (RD/BL) Start circuit NC (BLK) Pedal circuit ground (LT BL/BLK) Pedal circuit Motor +
Normal Condition/Measurement
Circuit Designation/Description (YLW) Pedal Circuit battery + (BLK) Pedal circuit ground (LT BL/BLK) Pedal circuit motor + (LT BL/ORG) Pedal circuit motor -
Normal Condition/Measurement
TILA 8 pin connector
Pin Number(s) J7/1 J7/3 J7/6 J7/8
Pinpoint Tests PINPOINT TEST A : COURTESY LAMP DRIVER TEST Test Step
Result / Action to Take
A1 Using WDS operate courtesy lamp drivers and monitor pin J3/12. Is pin low when drivers activated and high otherwise?
Yes
Return to sympton chart for next steps
No
Go to A2
A2 Check wiring to pin J3/12. Is wiring OK?
Yes
Replace BEM
No
Fix wiring
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01/2003 2003.0 BA Falcon
419-10-25
Body Electronics Module (BEM)
419-10-25
DIAGNOSIS AND TESTING (Continued) PINPOINT TEST B : HEATED BACKLIGHT TEST Test Step
Result / Action to Take
B1 Using WDS monitor (BACKL_SW) when pressing ICC backlite switch. Is input OK?
Yes
Go to B2
No
Check other probable causes on symptom chart.
B2 Turn on demist relay using WDS (HEAT_BCK) Check voltage at pin J2/10 is 0V. Turn demist relay off using WDS.
Yes
Check other probable causes on symptom chart.
No
Go to B3
Check voltage at pin J2/10 is 12V. Are results OK?
B3 Check wiring to pin J2/10 Is wiring OK?
Yes
Replace BEM
No
Fix wiring
PINPOINT TEST C : IGNITION SWITCH VOLTAGE LEVELS Test Step
Result / Action to Take
C1 Yes Does Battery Accessory and Ignition and ground have appropriate voltage levels when key in relevant ignition position? Return to symptom chart No
Check TILA and wiring
PINPOINT TEST D : IGNITION AND ACCESSORY LOW AT KEY OFF Test Step
Result / Action to Take
D1 Does ignition and Accessories go low at Ignition Off?
Yes
Return to symptom chart
No
Check TILA and wiring
PINPOINT TEST E : POWER WINDOW SUPPLY Test Step
Result / Action to Take
E1 Activate and deactivate BEM power window supply (PID WIND_OS#) Is the measured output voltage J2/11 as expected?
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Yes
Go to symptom chart.
No
Go to E2
01/2003 2003.0 BA Falcon
419-10-26
Body Electronics Module (BEM)
419-10-26
DIAGNOSIS AND TESTING (Continued) Test Step
Result / Action to Take
E2 Is wiring to pin J2/11 OK?
Yes
Change BEM
No
Fix wiring
PINPOINT TEST F : REMOTE RECEIVER OPERATION Test Step
Result / Action to Take
F1 Yes
Connect WDS. Monitor status of PID TNSMT_CMD while pressing different buttons on remote key. Does PID status reflect last button pressed ?
Go to symptom chart
No
Go to F2
F2 Take known good remote key and try and train it to the car Does BEM acknowledge receipt of key press as part of training procedure?
Yes
Original remote key was faulty. Replace original remote key.
No
Go to F3
F3 Change receiver and take known good remote key and try and train it to the car Does BEM acknowledge receipt of key press as part of training procedure?
Yes
Original receiver was faulty.
No
Replace BEM and repeat step F2. If still unsuccessful then replace ICC (Internal ICC wiring fault).
PINPOINT TEST G : DOOR LOCK INPUT Test Step
Result / Action to Take
G1 Monitor voltage at pin J2/24 while locking and unlocking the drivers door. Is voltage 0V when door unlocked and 12V when door locked?
Yes
Return to symptom chart
No
Check wiring and door lock feedback on motor.
PINPOINT TEST H : BATTERY SAVER CIRCUIT NOT FUNCTIONING Test Step
Result / Action to Take
H1 Ensure glovebox globe is present and operational
Yes
Activate PID BATTSAVRLY# command with Glove Box Door open
Battery saver circuit operating correctly. Return to symptom chart.
Does glove box lamp illuminate?
No
Go to H2
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01/2003 2003.0 BA Falcon
419-10-27
Body Electronics Module (BEM)
419-10-27
DIAGNOSIS AND TESTING (Continued) Test Step
Result / Action to Take
H2 Yes
Using WDS activate and deactivate battery saver and monitor pin J3/3.
Return to symptom chart.
Is voltage output as expected?
No
Go to H3
H3 Check wiring to pin J3/3. Is wiring OK?
Yes
Replace BEM
No
Fix wiring
PINPOINT TEST I : DOME LAMP NOT FUNCTIONING Test Step
Result / Action to Take
I1 Turn off ignition.
Yes
Monitor Personalizes settings TAXI_MODE, PANIC_ALR, DTRIG_MOD, MDT_MOD, HAZ_WARN, HORN_WARN, BAT_SAV, COURTESY.
No
Dome lamp operating correctly. Go to I2
Test 12V available on J3/3. Operate Dome switch on ICC. Does Dome lamp operate?
I2 Select PID LR_AJAR, RR_AJAR Did dome lamp turn on?
Yes
Return to symptom chart
No
Ground J3/12, Go to I3
I3 Does dome lamp light?
Yes
BEM fault
No
Wiring fault
PINPOINT TEST J : NO DEMIST FUNCTION Test Step
Result / Action to Take
J1 Are DTC’s B1348 and B1349 present?
Yes
Follow fault finding chart for these codes
No
Go to J2
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01/2003 2003.0 BA Falcon
419-10-28
Body Electronics Module (BEM)
419-10-28
DIAGNOSIS AND TESTING (Continued) Test Step
Result / Action to Take
J2 Check radio fuse 7.5A is not blown. Check backlight fuse 40A is not blown. Test heater element continuity.
Yes
Return to symptom chart.
No
Check CAN communications.
Test element earth point. Using PID BACKL_SW check status of heated backlight switch and status of output driver when switch operated with ignition on (PID HEAT_BCK#). Is the backlight status available?
PINPOINT TEST K : NO WASH FUNCTION Test Step
Result / Action to Take
K1 Yes
Ground J3/10.
Fault is in the wiring or wiper switch.
Does washer motor run?
No
Go to K2
K2 Confirm 12V is supplied to washer motor?
Yes
Go to K3
No
Check wiper fuse. If wiper fuse blown or missing, then replace. If fuse OK then check wiring.
K3 Using WDS control BEM washer motor output activate. PID WASHPUMP#. Monitor pin J3/10. Is pin 0V when output is activated and 12V otherwise?
Yes
Return to symptom chart.
No
Check wiring. If wiring OK then change BEM.
PINPOINT TEST L : POWER WINDOWS NOT WORKING Test Step
Result / Action to Take
L1 Connect WDS. Is the status of the power window relay with the ignition turned on OK?
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Yes
Return to symptom chart.
No
Test for 12 v output from the power window relay pin J2/11, check fuses.
01/2003 2003.0 BA Falcon
419-10-29
Body Electronics Module (BEM)
419-10-29
DIAGNOSIS AND TESTING (Continued) PINPOINT TEST M : DOOR AJAR INPUT TEST Test Step
Result / Action to Take
M1 Check Door ajar status with WDS (PID LR_AJAR, RR_AJAR, LF_AJAR, RF_AJAR) while opening and shutting doors. Does PID reflect door ajar status?
Yes
Return to symptom chart.
No
Go to M2
M2 Check voltage at following pins and compare to PIDs bits as follows: J1/14 - Drivers door - RF_AJAR J1/11 - Rear right - RR_AJAR J1/12 - Rear left - LR_AJAR
Yes
Return to symptom chart.
No
Go to M3
J1/13 - Front left - LF_AJAR Does PID status reflect voltage levels?
M3 Is wiring to relevant pins OK?
Yes
Change BEM.
No
Fix wiring.
PINPOINT TEST N : DOOR LOCK OUTPUT TEST Test Step
Result / Action to Take
N1 Ensure fuses and wiring are not faulty. Control door lock output status with WDS (PID D_LCKO#). Does this reflect soldier button requested position?
Yes
Return to symptom chart.
No
Go to N2
N2 Monitor voltage level at pins J5/2, J5/1 and J3/9 while locking and unlocking doors with WDS. Unlock all doors: J5/2 = 12V, J5/1 = 0V, J3/9 =0V. Note that 12V will only be supplied for 800ms. Lock all doors:J5/2 = 12V, J5/1 = 0V, J3/9 =0V. Note that 12V will only be supplied for 800ms. Are voltage levels as expected?
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Yes
Return to symptom chart
No
If fuses and wiring and motors have been checked to be OK then replace the BEM.
01/2003 2003.0 BA Falcon
419-10-30
Body Electronics Module (BEM)
419-10-30
GENERAL PROCEDURES
Remote Key Teaching 1. Have all remote keys to be taught to the system available for this session. 2. Turn the ignition switch to the accessories position, within 5 seconds, press the demist button 3 times, teach mode is acknowledged by the door locks changing state. i.e. lock to unlock or unlock to lock. When teach mode is entered all remote key codes stored in memory will be erased. 3. Once key teach mode has been entered, immediately press any button on the remote key. If the BEM learns the key, the doors locks will change state. 4. Select the next remote key to be taught, again press any button, and wait for the doors locks to change state. Repeat this procedure until all keys are taught (up to 8 keys may be taught). NOTE: High series seat memory data is only designed to work on two remote keys.
6. To exit at any time turn the ignition off for longer than 10 seconds. 7. Next perform a parameter reset to reteach the PCM ID to the BEM.
Customer DST Ignition Key Teach NOTE: PCM ID is not disturbed in this teach mode. 1. The customer must have 2 valid keys that are recognised by the BEM. 2. It is recommended that the customer sit in the vehicle with the doors closed. 3. Place the first key in the ignition and turn to accessories position turn to off and remove key. 4. Within 5 seconds place the second key into the ignition and turn to the ignition position. At this point the door locks will state to indicate learn mode is entered. 5. To teach a new key insert the new key within 5 seconds and turn to the ignition position, if successful an acknowledgment will be received.
Lost Keys
5. To exit mode, turn key to off or ignition on. The door locks will cycle to indicate the mode has been terminated. If the ignition key is moved from the accessories position during key teach the session will be terminated.
NOTE: It is recommended that the vehicle be taken to the dealer if keys are lost. The lost keys can be erased from the BEM and new keys taught.
Receiver Resynchronization
Customer Key Erasure
1. If a remote key is out of synchronization it may be NOTE: This procedure can only be used if more than resynchronized by transmitting with a valid key to 2 keys have been programmed to the BEM. the BEM then within 30 seconds transmit with the NOTE: The two keys used to enter teach mode will key to be resynchronized. not be erased.
Dealer DST Ignition Key Teach Mode
1. Enter Customer key teach mode and when acknowledgment is received. NOTE: This mode is used by dealers to teach DST keys to new P & BEM or for general DST key erasing 2. Place the second key used to enter teach mode in and teaching. Entering Dealer key teach mode will the ignition lock and turn to the ignition on also erase the PCM ID in the BEM. On completion of position, then off and remove, followed by the first the key teach the PCM will be prompted to perform a key which must also be turned to the ignition on parameter reset. It is recommended that the dealer be position then removed. The BEM will perform two seated in the vehicle with the doors closed. acknowledgments. 3. All other keys are erased. Leaving the ignition off 1. Starting with the key in the ignition position, turn for longer than 10 seconds will exit the mode and the ignition to the off position. an acknowledgment will be received. 2. Within 2 minutes of turning the key to the off position enter dealer key teach mode using the PCM Parameter Reset WDS. NOTE: Parameter reset is used whenever a BEM or 3. When the dealer key teach mode is entered the PCM is replaced or Dealer key teach is used. The PCM ID is erased, an acknowledgment will be WDS Diagnostic tool is used to perform this function. received. Place the first DST ignition key to be taught in the ignition switch and turn to ignition on, See also Changing a BEM. an acknowledgement will be received if teach is Cabin Temperature Sensor Calibration successful. Factor 4. Turn the key to off and remove the DST key. 5. Place the next key in the ignition and turn to on, 1. Whenever a cabin Temperature sensor, ICC or when the second key is taught 2 BEM is replaced the CTS calibration factor needs acknowledgments will be received and so on. Up to be taught to the BEM. to 8 keys may be taught in this way. G43562 en
01/2003 2003.0 BA Falcon
419-10-31
Body Electronics Module (BEM)
419-10-31
GENERAL PROCEDURES (Continued) 2. The CTS mounted on the ICC has a barcode sticker attached to it which has the letters CTS followed by the calibration factor. This calibration number should be loaded to the BEM using a WDS service tool. If the sticker is missing then ring ’OASIS’ hotline. 3. If a BEM is being replaced, the CTS calibration factor can be read from the original BEM by the WDS. Select "Module Programming" and "Programmable Parameters" - "Climate Control". It can then be automatically down loaded into the new BEM using "Module Installation" - "BEM" or manually by entering "Module Programming" and "Programmable Parameters" - "Climate Control" and selecting the correct value.
Changing BEM Whenever a BEM is to be replaced the following steps need to be done. Read and record the following values. 1. Cabin Temperature Sensor Calibration Factor (high series vehicle) 2. Body Type 3. Battery saver/ interior lamp operation (police/taxi/normal/etc) 4. Twilight settings (high series vehicle) When the new BEM is installed using WDS and "Module Installation" the above setting along with stored remote pad values should be automatically entered into the new BEM. If the data is unable to be recovered from the existing BEM then the data and values will need to be manually entered. In a separate operation WDS will be required to teach a minimum of two ignition keys to the new BEM and a parameter reset before the vehicle can be started.
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01/2003 2003.0 BA Falcon
419-10-32
Body Electronics Module (BEM)
419-10-32
REMOVAL AND INSTALLATION
The BEM and Remote Receiver The BEM and Remote Receiver are attached to the ICC. Therefore, please refer to the ICC in Section 413-08 for removal and installation instructions.
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01/2003 2003.0 BA Falcon
501-00-1
General Information
501-00-1
SECTION : 501-00 Body System - General Information VEHICLE APPLICATION :2003.0 BA Falcon CONTENTS
PAGE
SPECIFICATIONS Specifications .........................................................................................................................501-00-2 DESCRIPTION AND OPERATION Body .......................................................................................................................................501-00-3 Body System ........................................................................................................................501-00-3 Insulation ..............................................................................................................................501-00-3 Body Sealer Type and Application .......................................................................................501-00-3 DIAGNOSIS AND TESTING Body System ..........................................................................................................................501-00-4 Inspection and Verification ...................................................................................................501-00-4 Symptom Chart ....................................................................................................................501-00-4
01/2003 2003.0 BA Falcon
501-00-2
General Information
501-00-2
SPECIFICATIONS Lubricants, Fluids, Sealers and Adhesives Item Butyl sealer, fluid C9AZ-19554B Caulking strip D6AZ-19560-A Rubber seal adhesive E8AZ-19552-A Silicone grease C0AZ-19553-AA
G86726 en
Specification ESB-M4G162-A ESB-M4G32-A ESB-M2G14-A ESR-M13P4-A
01/2003 2003.0 BA Falcon
501-00-3
General Information
501-00-3
DESCRIPTION AND OPERATION
Body Body System The body shell structure consists of the following features: front section side members have set deformation zones for collision. transverse reinforcement at the bulkhead. all sheet metal surfaces prone to corrosion are galvanized. bolted, removable front fenders.
Exterior Vinyl Sealer After a new panel has been prepared for painting and prime coat has been applied, areas such as the inner edge of the hem flange and door frame must be sealed with a seam sealer. NOTE: A polyurethane adhesive such as Sikaflex 255 or equivalent is suitable and may be used.
Corrosion Protection Materials Use locally purchesed weld through primers and corrosion protection materials for all body work.
Insulation Insulation is composed of urethane, PVC, foam and recycled felt. Insulation is installed: above and below the instrument panel, at the cowl side panels, over the front floor pan and rear floor pan areas, over the luggage compartment floor.
Body Sealer Type and Application Interweld Sealer Hot applied heat expanding weldable sealer is now used in all seam joints throughout the body structure. This material is not suitable for in field use. When fitting replacement panels, all mating surfaces are to be cleaned of this sealant and the cleaned surfaces painted with zinc rich primer (weld through primer). The edges of seams should be closed by a sealer, applied after the primer coat and before the undercoat.
Expanding Sealers/Adhesives There are a number of areas in the body structure where an expanfing sealer is used to exclude dust and moisture from inside the struture. This material is formulated to foam up and expand when heat is applied. When fitting a new panel or section of a panel where an expanding sealer is located and welding is to take place, all sealant must be removed for at least 50mm each side of the area to be welded prior to final fit up of the replacement panel and the exposed surface primed with a zinc rich primer. Structural Composite Foam This material is deposited in the areas shown in section 5 during vehicle maintenance. It is formulated to expand and solidify with the application of heat. The material is not serviced for in field service use.
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01/2003 2003.0 BA Falcon
501-00-4
General Information
501-00-4
DIAGNOSIS AND TESTING
Body System Inspection and Verification 1. Verify the customer concern by operating the system. the symptom and refer to the Symptom 2. Visually inspect for obvious signs of mechanical or electrical damage. 3. If an obvious cause for an observed or reported concern is found, correct the cause (if possible) before proceeding to the next step. 4. If the concern is not visually evident, verify the symptom and refer to the Symptom Chart. Visual Inspection Chart Mechanical Dust Leaks Water Leaks
Symptom Chart Condition Dust Leaks
Water Leaks
Source Displaced sealer.
Refer to the service procedure below.
Damaged body parts.
Refer to the service procedure below.
Missing underbody grommets.
Refer to the service procedure below.
Misaligned doors.
Refer to the service procedure below.
Misaligned glass.
Refer to the service procedure below.
Displaced sealer.
Refer to the service procedure below.
Damaged body parts.
Refer to the service procedure below.
Missing underbody grommets.
Refer to the service procedure below.
Misaligned doors.
Refer to the service procedure below.
Misaligned glass.
Refer to the service procedure below.
Sealer locations should be considered when checking for dust or water leaks. The forward motion of the vehicle causes any unsealed small opening in the lower section of the body to permit air and dust to be drawn into the body. Opening the ventilator air ducts will equalise these pressures. Dust accumulates in the luggage compartment body opening and may move into the luggage compartment. To eliminate dust leakage, determine the exact point at which the dust enters. Under certain conditions, water may also enter the body at any point where dust can enter. To determine the exact location of a dust leak, it may be necessary to remove the following trim panels from the vehicle: Scuff plate. Section 501-05 C - Pillar trim. Section 501-05 Rear seat backrest and frame, and rear seat cushion and frame. Section 501-10 Luggage compartment floor covering G86728 en
Action
Spare tire Roof opening panel. After removing the trim panel(s), the location of most leaks will be evident. The entrance of dust is usually indicated by a point of dust or silt. Seal these leaks, then road test the vehicle on a dusty road to ensure all leaks are sealed. A suitable Leak Detector can locate dust leaks, wind and water leaks. After the road test, check for indications of a dust pattern around the door openings, cowl side trim panel, lower part of the quater panel and in the luggage compartment. Sometimes leaks can be located by putting bright lights under the vehicle, with the above components removed, and checking the interior of the body joints and weld lines. A light will show through where leaks exist.
01/2003 2003.0 BA Falcon
501-02-1
Front End Body Panels
501-02-1
SECTION : 501-02 Front End Body Panels VEHICLE APPLICATION : 2003.0 BA Falcon CONTENTS
PAGE
SPECIFICATIONS Specifications ........................................................................................................................501-02-2 DESCRIPTION AND OPERATION Front End Body Panels .........................................................................................................501-02-3 GENERAL PROCEDURES Hood Alignment ....................................................................................................................501-02-4 Fender Alignment ..................................................................................................................501-02-4 REMOVAL AND INSTALLATION Air Deflector ..........................................................................................................................501-02-7 Fender Splash Shield ............................................................................................................501-02-7 Cowl Panel Grille ..................................................................................................................501-02-7 Fender ...................................................................................................................................501-02-8 Modestry Panel .....................................................................................................................501-02-8 Hood Prop .............................................................................................................................501-02-8 Hood/Hood Hinge .................................................................................................................501-02-9
01/2003 2003.0 BA Falcon
501-02-2
Front End Body Panels
501-02-2
SPECIFICATIONS Torque Specifications Description Cowl grille screws Fender bolts Fender splash shield bolts Air deflector Hood hinge to dash panel bolts Hood hinge to hood bolts Wiper pivot arm nuts
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Nm 3 10 12 4.5 30 30 —
01/2003 2003.0 BA Falcon
501-02-3
Front End Body Panels
501-02-3
DESCRIPTION AND OPERATION
Front End Body Panels The front end body panel components consist of the following: air deflectors cowl grille fenders fender splash shields hood hood hinges hood prop
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01/2003 2003.0 BA Falcon
501-02-4
Front End Body Panels
501-02-4
GENERAL PROCEDURES
Hood Alignment
Fender Alignment
1. The hood is provided with fore and aft adjustment. 1. Loosen the fender retaining bolts. These directions refer to the position of the hood when it is fully lowered. Slots in the hinge provide fore and aft adjustment. 1. Raise the hood. 2. Adjust the hood bumpers by screwing them in or out of the panel to prevent over slam and hood movement.
NOTE: The fenders are set relative to the hood latch mounting point on the upper cross member during body assembly. There is no hood latch adjustment vertically or right to left. If vehicle damage results in a need to reset the hood margins then the fenders should be adjusted relative to the hood.
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01/2003 2003.0 BA Falcon
501-02-5
Front End Body Panels
501-02-5
GENERAL PROCEDURES (Continued) Fender to Bumper
2. Adjust the fender to obtain hood/door margins as shown below (Alignment Diagrams). Fender Margins
Item 1 2 3 4 5
Description Fender to Hood Fender to Bumper Fender to Bumper Fender to Lower Body Panel Side Repeater Lamp to Fender
Fender to Bumper
Fender to Lower Body Panel
Fender to Hood
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01/2003 2003.0 BA Falcon
501-02-6
Front End Body Panels
501-02-6
GENERAL PROCEDURES (Continued) Side Repeater Lamp to Fender
3. Tighten the fender bolts to the specified torque. 4. Verfy alignment and repeat procedure if necessary.
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01/2003 2003.0 BA Falcon
501-02-7
Front End Body Panels
501-02-7
REMOVAL AND INSTALLATION
Air Deflector Removal 1. Remove the 10 attaching screws and 2 plastic push-in rivets.
3. Remove the fender splash shield. Remove the retaining scrivets (10 x 6mm), screws and firtree clips. NOTE: There are a total of 2 screws attaching the front lower section of the splashshield. NOTE: Adjust torque specifications at the front of the document.
Item 1 2 3 4
Description Lower Radiator Deflector Assembly Screw Scrivet Front Bumper Assembly
2. Slide the deflector rearwards. Installation 1. To install, reverse the removal procedure.
Item 1 2 3 4 5
Description Fender Splash Shield Firtree clip 6.5x25mm (2 off) Scrivets - 6mm (10 off) Screw - 5mm (1 off) Screw - 5mm (2 off)
Fender Splash Shield
Installation 1. To install, reverse the removal procedure.
Removal 1. Raise and support the vehicle. For additional information, refer to Section 100-02. 2. Remove the wheel and tire. For additional information, refer to Section 204-04.
Cowl Panel Grille
G36756 en
Removal 1. Remove the wiper front pivot arms. For additional information refer to, Section 501-16. 2. Remove the 5 retaining scrivets.
01/2003 2003.0 BA Falcon
501-02-8
Front End Body Panels
501-02-8
REMOVAL AND INSTALLATION (Continued) 3. Remove the LH cowl grille.
Item 1 2
Description Scrivet LH Cowl Grill Assembly
4. Remove the RH cowl grille.
6. Remove 4 remaining bolts as shown. For additional information, refer to Section 501-02.
Item 1 2
Description Bolt Front Fender
NOTE: Front fender bolt is removed during headlight removal process. Installation 1. To install, reverse the removal procedure.
Modestry Panel Removal 1. Remove the grille. For additional information, refer to Section 501-08. 2. Remove the 2 retaining scrivets and release the retaining legs from the metal bracket below the modestry panel. Item 1 2
Description Scrivet RH Cowl Grill Assembly
Installation 1. To install, reverse the removal procedure.
Fender Removal 1. Remove wheels. For additional information, refer to Section 200-04. 2. Remove splashshield. For additional information, refer to Section 501-02. 3. Remove side indicator lamp. For additional information, refer to Section 417-01. 4. Remove front bumper. For additional information, refer to Section 501-00. 5. Remove headlamp. For additional information, refer to Section 417-01.
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3. Remove the modesty panel. Installation 1. To install, reverse the removal procedure.
Hood Prop Removal 1. Raise hood and support it. 2. Pry the prop the retaining clips from the ball retainers using small screw driver. 01/2003 2003.0 BA Falcon
501-02-9
Front End Body Panels
501-02-9
REMOVAL AND INSTALLATION (Continued) 3. Remove prop from vehicle.
Installation 1. Install spring clips to ball retainers. 2. Snap ball retainers onto ball studs. Check operation.
Hood/Hood Hinge Removal 1. Open hood and suport hood in the open position. 2. Fit fender covers. 3. Remove the hood props. 4. Scribe around hinge and remove hinge retaining bolts, remove hood from vehicle.
Item 1 2 3
Item 1 2
Description Hinge Bolt
Installation 1. Reverse the removal procedure. Care must taken when aligning hinge to hood prop/s to tighten attaching the bolts.
Description Hinge Bolt Hood
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01/2003 2003.0 BA Falcon
501-03-1
Body Closures
501-03-1
SECTION : 501-03 Body Closures VEHICLE APPLICATION : 2003.0 BA Falcon CONTENTS
PAGE
REMOVAL AND INSTALLATION Door Windlace ......................................................................................................................501-03-2 Weatherstrip Front and Rear Doors ......................................................................................501-03-3 Decklid Weatherstrip .............................................................................................................501-03-4 Liftgate Weatherstrip .............................................................................................................501-03-4 Roof Side Rail - Sedan .........................................................................................................501-03-4 Roof Side Rail — Wagon ......................................................................................................501-03-6 Dash Panel Upper Seal ........................................................................................................501-03-6 Hood Inner Seal ....................................................................................................................501-03-6 Front Door Beltline Outer ......................................................................................................501-03-7 Rear Door Beltline Outer ......................................................................................................501-03-7 Rear Door Beltline Inner .......................................................................................................501-03-7 Rear Door Beltline Inner .......................................................................................................501-03-7 B Pillar Aplique ......................................................................................................................501-03-8 Rocker Margin Seal ..............................................................................................................501-03-8 Weatherstrip Door Outer — Ute ...........................................................................................501-03-8 Exterior — Ute ......................................................................................................................501-03-8 Front Door Glass Run ...........................................................................................................501-03-9 Rear Door Glass Run ...........................................................................................................501-03-9
01/2003 2003.0 BA Falcon
501-03-2
Body Closures
501-03-2
REMOVAL AND INSTALLATION
Door Windlace 1. The door opening weatherstrip is a roll on fit, attaching to the body pinch weld flange. Refer to illustration for assembly start and finish point locations.
Installation 1. Fit windlace starting at bottom of B pillar pushing down B pilar until windlace will not go down any further. Then roll up B pillar fitting over flange as you go. Roll around B pillar corner making sure windlace fits up tight into corner but does not sit up high on style line. Continue rolling along header.
G80840 en
Repeat B pillar corner process on A pillar corner finish fitting windlace down A pillar. Check and smooth out any bumps in windlace fitment using crimping tool to crimp windlace in B pillar corner.
01/2003 2003.0 BA Falcon
501-03-3
Body Closures
501-03-3
REMOVAL AND INSTALLATION (Continued)
Weatherstrip Front and Rear Doors
Rear Door
Removal Front Door
NOTE: The weatherstrips are attached to the doors via a retaining channel above beltline and by push fit fasteners below beltline. Above Beltline 1. Remove at corner cup, pull w/strip to remove from door retainer recess. Below Beltline 1. Grasp the weatherstrip beside fastener and pull, stretch and lift the weatherstrip to detach it from the end of the fastener. Slide the weatherstrip in the opposite direction to disengage from the other end of the fastener. 2. Using a pair of pliers firmly grasp the fastener and pull from the door panel. Fasteners must be renewed after removal. Installation Above Beltline 1. Affix top corner clip and first clip on A-and B-pillar. 2. Sit lower edge of weatherstrip base in to retainer and then, push upper edge of base into retainer. Below Beltline 1. Assemble the fasteners to the weatherstrip and install to the door panel. Ensure the fasteners are fully seated. G80840 en
01/2003 2003.0 BA Falcon
501-03-4
Body Closures
501-03-4
REMOVAL AND INSTALLATION (Continued)
Decklid Weatherstrip
Liftgate Weatherstrip
Removal 1. Remove Decklid Weatherstrip as shown in figure.
Removal 1. Remove liftgate weatherstrip as shown in figure.
Installation 1. Reverse removal procedure. NOTE: Vulcanised joint to be on centre line. Yellow dot signifies centre line near latch. A rubber moller may be used to assist installation.
Roof Side Rail - Sedan
Installation 1. Reverse removal procedure NOTE: The weatherstrip must be positioned with the trim panel lip on the inboard side of the body flange and covering the trim panel. Vulcanised joint to be on centre line near latch. Fully insert the weatherstrip onto the flange. A rubber moller may be used to assist installation.
G80840 en
Removal 1. Remove flange from fitting along complete length, except… 2. At sequence Z, unclip flange. 3. At sequence Y, remove adhesive from ditch moulding on underside edge of top of weatherstrip.
01/2003 2003.0 BA Falcon
501-03-5
Body Closures
501-03-5
REMOVAL AND INSTALLATION (Continued)
Installation 1. Reverse removal procedure.
G80844 en
01/2003 2003.0 BA Falcon
501-03-6
Body Closures
501-03-6
REMOVAL AND INSTALLATION (Continued)
Roof Side Rail — Wagon
2. At sequence Z, unclip flange. 3. At sequence Y, align weatherstrip to corner.
Removal 1. Remove flange from fitting along complete length, except…
Installation 1. Reverse removal procedure.
Dash Panel Upper Seal Removal 1. Remove dash panel weatherstrip as shown in figure.
G80844 en
Installation 1. Reverse removal procedure. NOTE: Trim panel to be facing towards front of vehicle.
Hood Inner Seal Removal 1. Remove hood inner weatherstrip as shown in figure.
01/2003 2003.0 BA Falcon
501-03-7
Body Closures
501-03-7
REMOVAL AND INSTALLATION (Continued) Installation 1. Reverse removal procedure. NOTE: "Yellow" ID dot on right end of seal.
Front Door Beltline Outer
Front Door Beltline Inner Removal 1. Remove front door beltline inner weatherstrip as shown in figure.
Removal 1. Remove front door beltline outer weatherstrip as shown in figure.
Installation 1. Reverse removal procedure. NOTE: Part must be fully seated onto flange. Installation Rear Door Beltline Inner 1. Reverse removal procedure. NOTE: Item 1 must click into door panel to ensure Removal 1. Remove rear door beltline inner weatherstrip as clips are fully seated. shown in figure.
Rear Door Beltline Outer
Removal 1. Remove rear door beltline outer weatherstrip as shown in figure.
Installation 1. Reverse removal procedure. NOTE: Part must be fully seated onto flange. Weatherstrip angle cut to rear. Installation 1. Reverse removal procedure. NOTE: Item 1 must click into door panel to ensure clips are fully seated.
G80849 en
01/2003 2003.0 BA Falcon
501-03-8
Body Closures
501-03-8
REMOVAL AND INSTALLATION (Continued)
B Pillar Aplique
Weatherstrip Door Outer — Ute
Removal 1. Applique to be pulled off at clip.
Removal 1. Remove door outer weatherstrip as shown in figure.
2. Remove remaining tape. 3. Use thinners to remove remaining tape off vehicle. Installation 1. Applique to be clipped in at front. 2. Applique to be pushed forward on door steel. 3. Tape pushed down to adhere to sheet steel.
Rocker Margin Seal Removal 1. Remove rocker margin seal weatherstrip as shown in figure.
Installation 1. Reverse removal procedure.
Exterior — Ute Removal 1. Remove exterior weatherstrip as shown in figure.
Installation 1. Reverse removal procedure.
Installation 1. Reverse removal procedure. G80849 en
01/2003 2003.0 BA Falcon
501-03-9
Body Closures
501-03-9
REMOVAL AND INSTALLATION (Continued)
Front Door Glass Run
Rear Door Glass Run
Removal NOTE: To aid installation, lubricate the corner mouldings lightly with water based lubricant (eg tyre lube, KY). Do not use petroleum based lubricants.
Removal NOTE: To aid installation, lubricate the corner mouldings lightly with water based lubricant (eg tyre lube, KY). Do not use petroleum-based lubricants.
NOTE: The B pillar corner is the alignment datum for the front door Glass Run Weatherstrip.
NOTE: For the rear door, the division bar corner is the alignment datum.
1. Fit the B pillar corner moulding first and the adjacent 100mm of the top bar. Use the adjacent extrusions to position the corner mould. 2. Refer to Fig. 9. Assemble the B pillar extrusion with an even gap all the way down for later fitment of the B pillar applique. 3. Fit the A pillar corner. Again use the extrusion to position the lubricated corner. 4. Assemble the remainder of the top bar extrusion. 5. Assemble the A pillar extrusion. NOTE: Assembly of the top bar section to the door upper requires the outer lip to be pushed in first before the inner lip can be pushed home. (This also applies to the vertical A pillar and B pillar extrusions).
1. Fit the division bar corner first. Use the top bar extrusions to position the lightly lubricated corner mould. 2. Work forward along the top bar towards the B pillar corner. Fit the B pillar corner again using the adjacent extrusions to position the corner mould. 3. Refer Fig. 9. Assemble the B pillar extrusion with an even gap all the way down for later fitment of the B pillar applique. 4. Fit the division bar extrusion. NOTE: Assembly of the top bar section to the door upper requires the outer lip to be pushed in first before the inner lip can be pushed home. (This also applies to the vertical A pillar and B pillar extrusions).
Installation 1. Reverse removal procedure.
Installation 1. Reverse removal procedure.
G80853 en
01/2003 2003.0 BA Falcon
501-04-1
Pickup Bed and Platform Body
501-04-1
SECTION : 501-04 Pickup Bed and Platform Body VEHICLE APPLICATION : 2003.0 BA Falcon CONTENTS
PAGE
GENERAL PROCEDURES Hoisting the vehicle ................................................................................................................501-04-2 REMOVAL AND INSTALLATION Pickup Box .............................................................................................................................501-04-3 Aluminium Tray ......................................................................................................................501-04-5
01/2003 2003.0 BA Falcon
501-04-2
Pickup Bed and Platform Body
501-04-2
GENERAL PROCEDURES
Hoisting the vehicle Hoisting Area - Ute Rear
Item 1 2
Description Hoisting area pad Hoist arm
CAUTION: When Hoisting the vehicle the unitized body-frame construction requires special precautions and procedures when the vehicle is jacked up or hoisted. In some cases, special hoist adapters must be used as recommended by specific hoist manufacturers. Refer to the Owner’s Manuals when using the jack supplied with the car. CAUTION: Drive-on Type Hoist To prevent possible damages to the underbody, do not drive the vehicle on to any type hoist without first checking for possible interference between the upright flanges of the hoist rails and the underbody. Should there be interference, the hoist flanges should be modified as necessary and/or the approach ramps built up to provide the needed clearance. CAUTION: Adapters Front and rear adapters to hoist plates must be carefully positioned in contact with the side rail to ensure safe, accurate lifting. CAUTION: Trolley Jack When a trolley jack is used it is to be located in the same position as for hoist lifting.
G34530 en
01/2003 2003.0 BA Falcon
501-04-3
Pickup Bed and Platform Body
501-04-3
REMOVAL AND INSTALLATION
Pickup Box
10. Remove eight bolts (Item 1 ) retaining the box to the chassis through floor cross members.
Removal 1. Remove tonneau cover. 2. Remove twelve M6 Bolts retaining bedliner load tiedown brackets (Only 6 LH side ones shown).
11. Attach overhead lifting device by the means of four equally spaced hooks located under the top rail section at the position shown. Two on R/H side of box and two on L/H of box. 3. Remove four screws retaining bedliner along the rearsection in tailgate opening.
4. Pull in both walls & bow floor section of bedliner up to release locking tabs at wheel arch. 5. Remove bedliner from vehicle. 6. Remove two bolts that retain taillights ( LH and RH ). 7. Remove taillights and allow globe holders to drop back inside cavity. 8. Carefully remove the fir-tree clips retaining the wiring for each taillight. 9. Disconnect reversing lamp/number plate illumination connector.
G34531 en
WARNING: The inner angle section adjacent to the wheelarch must not be used to lift the box. NOTE: Ensure the chains / slings on the overhead lifting device are near vertical when viewed from the rear to minimize "pull-in" on the bodysides.
12. Remove scrivets retaining the plastic inner wheel arch mud deflector to chassis (LH and RH.).
01/2003 2003.0 BA Falcon
501-04-4
Pickup Bed and Platform Body
501-04-4
REMOVAL AND INSTALLATION (Continued) 13. Raise the box, carefully manoeuvreing around the fuel filler neck. Store the box on trestles locating on cross beams under the floor. Installation 1. Reverse removal procedure. WARNING: Corflex bolts must be re-started by hand. Attempting to restart a corflex bolt with a rattle gun can result in stripped threads. CAUTION: Ensure rubber insulators have been replaced on the vertical pins if dislodged during removal.
G34531 en
01/2003 2003.0 BA Falcon
501-04-5
Pickup Bed and Platform Body
501-04-5
REMOVAL AND INSTALLATION (Continued)
Aluminium Tray Removal
Item 1 2 3 4
Description Floor Assy. RR Flatbed Bolt rear chasis mount Bolt mid tray Bolt front tray
1. Remove the four bolts retaining the front tray mounting brackets to the tray. NOTE: To remove the actual tray mounting bracket from the x-member, the fuel tank must be removed to access the lower bolt on the LH bracket. 2. Remove four bolts retaining the middle traymounting bracket to the chassis rail on both sides. 3. Remove the four bolts attaching the rearmounting brackets to the chassis rail on both sides. 4. Attach lifting device, ensuring the tray is lifted with equal loading of all four corner points. Installation 1. Reverse removal procedure. WARNING: Corflex bolts must be re-started by hand. Attempting to restart a corflex bolt with a rattle gun can result in stripped threads.
G34532 en
01/2003 2003.0 BA Falcon
501-05-1
Interior Trim and Ornamentation
501-05-1
SECTION : 501-05 Interior Trim and Ornamentation VEHICLE APPLICATION : 2003.0 BA Falcon CONTENTS
PAGE
SPECIFICATIONS Specifications .........................................................................................................................501-05-2 DESCRIPTION AND OPERATION Interior Trim and Ornamentation ............................................................................................501-05-3 Interior Trim ..........................................................................................................................501-05-3 Luggage compartment Interior Trim System ........................................................................501-05-3 REMOVAL AND INSTALLATION A — Pillar Trim Panel ............................................................................................................501-05-4 B — Pillar Upper & Lower Trim Panel ...................................................................................501-05-4 C — Pillar Trim Panel ............................................................................................................501-05-4 D — Pillar Trim Panel — Wagon ...........................................................................................501-05-4 Front Door Trim Panel ...........................................................................................................501-05-4 Rear Door Lo Series Trim Panel ............................................................................................501-05-5 Rear Quarter Trim Panel — Wagon ......................................................................................501-05-6 Quarter Trim Panel — Ute .....................................................................................................501-05-6 Loadspace Trim Panel — Ute ................................................................................................501-05-7 Liftgate Upper Trim ................................................................................................................501-05-7 Liftgate Lower Trim ................................................................................................................501-05-7 Parcel Shelf ............................................................................................................................501-05-7 Sunvisor .................................................................................................................................501-05-8 Headliner — Wagon ...............................................................................................................501-05-8 Headliner — Sedan ................................................................................................................501-05-8 Headliner — Ute ....................................................................................................................501-05-9 Luggage Compartment Cover Lower Back ............................................................................501-05-9 Luggage Compartment Quarter Trims .................................................................................501-05-10 Luggage Compartment Load Floor Carpet ..........................................................................501-05-10 Spare Wheel Board ..............................................................................................................501-05-10 Package Tray Insulator ........................................................................................................501-05-11 Decklid Trim ........................................................................................................................501-05-11 Front Door Watershield ........................................................................................................501-05-12 Rear Door Watershield ........................................................................................................501-05-12 Front Inner Scuff Plate (RH) ................................................................................................501-05-12 Front Inner Scuff Plate (LH) .................................................................................................501-05-13 Rear Inner Scuff Plate ..........................................................................................................501-05-13 Rear Outer Scuff Plate .........................................................................................................501-05-13
01/2003 2003.0 BA Falcon
501-05-2
Interior Trim and Ornamentation
501-05-2
SPECIFICATIONS Torque Specifications Description B-Pillar trim panel screws Sunvisor screws Sunvisor check block Liftgate lower panel nut and washer assembly D-Pillar panel screw
G11849 en
Nm 1.5-1.9 1.7 1.7 3 1.5
01/2003 2003.0 BA Falcon
501-05-3
Interior Trim and Ornamentation
501-05-3
DESCRIPTION AND OPERATION
Interior Trim and Ornamentation Interior Trim The interior trim consists of the following components: A-pillar lower trim panels B-pillar trim panels C-pillar trim panels D-pillar trim panels front door sail panels front door scuff plate trim panels front door trim panels headliner liftgate scuff plate trim panel liftgate trim panel rear door sail panels rear door scuff plate trim panels rear door trim panels front quarter trim panels sun visors window control switch panel cover
Luggage compartment Interior Trim System The luggage compartment consists of the following trim components: Cover lower back Quarter trims Load floor carpet Spare wheel board Package tray insulator Decklid trim (Hi series only)
G11850 en
01/2003 2003.0 BA Falcon
501-05-4
Interior Trim and Ornamentation
501-05-4
REMOVAL AND INSTALLATION
A — Pillar Trim Panel
C — Pillar Trim Panel
Removal 1. Follow removal instructions as shown in figure.
Removal 1. Follow removal instructions shown in figure.
Item 1 2
Description Moulding assy w/shield garn Panel body side LH
Item 1 2
Description Quarter trim panel - upper Quarter panel outer
Installation 1. Reverse removal procedure.
Installation 1. Reverse removal procedure.
B — Pillar Upper & Lower Trim Panel
D — Pillar Trim Panel — Wagon
Removal 1. Follow removal instructions shown in figure.
Removal 1. Follow removal instructions shown in figure.
Item 1 2 3
Description Panel - Centre body pillar I/S fin Cover - Front seat belt adjuster Screw #8 18x0.5 Round washer head
Installation 1. Reverse removal procedure.
Item 1 2
Description Rear pillar trim Screw
Installation 1. Reverse removal procedure.
Front Door Trim Panel Removal 1. Insert small flat head screw driver at point shown.
G11851 en
01/2003 2003.0 BA Falcon
501-05-5
Interior Trim and Ornamentation
501-05-5
REMOVAL AND INSTALLATION (Continued) 2. Lever out and remove grab handle cap, taking 7. Remove screws from grab handle. care not to mark surface of door trim grab handle.
3. Remove Interior Latch Release. For additional information, refer to Door Latch Interior Release in this section. 4. Remove 2 lower screw covering caps and screws. 5. Remove Rear upper screw fixing. 6. Remove Front upper screw fixing.
Item 1 2 3
Description Front door trim Interior latch release Screw
8. Disengage door trim retention clips by pulling door trim away from sheet metal (in direction of arrow), starting at lower edge. NOTE: Pull along edge of trim; do not use the grab handle.
Item 1 2
Description Front door trim Screw
9. When trim is loose, lift up and over lock rod (indicated by circle). 10. Disconnect electrical connectors if required and remove door trim panel assembly. Installation 1. Reverse removal procedure.
Rear Door Lo Series Trim Panel Removal NOTE: Rear door trim with pull cup / window winder. For rear door trim with power windows, refer to Front Door Trim notes for removal and installation. 1. Remove pull cup screw. 2. Remove pull cup. 3. Remove Window Winder.
G11871 en
01/2003 2003.0 BA Falcon
501-05-6
Interior Trim and Ornamentation
501-05-6
REMOVAL AND INSTALLATION (Continued) 4. Remove Door Latch Interior Release handle.
Rear Quarter Trim Panel — Wagon Removal 1. Follow removal instructions shown in figure.
Item 1 2 3
Description Screw Ash tray Rear door trim - Lo Series
5. Remove 2 lower screw fixings. 6. Remove forward upper screw fixing. 7. Remove rear upper screw fixing.
Item 1 2 3 4 5
Description Quarter panel trim Sunvisor check block Luggage compartment carpet Wheel arch Screw
Installation 1. Reverse removal procedure.
Quarter Trim Panel — Ute Removal 1. Remove the right and left hand side quarter trim panel as shown.
Item 1 2
Description Rear door trim - Lo series Screw
8. Disengage door trim retention clips by pulling door trim away from sheet metal. Start at lower edge, working around the edge of the door trim. 9. Disconnect electrical connectors if required and remove door trim panel assembly. Installation Item 1. Reverse removal procedure. 1 2
Description Trim panel Locator plug
Installation 1. Reverse the removal procedure.
G11871 en
01/2003 2003.0 BA Falcon
501-05-7
Interior Trim and Ornamentation
501-05-7
REMOVAL AND INSTALLATION (Continued)
Loadspace Trim Panel — Ute
Liftgate Lower Trim
Removal 1. Follow removal instructions shown in figure.
Removal 1. Follow removal instructions shown in figure.
Item 1 2 3
Description Clip fir tree Cover Assy Back panel trim Child restraint anchorage
Installation 1. Reverse removal procedure.
Item 1 2 3 4 5
Description Liftgate lower trim Pull strap Scrivet Nut and washer Assy. M6 Clip
Liftgate Upper Trim
Installation 1. Reverse removal procedure.
Removal 1. Follow removal instructions shown in figure.
Parcel Shelf Removal 1. Carefully remove the barbed clips. (4 x No. 1 and 1 x No. 2) 2. Lift the Package tray trim from the parcel shelf sheet metal.
Item 1 2 3 4
Description Liftgate upper trim LH Liftgate upper trim RH Push on clip (Type A) Push on clip (Type B)
Installation 1. Reverse removal procedure.
Item 1 2
Description Barbed clip no. 1 Barbed clip no. 2
Installation 1. Reverse the removal procedure.
G11857 en
01/2003 2003.0 BA Falcon
501-05-8
Interior Trim and Ornamentation
501-05-8
REMOVAL AND INSTALLATION (Continued)
Sunvisor
8. Remove headlining via liftgate opening.
Removal 1. Remove sunvisor as shown in figure.
Item 1 2 3
Description Sunvisor Screw Screw
Installation 1. Reverse the removal procedure.
Headliner — Wagon Removal 1. Remove grab handles and hook. 2. Remove sunvisors and check blocks. 3. Remove A,B,C and D pillar interior trim parts. 4. Remove dome light lens and body and disconnect wiring. 5. Remove rear courtesy light lens and body and disconnect wiring. 6. Remove upper sections of door and liftgate opening weatherstrip. 7. Remove barbed clips.
Item 1 2 3
Description Headlining Barbed clip Sunvisor check block
Installation 1. Reverse removal procedure. NOTE: Care should be taken when handling headlining not to be bend unnecessarily.
Headliner — Sedan Removal 1. Remove grab handles and hook. 2. Remove sunvisors and check blocks. 3. Remove A,B,C and pillar interior trim parts. 4. Remove dome light lens and body and disconnect wiring.
Item 1 2 3
Description Headlining Barbed clip Sunvisor check block
NOTE: Avoid folding or creasing the headlining during removal.
G11857 en
01/2003 2003.0 BA Falcon
501-05-9
Interior Trim and Ornamentation
501-05-9
REMOVAL AND INSTALLATION (Continued) Installation 1. Reverse removal procedure.
Headliner — Ute
2. Undo spare wheel board tie down and remove spare wheel cover.(Refer removal of spare wheel cover in this section.)
Removal 1. Remove A,B,C pillar interior trim parts. 2. Remove sunvisors and check blocks. 3. Remove grab handles and hook. 4. Locate interior light wiring connector at base of "A" pillar trim and disconnect. 5. Remove barbed clips. 6. Remove headlining via door opening.
3. Remove 3 fir tree clips from front of cover lower back.
Item 1
Description Panel assy. roof trim
Installation 1. Reverse removal procedure. NOTE: Care should be taken when handling headlining not to bend unnecessarily.
Luggage Compartment Cover Lower Back Removal 1. Lift carpet.
Item 1
Description Fir tree clip
4. Remove cover lower back with an upwards motion. NOTE: Be careful not to damage hooks located on both the LH and RH extremities.
Installation 1. Reverse removal procedure.
G11864 en
01/2003 2003.0 BA Falcon
501-05-10
Interior Trim and Ornamentation
501-05-10
REMOVAL AND INSTALLATION (Continued)
Luggage Compartment Quarter Trims Removal 1. Remove 2 fir tree clips on luggage compartment side. NOTE: On high series vehicles that have luggage net fitted, luggage net hook will be removed instead of a fir tree.
2. Fold carpet from underneath seat backs into the luggage compartment. 3. Remove carpet.
Installation 1. Reverse removal procedure.
Spare Wheel Board Item 1 2 3 4
Description Quarter trim Fir tree clip Fir tree clip Plug
Removal 1. Fold carpet back.
2. Lower seat back in cabin. (Refer to Section 501-10.) 3. Loosen package tray trim at front edge. 4. Remove 2 fir tree clips located behind seat back.
2. Undo spare wheel tie down.
Installation 1. Reverse removal procedure.
Luggage Compartment Load Floor Carpet Removal 1. Lower seat back in cabin. (Refer to Section 501-10.)
G11864 en
Item 1 2
Description Strap Cover 01/2003 2003.0 BA Falcon
501-05-11
Interior Trim and Ornamentation
501-05-11
REMOVAL AND INSTALLATION (Continued) Item 3
Description Spare wheel
3. Remove spare wheel board. Installation 1. Reverse removal procedure.
Package Tray Insulator Removal 1. Remove both LH and RH quarter trims.(Refer removal of quarter trim in this section.) 2. Remove package tray trim. (Refer to removal of Parcel Shelf in this section.) 3. Remove 2 fir tree clips located on front edge of package tray insulator behind seat backs.
Installation 1. Reverse removal procedure.
Decklid Trim Removal Short Wheel Base 1. Remove 14 fir tree clips. 2. Slide trim off decklid latch.
Item 1 2
Description Decklid trim - SWB Fir tree clips
Long Wheel Base Item 1 2
Description Package tray insulator Fir tree clip
1. Remove 13 fir tree clips. 2. Remove pulldown handle.
4. Remove clips on rear edge of package tray insulator.
Item 1 2 3 Item 1 2
Description Package tray insulator Plastic snap clip
Description Decklid trim - LWB Fir tree clips Pull down handle
3. Slide decklid trim off decklid latch. Installation 1. Reverse removal procedure.
5. Bend part through the middle and slide through pass through into luggage compartment.
G11869 en
01/2003 2003.0 BA Falcon
501-05-12
Interior Trim and Ornamentation
501-05-12
REMOVAL AND INSTALLATION (Continued)
Front Door Watershield
Front Inner Scuff Plate (RH)
Removal 1. Remove watershield as shown in figure.
Removal 1. Remove plug from front of plate (dash panel side).
Item 1 2
Description Pull through hole in watershield Front door trim watershield
2. Remove plug from door side.
Installation 1. Reverse removal procedure.
Rear Door Watershield Removal 1. Remove watershield as shown in figure.
3. Pull scuff plate towards centre of vehicle.
Installation 1. Reverse removal procedure.
Installation 1. Reverse removal procedure.
G11869 en
01/2003 2003.0 BA Falcon
501-05-13
Interior Trim and Ornamentation
501-05-13
REMOVAL AND INSTALLATION (Continued)
Front Inner Scuff Plate (LH)
Rear Outer Scuff Plate
Removal 1. Remove front inner scuff plate (LH) as shown in figure .
Removal 1. Remove outer scuff plate as shown in figure.
Installation 1. Reverse removal procedure.
Rear Inner Scuff Plate Removal 1. Remove rear inner scuff plate as shown in figure.
Item 1 2 3 4
Description Screw Front Outer Scuff Plate Screw Grommet Rear Outer Scuff Plate
Installation 1. Reverse removal procedure.
Installation 1. Reverse removal procedure.
G11876 en
01/2003 2003.0 BA Falcon
501-08-1
Exterior Trim and Ornamentation
501-08-1
SECTION : 501-08 Exterior Trim and Ornamentation VEHICLE APPLICATION : 2003.0 BA Falcon CONTENTS
PAGE
DESCRIPTION AND OPERATION Exterior Trim and Ornamentation .........................................................................................501-08-2 REMOVAL AND INSTALLATION Radiator Grille .......................................................................................................................501-08-3 Licence Plate Housing ..........................................................................................................501-08-3 Rear Decklid Moulding — High Series, SWB Sedan ............................................................501-08-4 Rear Decklid Moulding — Low Series, SWB Sedan ............................................................501-08-4 Rear Liftgate Moulding — Wagon .........................................................................................501-08-5 Rear Decklid Moulding — Wagon .........................................................................................501-08-5 Window Moulding ..................................................................................................................501-08-5 Door Moulding — All Vehicles ..............................................................................................501-08-6 Rocker Panel Moulding — SWB & LWB ..............................................................................501-08-7 Body Side Protection Moulding .............................................................................................501-08-7 Roof Ditch Moulding ..............................................................................................................501-08-8 Decklid Spoiler ......................................................................................................................501-08-8
01/2003 2003.0 BA Falcon
501-08-2
Exterior Trim and Ornamentation
501-08-2
DESCRIPTION AND OPERATION
Exterior Trim and Ornamentation Component Location
Item 1 2 3 4 5 6 7 8 9
Description Radiator Grille Hood Moulding Door Moulding Window Moulding Roof Ditch Moulding Decklid Spoiler Licence Plate Moulding Rocker Pane Moulding Door Moulding
G86721 en
01/2003 2003.0 BA Falcon
501-08-3
Exterior Trim and Ornamentation
501-08-3
REMOVAL AND INSTALLATION
Radiator Grille
Licence Plate Housing
Removal 1. Raise the Hood. 2. Remove the two scrivets along the top rear edge of the grille. 3. Lift the grille up and away.
Removal 1. Gently use a screwdriver to depress the clip tab on the side of the lamp housing to remove it from the applique. NOTE: The lamp will still be attached to the applique by the bulb holder and wiring. Hi Series
Item 1 2
Description Scrivet - 8mm Grille - SWB/UTE
Item 1
Description Number Plate Lamp
Lo Series
Item 1 2
Description Scrivet - 8mm Grille - LWB
Installation 1. To install, reverse the removal procedure.
G86722 en
Item 1
Description Number Plate Lamp
2. Turn the bulb holder approximately 1/8 of a turn anti-clockwise until it is free of the lamp housing. Installation 1. To install, reverse the removal procedure. NOTE: Tabs prevent the bulb holder from being inserted into the lamp housing at the incorrect orientation. Do not apply force.
01/2003 2003.0 BA Falcon
501-08-4
Exterior Trim and Ornamentation
501-08-4
REMOVAL AND INSTALLATION (Continued)
Rear Decklid Moulding — High Series, Rear Decklid Moulding — Low Series, SWB Sedan SWB Sedan Removal 1. Remove 6 off nuts from inside decklid.
Item 1
Description Nut - M5
2. Carefully release the two lower inboard retainers from within the decklid using a screwdriver to depress the locking tabs and remove the moulding. 3. Pull out the wiring grommet and unplug the wiring connector for license plate lamps. Installation 1. Feed in license plate lamp wire into decklid and insert lamp wire grommet. 2. Plug in connector. 3. Line up top 4 off studs with decklid and rotate moulding so as to insert lower two outboard studs and two inboard retainers, and press home (Insure seals are fitted to moulding including retainers). 4. Insert screws and torque.
G86722 en
Removal 1. Remove 4 off nuts from inside decklid.
Item 1 2
Description Nut - M5 Ornament Assy Lugg Comp Door
2. Carefully remove the moulding. 3. Pull out wiring grommet and unplug wiring connector for license plate lamps. Installation 1. Feed in license plate lamp wire into decklid and insert lamp wire grommet. 2. Plug in connector. 3. Line up 4 off studs with decklid and insert (Insure seals are fitted to appliqué). 4. Insert screws and torque.
01/2003 2003.0 BA Falcon
501-08-5
Exterior Trim and Ornamentation
501-08-5
REMOVAL AND INSTALLATION (Continued)
Rear Liftgate Moulding — Wagon
Window Moulding
Removal 1. Remove the liftgate interior trim. 2. Remove the four mounting screws.
Removal
Item 1 2
Description Moulding - Liftgate Nut - M5x0.8
3. Unplug the wiring connector. Installation 1. To install, reverse the removal procedure.
Rear Decklid Moulding — Wagon Removal 1. Remove 6 off nuts from inside decklid.
2. Carefully remove the moulding. Installation 1. Line up 6 off studs with decklid and insert (Insure seals are fitted to moulding). 2. Insert screws and torque.
G86727 en
01/2003 2003.0 BA Falcon
501-08-6
Exterior Trim and Ornamentation
501-08-6
REMOVAL AND INSTALLATION (Continued)
Door Moulding — All Vehicles Removal 1. Remove the applique moulding by pulling the clip. Sedan
Item 1 2 3 Item 1 2 3
Description Applique Wheatherstrip Foam Tape
Description Rivet Moulding Clip
2. Use an adhesive cleaner to remove all tape residue on the vehicle. Installation 1. Remove the backing tape from the applique.
Ute
Item 1 2 3 4
Description Wheatherstrip Door Inner Applique Rivet
G86727 en
Item 1 2 3
Description Applique - B Pillar Rear Door Applique - B Pillar Front Door Rivet
2. Insert the applique into position and clip it at the top. 3. Push the applique forward onto the door frame. 4. Press firmly on the surface of the applique to ensure tape contact over the full length.
01/2003 2003.0 BA Falcon
501-08-7
Exterior Trim and Ornamentation
501-08-7
REMOVAL AND INSTALLATION (Continued)
Rocker Panel Moulding — SWB & LWB
4. Remove all rocker moulding seal clips from the top slots.
Removal 1. Remove the three clips along the underside of the rocker panel moulding.
Item 1 2
Description Location of Metal Clip Rocker Moulding
2. Dislodge the metal clip.
5. Remove rocker panel moulding. Installation 1. Locate rocker moulding lower fixing channel onto rocker panel weld seam. 2. Roll rocker panel in vertical position to locate rocker seal clips into corresponding top slots. 3. Fully insert all rocker moulding clips starting from the first front clip. 4. Ensure all clips are fully located home. 5. Fully insert the three fir tree clips on the underside, to the floor in corresponding holes. 6. Insert 2 front splash shield to rocker scrivets.
Body Side Protection Moulding Removal NOTE: The procedures below covers the removal and Installation of the double sided tape as used on Falcon BSPMs and other Falcon applications.
3. Remove the 2 scrivets attaching front splash shield to the rocker.
1. Carefully cut the end of the tape on the BSPM vertically to split the foam. 2. Peel the BSPM off the door, taking care not to damage it if the BSPM is to be reused (not recommended). 3. Use an adhesive cleaner to remove tape residue on the vehicle. Saturate the remaining tape and use a squeegee to remove. All the adhesive residue must be cleaned off the vehicle. 4. Give the vehicle a final wipe with a 70% isopropyl alcohol and water mixture (rubbing alcohol). 5. Dry with a clean cloth. Installation 1. Wipe metal surface with clean rag and isopropyl alcohol solution (50/50 min. solution). NOTE: Ensure ambient temperature is at a minimum of 16 deg Celsius and is dry. 2. Remove the backing tape without contaminating the adhesive surface.
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01/2003 2003.0 BA Falcon
501-08-8
Exterior Trim and Ornamentation
501-08-8
REMOVAL AND INSTALLATION (Continued) 3. Press the BSPM firmly onto body starting from the front of the panel and apply minimum of 100N pressure over the full length of BSPM. Repeat to ensure adequate wet-out of the double sided tape. NOTE: Moulding should have a constant gap to the door feature line and be consistent to the other door. Moulding should not be riding up on the door or fender feature line.
Item 1 2 3 4
Description Moulding Asy Body Side Half Car Set Moulding Asy Front Door Moulding Asy Rear Door Moulding Asy Body Side Rear
Roof Ditch Moulding Item 1 2 3
Item 1 2 3 4
Description Moulding Asy Body Side Half Car Set Moulding Asy Front Door Moulding Asy Rear Door
Description Moulding Asy Body Side Half Car Set Moulding Asy Door Moulding Asy Cabin Side Moulding Asy Style Side Box
Removal 1. Remove the existing roof ditch moulding.
2. Use an adhesive cleaner to remove tape residue from the channel. Installation 1. Remove the backing tape from the new moulding. 2. Align corner of moulding tail with the rear corner of roof. 3. Place body of moulding in channel. 4. Ensure uniform pressure is applied to molding using a roller.
Decklid Spoiler Removal 1. Disconnect the wiring loom from the license plate lamp via the rear of inside left hand side decklid panel.
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01/2003 2003.0 BA Falcon
501-08-9
Exterior Trim and Ornamentation
501-08-9
REMOVAL AND INSTALLATION (Continued) 2. Remove the screws from each spoiler foot via the inside edges of decklid.
Item 1 2
Description Nut Rear Spoiler
3. Lift the spoiler assembly off the decklid, pulling the wiring loom through the hole.
Item 1 2
Description Rear Spoiler Nut
Installation 1. To install, reverse the removal procedure.
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01/2003 2003.0 BA Falcon
501-09-1
Rear View Mirrors
501-09-1
SECTION : 501-09 Rear View Mirrors VEHICLE APPLICATION : 2003.0 BA Falcon CONTENTS
PAGE
SPECIFICATIONS Specifications .........................................................................................................................501-09-2 DESCRIPTION AND OPERATION Rear View Mirrors ..................................................................................................................501-09-3 DIAGNOSIS AND TESTING Rear View Mirrors ..................................................................................................................501-09-4 Inspection and Verification ...................................................................................................501-09-4 Symptom Chart ....................................................................................................................501-09-4 Connector Circuit Reference ................................................................................................501-09-6 Pinpoint Tests ......................................................................................................................501-09-7 REMOVAL AND INSTALLATION Power Mirror Switch ............................................................................................................501-09-12 Exterior Mirror Glass ...........................................................................................................501-09-13 Exterior Mirror & Round Plug in Door Trim ..........................................................................501-09-14 Interior Rear View Mirror .....................................................................................................501-09-14 Ambient Temperature Sensor ..............................................................................................501-09-14
01/2003 2003.0 BA Falcon
501-09-2
Rear View Mirrors
501-09-2
SPECIFICATIONS Torque Specifications Description Exterior rear view mirror screws (Part No:V810181)
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Nm 3-5
01/2003 2003.0 BA Falcon
501-09-3
Rear View Mirrors
501-09-3
DESCRIPTION AND OPERATION
Rear View Mirrors The rear view mirrors consist of the following components: exterior rear view mirrors (standard electric operation or memory operation) exterior mirror control switch door switch control module (memory mirrors only) interior rear view mirror integral ambient temperature sensor in LH exterior mirror only The exterior rear view mirrors are adjusted by the exterior mirror control switch or via the memory seat/mirror function buttons.
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01/2003 2003.0 BA Falcon
501-09-4
Rear View Mirrors
501-09-4
DIAGNOSIS AND TESTING
Rear View Mirrors Refer to Wiring Diagram Section for schematic and connector information. Special Tool(s) 73III Automotive Meter 105-R0057 or equivalent
Inspection and Verification 1. Verify the customer concern by operating the system, using appropriate standard mirror or memory mirror flowchart.
2. Visually inspect for obvious signs of mechanical and electrical damage. Visual Inspection Chart Mechanical Electrical Exterior rear view Central junction box mirror(s) (CJB) Fuse: RADIO No.2 7.5A Circuitry Exterior rear view mirror motor(s) Exterior mirror control switch 3. If an obvious cause for an observed or reported concern is found, correct the cause (if possible) before proceeding to the next step. 4. If the concern is not visually evident, determine the symptom and proceed to the Fault Diagnosis Tables.
Symptom Chart NOTE: Refer to fault diagnostic tables (Standard mirror & Memory mirror). Standard Mirror Fault Diagnostic Flow Chart
1) Are both mirrors operational ?
No
Switch vehicle electrics on via ignition. Operate both LH & RH mirrors via door mirror control switch. Both mirrors non-functional. Check fuse for mirror system at fusebox GO to Step 2. One mirror non-functional. Remove mirror & check for +12V & GND at door connector using multimeter whilst operating mirror switch (Refer to pinpoint tests A3 & B1) Go to Step 6. No system mulfunction Replace fuse and retest. Go to Step 3. Remove mirror switch and check for +12V and GND at connector using multimeter. Refer pinpoint test A1 and A2. Go to Step 4. Remove mirror switch and check for +12V and GND at connector using multimeter. Refer pinpoint test A1 and A2. Go to Step 4. No system mulfunction Possible wiring malfunction. Check for continuity from fuse/GND to corresponding pins at switch connector Repair discontinuous wiring. Recheck operation of mirrors via switch. Go to Step 5. Replace faulty switch. Recheck operation of mirrors via switch. Go to Step 5. Replace door mirror and retest. Go to Step 7.
Yes
No system mulfunction
No No
2) Is fuse intact ?
3) Is system functioning correctly ?
4) Is +12V and GND available at switch ?
Yes No Yes No Yes No
Yes 5) Is system functioning correctly ?
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01/2003 2003.0 BA Falcon
501-09-5
Rear View Mirrors
501-09-5
DIAGNOSIS AND TESTING (Continued) 6) Is +12V and GND available at door/mirror connector ? 7) Does new mirror or switch function correctly ?
No
Replace mirror control switch and retest. Go to Step 7.
Yes Yes
Replace door mirror and retest. Go to Step 7. No system mulfunction
Memory Exterior Mirror Fault Diagnostic Flow Chart NOTE: Various memory positions for seats and mirrors must be selected and stored in seat module prior to commencement of checklist, as long as the system is (partially) operating.
1) Are both mirrors operational ?
No
No Yes 2) Do both mirrors and seats operate ? 3) Do both mirrors operate?
No Yes No Yes
4) Is +12V and GND available at connector ? 5) Does replaced mirror function ? 6) Do seats and mirrors move ?
No Yes No Yes No Yes
7) Do mirrors operate with new switch ? 8) Do mirrors work with new module ?
No Yes No Yes
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Switch vehicle electrics on via ignition. Operate both LH & RH mirrors via door mirror control switch. Both mirrors non-functional. Check fuses for mirrors and seat control module. Press seat/mirror memory buttons and check for seat and mirror movement. GO to Step 6. One mirror only works. Press seat/mirror memory buttons and check for seat and mirror movement. Go to Step 3. Both mirrors functional. Press seat/mirror buttons and check for seat and mirror movement. Go to Step 2. Refer to Seat module diagnostics and replace module if necessary and retest. No system mulfunction Remove suspect mirror and check for +12V and ground at door/mirror connector. (Refer pinpoint test D1 & D2). Go to Step 4. Possible faulty door switch module. Replace module 1R23 17E704 AA. Go to Step 8. Trace power and ground supply from door connector to source and repair. Replace faulty mirror and retest. Go to Step 5. Refer to Seat module diagnostics and replace module if necessary and retest. No system mulfunction Refer to Seat module diagnostics and replace module if necessary and retest. Possible faulty door mirror switch. Replace switch. Go to Step 7. Possible faulty door switch module. Replace module 1R23 17E704 AA. Go to Step 8. No system mulfunction Refer to Seat module diagnostics and replace module if necessary and retest. No system mulfunction
01/2003 2003.0 BA Falcon
501-09-6
Rear View Mirrors
501-09-6
DIAGNOSIS AND TESTING (Continued) Connector Circuit Reference C86
Pin Number(s) 1 2 3
Circuit Designation/Description Normal Condition/Measurement Circuit 540A (R) 0 voltage, less than 5 ohms between power mirror switch and right front mirror motor Circuit 541B (L) 0 voltage, less than 5 ohms between power Mirror x direction control mirror switch and right front mirror motor Circuit 544A (V) 0 voltage, less than 5 ohms between power Mirror y direction control mirror switch and right front mirror motor
C88
Pin Number(s) 1 2 3 4 5 6 7
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Circuit Designation/Description Circuit 299 (V-R) Power mirror switch power input Circuit 57F (B) Power mirror switch ground Circuit 540B (R) Circuit 541A (L) Right mirror x direction control Circuit 541B (L) Left mirror x direction control Circuit 544A (V) Right mirror y direction control Circuit 544B (V) Left mirror y direction control
Normal Condition/Measurement 0 voltage, less than 5 ohms between the power mirror switch and ignition switch 0 voltage, less than 5 ohms between and chassis ground 0 voltage, less than 5 ohms between power mirror switch and front mirror motors 0 voltage, less than 5 ohms between power mirror switch and right front mirror motors 0 voltage, less than 5 ohms between power mirror switch and left front mirror motors 0 voltage, less than 5 ohms between power mirror switch and right front mirror motors 0 voltage, less than 5 ohms between power mirror switch and left front mirror motors
01/2003 2003.0 BA Falcon
501-09-7
Rear View Mirrors
501-09-7
DIAGNOSIS AND TESTING (Continued) C94
Pin Number(s) 1 2 3
Circuit Designation/Description Normal Condition/Measurement Circuit 540A (R) 0 voltage, less than 5 ohms between power mirror switch and left front mirror motor Circuit 541 (L) 0 voltage, less than 5 ohms between power Mirror x direction control mirror switch and left front mirror motor Circuit 544 (V) 0 voltage, less than 5 ohms between power Mirror y direction control mirror switch and left front mirror motor
C377
Pin Number(s) 1 2 3
Circuit Designation/Description Normal Condition/Measurement Circuit 540A (R) 0 voltage, less than 5 ohms between power mirror switch and left front mirror motor Circuit 541 (L) 0 voltage, less than 5 ohms between power Mirror x direction control mirror switch and left front mirror motor Circuit 544 (V) 0 voltage, less than 5 ohms between power Mirror y direction control mirror switch and left front mirror motor
Pinpoint Tests STANDARD MIRROR (NON MEMORY) PINPOINT TEST A : THE MIRRORS ARE INOPERATIVE Test Step A1
Result / Action to Take
CHECK CIRCUIT 299 (V/R) FOR VOLTAGE Disconnect Exterior Mirror Control Switch. Key in ON position. Measure voltage between exterior mirror control switch Connector C88, Circuit 299 (V/R), harness side and ground. Is the voltage greater than 10 volts?
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Yes
Go to A2.
No
REPAIR the circuit. TEST the system for normal operation.
01/2003 2003.0 BA Falcon
501-09-8
Rear View Mirrors
501-09-8
DIAGNOSIS AND TESTING (Continued) Test Step A2
Result / Action to Take
CHECK CIRCUIT 57 B/F (B) FOR AN OPEN
Yes
Measure the resistance between exterior mirror control switch Connector C88, Circuit 57(B/F), harness side and ground.
Go to A3.
Is the resistance less than 5 ohms?
No
REPAIR the circuit. TEST the system for normal operation.
A3
CHECK CIRCUIT 540 (R) FOR OPEN Disconnect Inoperative Exterior Rear View Mirror/s C520. Measure the resistance between inoperative rear view mirror Connector (C86/C94/C377) and mirror control switch Connector C88, Circuit 540 (R).
Yes
INSTALL a new exterior mirror control switch. TEST the system for normal operation.
No
REPAIR the circuit. TEST the system for normal operation.
Is the resistance less than 5 ohms?
PINPOINT TEST B : A SINGLE MIRROR IS INOPERATIVE Test Step B1
Result / Action to Take
CHECK CIRCUITS 541 (L) AND 544 (V) FOR VOLTAGE Disconnect Inoperative Exterior Rear View Mirror Connector.
Go to A3.
Key in ON position. Select the inoperative mirror on the exterior mirror control switch. Measure the voltage between the inoperative exterior rear view mirror connector, harness side and ground while operating the exterior mirror control switch to the specified direction.
Driver mirror
Passenger mirror
C86 circuit 541
C94/C377 circuit 541 C94/C377 circuit 544
C86 circuit 544
Yes No
Go to B2.
Mirror control direction UP RIGHT
Are the voltages greater than 10 volts?
B2
CHECK FOR AN OPEN CIRCUIT
Yes
Key in OFF position. Disconnect Exterior Mirror Control Switch C88.
INSTALL a new exterior mirror control switch. TEST the system for normal operation.
Measure the resistance between the inoperative exterior rear view mirror connector, harness side and exterior mirror control switch connector, harness side.
No
REPAIR the suspect circuit. TEST the system for normal operation.
Circuit Driver 541 A (L) 544 A (V) Passenger 544 B (V) 541 B (L) Are all of the resistances less than 5 ohms?
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01/2003 2003.0 BA Falcon
501-09-9
Rear View Mirrors
501-09-9
DIAGNOSIS AND TESTING (Continued) Test Step B3
Result / Action to Take
CHECK CIRCUIT 540 (R) FOR OPEN Disconnect Inoperative Exterior Rear View Mirror/s. Measure the resistance between the inoperative exterior rear view mirror connector, circuit 540 (R), harness side and exterior mirror control switch C88, circuit 540 (R), harness side. Is the resistance less than 5 ohms?
G90852 en
Yes
INSTALL a new exterior rear view mirror. Refer to Exterior Mirror in this section. TEST the system for normal operation.
No
REPAIR the circuit. TEST the system for normal operation.
01/2003 2003.0 BA Falcon
501-09-10
Rear View Mirrors
501-09-10
DIAGNOSIS AND TESTING (Continued) PINPOINT TEST C : A SINGLE MIRROR DOES NOT FUNCTION WITH SWITCH LOGIC Test Step C1
Result / Action to Take
CHECK FOR THE CORRECT INPUT TO THE EXTERIOR REAR VIEW MIRROR
Yes
Disconnect Inoperative Exterior Rear View Mirror. Key in ON position. Select the inoperative exterior rear view mirror on the exterior mirror control switch. Measure the voltage or resistance between the suspect exterior rear view mirror connector, harness side and ground while operating the exterior mirror control switch to the specified position. Refer to the following chart:
Exterior mirror Connector
Circuit
C86
Mirror control position Driver 540 A Down
C86
540 A
Up
C86
540 A
Right
C86
540 A
Left
C86/C94/C377
Driver and Passenger 541 A/B Up
C86/C94/C377
541 A/B
Down
C86/C94/C377
541 A/B
Left
C86/C94/C377
541 A/B
Right
C94/C377
Passenger 540 B Down
C94/C377
540 B
Up
C94/C377
544 B
Right
C94/C377
544 B
Left
INSTALL a new exterior rear view mirror. Refer to Exterior Mirror in this section. TEST the system for normal operation.
No
Go to C2.
Measurement
Greater than 10 volts Less than 50 ohms Greater than 10 volts Less than 50 ohms Greater than 10 volts Less than 50 ohms Greater than 10 volts Less than 50 ohms Greater than 10 volts Less than 50 ohms Greater than 10 volts Less than 50 ohms
Are the measurements as indicated?
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01/2003 2003.0 BA Falcon
501-09-11
Rear View Mirrors
501-09-11
DIAGNOSIS AND TESTING (Continued) Test Step C2
Result / Action to Take
CHECK THE EXTERIOR REAR VIEW MIRROR CIRCUITS FOR A SHORT TO GROUND Yes
Key in OFF position. Disconnect Exterior Mirror Control Switch C88.
INSTALL a new exterior mirror control switch. TEST the system for normal operation.
Measure the resistance between the exterior rear view mirror connector, harness side and ground. Refer to the following chart:
No
Exterior mirror pin
REPAIR the suspect circuit. TEST the system for normal operation.
Circuit Driver
C86 C86 C86
540 A 541 A 544 A Passenger
C94/C377 C94/C377 C94/C377
540 B 541 B 544 B
Are all of the resistances greater than 10,000 ohms?
MEMORY MIRROR PINPOINT TEST D : THE MIRRORS ARE INOPERATIVE Test Step D1
Result / Action to Take
CHECK CIRCUIT 541 A/B (R) FOR VOLTAGE Disconnect Exterior Mirror Connector. Key in ON position.
Yes
Go to D2.
Measure voltage between exterior mirror Connector C377/C86, Circuit No Trace power supply from mirror connector to 541 A/B, harness side and ground. source and repair. (Refer to Seat Module Is the voltage greater than 10 volts? Diagnostics + Repair).
D2
CHECK CIRCUIT 544 A/B (R) FOR AN OPEN Disconnect Exterior Mirror Control Switch. Key in ON position. Measure the resistance between exterior mirror Connectors C86/C377, harness side and ground. Is the resistance less than 50 ohms?
Yes
Replace faulty mirror and retest.
No
Trace ground supply from mirror connector to source and repair. (Refer to Seat Module Diagnostics + Repair).
PINPOINT TEST E : TEMPERATURE SENSOR — AMBIENT (part of LH exterior mirror assembly) NOTE: For diagnosis and testing of the ambient temperature sensor which is an integral part of the LH exterior mirror assembly, refer to the section 412-04, Pinpoint test A.
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01/2003 2003.0 BA Falcon
501-09-12
Rear View Mirrors
501-09-12
REMOVAL AND INSTALLATION 6. Gently pull the wiring harness connector from its socket. (It may be necessary to use the screwdriver as a lever, to allow the switch socket Removal enough gap to clear the barbed lock tag of the 1. Remove the door trim as per Section 501-5. harness connector). Be extremely careful when removing the harness connector from the socket WARNING: Do not attempt to remove the by making sure the two halves of the switch do mirror switch before the trim has been not break away and separate. removed. Installation 2. Once the door trim is removed from the door, support the trim by taking care to make sure that 1. Reassemble the door trim to the door making sure it is not pulling against the power mirror switch the wiring harness for the mirror switch is fed and the wiring harness through the hole for the mirror switch. 3. Remove the mirror switch from the door trim by 2. When the trim has been reassembled to the door, pushing firmly and evenly on the flat base of the fit the mirror switch last. switch until it pops out from the trim. Gently push 3. Connect the protruding wiring harness and the two mirror retaining clips inwards so that the connector to the switch socket. ends are clear of the hole and push the switch out 4. Carefully feed the mirror switch into the door trim from the cut out. and match the switch locator with the locating slot 1. If door switch is difficult to remove then insert in the trim. a fine, flat blade screwdriver where the 5. Push down firmly on the outside of the mirror retaining clips are and gently push up on the switch until it pops into place. DO NOT PUSH mirror switch. DOWN ON THE SWITCH ADJUSTER KNOB.
Power Mirror Switch
4. Pull the switch through the trim hole so there is enough room to be ableto access the rear of the switch and harness connector and socket. 5. Insert a fine, flat blade screwdriver into the harness connector near the barbed lock tag and support the lower switch body.
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WARNING: Warranty claims for power mirror switches returned with a broken switch base as a reult of incorrect removal will not be accepted as a warrantable defect. Supplier assessment for functional faults in the manufacture of the switch is not when the switch is broken at the base. Warranty Status - Reimbursable within the provisions of the Warranty and Policy Manual. Damage to the switch through not using the correct removal procedure is not warrantable.
01/2003 2003.0 BA Falcon
501-09-13
Rear View Mirrors
501-09-13
REMOVAL AND INSTALLATION (Continued)
Exterior Mirror Glass Removal 1. Remove broken glass and backing plate.
2. Remove spring wire taped to rear surface of backing plate. Re-install spring wire into spring housing on rear surface of backing plate.
4. Cover glass surface with cloth and apply even pressure to engage all clips. Manually adjust the glass angle outward and confirm that the wire spring is positioned correctly in guide track.
5. Check mirror glass operation. If glass vibrates when adjusted, or if inward movement is restricted, repeat steps 1 to 4 to ensure correct wire spring position and that clips are fully engaged. Installation 1. Reverse the removal instruction.
Exterior Mirror & Round Plug in Door Trim Removal 1. Remove interior triangular trim panel to access rear of mirror assembly. 2. Remove mirror retaining screws and remove mirror assembly. 3. Position spring into guide track and align backing plate clips with slots on the mirror adaptor plate.
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CAUTION: Do not drop screws into door.
01/2003 2003.0 BA Falcon
501-09-14
Rear View Mirrors
501-09-14
REMOVAL AND INSTALLATION (Continued) 3. Disconnect electrical connector from mirror assembly. (Small screwdriver required for temperature sensor 6 pin connector (C377) LH mirror only.
Installation 1. Reverse the removal instruction.
Interior Rear View Mirror NOTE: The interior rear view mirror is adhered to the windscreen and should not be removed due to the possibility of cracking the windscreen.
Ambient Temperature Sensor The Ambient Temperature Sensor is integral in the left hand exterior mirror. The sensor is not a serviceable item, and if faulty, the complete LH external mirror assembly should be replaced.
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01/2003 2003.0 BA Falcon
501-10-1
Seating
501-10-1
SECTION : 501-10 Seating VEHICLE APPLICATION : 2003.0 BA Falcon CONTENTS
PAGE
SPECIFICATIONS Specifications ........................................................................................................................501-10-2 DESCRIPTION AND OPERATION Seating ..................................................................................................................................501-10-3 Seats ....................................................................................................................................501-10-3 DIAGNOSIS AND TESTING Seats .....................................................................................................................................501-10-4 Inspection and Verification ...................................................................................................501-10-4 Symptom Chart ....................................................................................................................501-10-4 Connector Circuit Reference ................................................................................................501-10-6 Pinpoint Tests ....................................................................................................................501-10-12 REMOVAL AND INSTALLATION Front Seat Assembly ...........................................................................................................501-10-18 Rear Seat Cushion ..............................................................................................................501-10-19 Rear Seat Bolster ................................................................................................................501-10-19 Rear Seat Back ...................................................................................................................501-10-19 DISASSEMBLY AND ASSEMBLY Front Head Restraint ...........................................................................................................501-10-21 Back Cover .........................................................................................................................501-10-21 Headrest Guides .................................................................................................................501-10-22 Lumbar Knob ......................................................................................................................501-10-22 Inner Side Cover .................................................................................................................501-10-23 Recliner Knob and Outer Side Cover ..................................................................................501-10-23 Front Seat Back ..................................................................................................................501-10-24 Airbag ..................................................................................................................................501-10-26 Front Seat Back Trim Cover ...............................................................................................501-10-27 Pre-tensioner ......................................................................................................................501-10-28 Seat Operating Switch ........................................................................................................501-10-29 Memory Module ..................................................................................................................501-10-29 Front Seat Cushion (2-way) ................................................................................................501-10-30 Front Seat Cushion (4-way & 6-way non-memory) ............................................................501-10-30 Front Seat Cushion (6-way memory) ..................................................................................501-10-31
01/2003 2003.0 BA Falcon
501-10-2
Seating
501-10-2
SPECIFICATIONS General Specifications Description Front seat track travel Fore/aft Front seat front height travel Front seat rear height travel Headrest height travel Torque Specifications Description Cushion to tracks Front seat back to cushion Pre-tensioner bolt SIAB nut to FSB frame Front seat to floor bolt
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Specification(mm) 264 55 55 50 Nm 28 ± 4 32 ± 5 33 ± 3 5.4 ± 0.9 35 ± 5
01/2003 2003.0 BA Falcon
501-10-3
Seating
501-10-3
DESCRIPTION AND OPERATION
Seating Seats The front seats are of a steel frame construction and have a sprung suspension mat in the seat cushion and a sprung mat with an adjustable lumbar section in the seat back (where applicable). Seat adjustments improve occupant comfort and the key features are summarized below: Pull up towel bar at front of seat cushion to facilitate fore/aft manual travel adjustment Raise/Lower switch knob at side of seat cushion to raise/lower seat height (independent front & rear) Slide fore/aft switch knob at side of seat cushion for fore/aft electrical travel 6-way power seat Rotate knob at side of seat for recline adjustment Rotate knob at side of seat for lumbar adjustment Push handle at side of seat for dump forward of seat back (utility only) Vertically adjustable head rest. When specified, a side impact bag is packaged in the seat back to maximize occupant protection.
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01/2003 2003.0 BA Falcon
501-10-4
Seating
501-10-4
DIAGNOSIS AND TESTING
Seats Inspection and Verification 1. Verify the customer concern by operating the system. 2. Visually inspect for obvious signs of mechanical or electrical damage. 3. If an obvious cause for an observed or reported concern is found, correct the cause (if possible) before proceeding to the next step. 4. If the concern is not visually evident, verify the Symptom Chart.
Visual Inspection Chart Mechanical Seat tracks obstructed or damaged Seat base track alignment Mechanical linkage(s) obstructed or damaged Seat frame alignment Internal operating cables obstructed, damaged or broken
Electrical Fuse(s) Wiring harness Loose or corroded connector(s) Motor(s) Multifunction switch Damaged connector(s) Memory button(s) LED
Symptom Chart Condition
Source
Action
The power seat is inoperative
Connector(s) Circuit
Go to PinPoint Test A.
The power seat moves but is noisy
Seat base assembly Motor(s)
Go to PinPoint Test B.
The power seat moves but is loose
Seat track(s) Seat base assembly
Go to PinPoint Test C.
The power seat does not make full travel
Fastening hardware Seat base assembly Circuit
Check Diagnostics then Go to PinPoint Test D.
The pedal does not remember stored positions
Circuit Potentiometer
Go to PinPoint Test E
The power seat does not move horizontally/vertically
Motor(s) Connector(s) Switch pack
Check diagnostics then Go to PinPoint Test F.
The power seat does not recline (10 way seat only)
Connector(s) Switch pack Motor
Check diagnostics then Go to PinPoint Test G.
The power lumbar is inoperative (10 way seat only)
Motor Connector(s) Circuit Switch pack Seat lumbar assembly
Check diagnostics then Go to PinPoint Test H.
Memory recall is inoperative
Connector(s) Memory buttons
Check diagnostics then Go to PinPoint Test I.
Priority recall is inoperative
Connector(s) Circuit
Check diagnostics then Go to PinPoint Test I.
Mirror dip is inoperative
Connector(s) Circuit
Check diagnostics then Go to PinPoint Test K.
NOTE: Put the seat into Diagnostic mode: Checking Diagnostic Trouble Codes Entering Diagnostics Step 1 2
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Do Ignition on Using the Ford service tool, select to enter plant mode
Seat does No change from previous state Seat will flash out DTC
01/2003 2003.0 BA Falcon
501-10-5
Seating
501-10-5
DIAGNOSIS AND TESTING (Continued)
Phase 1 2 3 4 5
Diagnostic Flash Code Phases Seat does Flash out high value (count number of times light turns off). Green light ON for about 1 second. Flash out low value(count number of times light turns off). Green light ON for about 3 seconds. Pressing memory button ‘2’ will go to the next DTC. Return to phase 1 and start again
NOTE: Check codes against table. Diagnostic Test Codes
1 1 1 1 1 1 2 2 2 2 2 3
Flash Codes First group Second group 1 2 3 4 5 6 1 2 3 5 6 1
3
2
3 3 3 3
3 4 5 6
6 6
3 6
Code 6 way seat 10 way seat No Priority Data No Priority Frame Synchronisation No Ignition No Reverse No Fore lift motor sensor No Aft lift motor sensor No Track motor sensor No Recliner motor sensor No lumbar motor sensor Button stuck (Memory) Button stuck (Position, including lumbar) Button stuck (Pedals) LH mirror not responding or faulty RH mirror not responding or faulty Mirror button pack not responding or faulty Internal error End of errors
Action Ensure seat is 6 way. Ensure seat is 10 way. Go to J1. Go to J1. Go to K1. Go to K1. Go to I1. Go to I1. Go to D3&I1. Go to I1. Go to I1. Replace button/board which ever is at fault. Replace switch pack. Replace button. Replace Mirror. Replace Mirror. Replace Mirror botton pack. Replace Module. No Action
NOTE: After finishing repeat to ensure DTC is current fault code.
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01/2003 2003.0 BA Falcon
501-10-6
Seating
501-10-6
DIAGNOSIS AND TESTING (Continued) Connector Circuit Reference Seat Power
Pin Number(s) 1 2 3 4
Circuit Designation/Description Circuit 1 (Black) ~0V Ground Circuit 2 (Red) >10V Power Circuit 3 (Green/Pink) Polack Circuit 4 (pink/Orange) Polack
Normal Condition/Measurement
Circuit Designation/Description Circuit 1 (Green) AI reserved Circuit 2 (Black/Blue) Ignition Circuit 3 (Black/Red) Reverse Circuit 4 (Black/White) Mirror Ground Circuit 5 (Green/Black) Mirror Power Circuit 6 (Black/Yellow) Electronics Ground Circuit 7 Not Connected Circuit 8 (Red/Orange) Priority Data
Normal Condition/Measurement
Vehicle Inputs
Pin Number(s) 1 2 3 4 5 6 7 8
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>10V if ignition on >10V if in Reverse ~0V >0V when seat LED on ~0V
Refer to DTC
01/2003 2003.0 BA Falcon
501-10-7
Seating
501-10-7
DIAGNOSIS AND TESTING (Continued) Pin Number(s) 9 10
Circuit Designation/Description Normal Condition/Measurement Circuit 9 (White/Pink) Refer to DTC Priority FS Circuit 10 (Yellow/Grey) Refer to DTC Mirror Data
Pedal Memory
Pin Number(s) 1 2 3 4 5 6
Circuit Designation/Description Circuit 1 (Blue/Yellow) Pedal Fwd Circuit 2 (Black/Brown) Pedal Bwd Circuit 3 (Yellow) Pedal Pot Circuit 4 (Red/Black) Pedal Pot Circuit 5 (Grey/Black) Pedal Motor Circuit 6 (Black/White) Pedal Motor
Normal Condition/Measurement 12V if selected 12V if selected 0 to 4.5KΩ 0 to 4.5KΩ 12V or 0V 0V to 12V
Module Power Connector A
Pin Number(s) 1 2 3 4 5
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Circuit Designation/Description Circuit 1 (Red) Power Circuit 2 (Green/Yellow) Rear Lift Motor Circuit 3 (Brown/Green) Rear Lift Motor Circuit 4 (Blue/Red) Front Lift Motor Circuit 5 (Green/Pink) Track Motor
Normal Condition/Measurement >10V 0 or 12V 0 or 12V 0 or 12V 0 or 12V
01/2003 2003.0 BA Falcon
501-10-8
Seating
501-10-8
DIAGNOSIS AND TESTING (Continued) Pin Number(s) 6 7 8 9 10 11 12
Circuit Designation/Description Circuit 6 Not Connected Circuit 7 (Black) Ground Circuit 8 (Black/Yellow) Electronics GND Circuit 9 (Grey) Track Motor Circuit 10 (Black/White) Pedal Motor Circuit 11 (Black/Blue) Front Lift Motor Circuit 12 (Grey/Black) Pedal Motor
Normal Condition/Measurement 0V 0V 0 or 12V 0 or 12V 0 or 12V 0 or 12V
Module Power Connector B
Pin Number(s) 1 2 3 4 5 6 7 8 9 10 11 12 13 14
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Circuit Designation/Description Circuit 1 (Brown) Front Lift Pot Circuit 2 (Green/Violet) Rear Lift Pot Circuit 3 (Black/Orange) Track Pot Circuit 4 (Blue/Green) Track Pot Circuit 5 (Red/Orange) Priority Data Circuit 6 (white/Pink) Priority FS Circuit 7 (Black/Red) Reverse Circuit 8 Not Connected Circuit 9 (Black/White) Mirror Ground Circuit 10 (Blue) Memory Scan Circuit 11 (Brown/Black) Position Scan Circuit 12 Not Connected Circuit 13 (Red/Black) Pedal Pot Circuit 14 (Yellow) Pedal Pot
Normal Condition/Measurement 0 to 10KΩ 0 to 10KΩ 0 to 10KΩ 0 to 10KΩ Refer to DTC Refer to DTC >10V
0V 0V 0V
0 to 10KΩ 0 to 10KΩ
01/2003 2003.0 BA Falcon
501-10-9
Seating
501-10-9
DIAGNOSIS AND TESTING (Continued) Pin Number(s) 15 16
Circuit Designation/Description Normal Condition/Measurement Circuit 15 (Brown/Blue) Refer to cct1 Front Lift Pot Circuit 16 (Green/Red) Refer to cct2 Rear Lift Pot
Lift Motor Connectors
Pin Number(s) 1 2 3 4
Circuit Designation/Description Circuit 1 (Blue/Red) Front Lift Motor Circuit 2 (Black/Blue) Front Lift Motor Circuit 3 (Green/Yellow) Rear Lift Motor Circuit 4 (Brown/Green) Rear Lift Motor
Normal Condition/Measurement 0 or 12V 0 or 12V 0 or 12V 0 or 12V
Track Motor Connector
Pin Number(s) 1 2
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Circuit Designation/Description Normal Condition/Measurement Circuit 1 (Grey) 0 or 12V Track Motor Circuit 2 (Green/Pink) 0 or 12V Track Motor
01/2003 2003.0 BA Falcon
501-10-10
Seating
501-10-10
DIAGNOSIS AND TESTING (Continued) Motor Potentiometer Connectors
Pin Number(s) 1 2 3 4 5 6 7 8
Circuit Designation/Description Circuit 1 (Black/Orange) Track Pot Circuit 2 (Blue/Green) Track Pot Circuit 3 (Brown) Front Lift Pot Circuit 4 (Brown/Blue) Front Lift Pot Circuit 5 Not Connected Circuit 6 Not Connected Circuit 7 (Green/Violet) Rear Lift Pot Circuit 8 (Green/Red) Rear Lift Pot
Normal Condition/Measurement 0 to 10kΩ 0 to 10kΩ 0 to 10kΩ 0 to 10kΩ
0 to 10kΩ 0 to 10kΩ
Lumbar & Recliner Connector
Pin Number(s) 1 2 3 4 5 6
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Circuit Designation/Description Circuit 1 (Violet/Green) Backrest Motor Circuit 2 (Pink/Orange) Backrest Motor Circuit 3 (Blue/Whiten) Lumbar Motor Circuit 4 (Green/Brown) Backrest Pot Circuit 5 (Orange/Brown) Backrest Pot Circuit 6 (Blue/Violet) Lumbar Pot
Normal Condition/Measurement 0 to 12V 0 to 12V 0 to 12V 0 to 10kΩ 0 to 10kΩ 0 to 10kΩ
01/2003 2003.0 BA Falcon
501-10-11
Seating
501-10-11
DIAGNOSIS AND TESTING (Continued) Pin Number(s) 7 8
Circuit Designation/Description Normal Condition/Measurement Circuit 7 (Violet/Blue) 0 to 10kΩ Lumbar Pot Circuit 8 (White/Blue) 0 to 12V Lumbar Motor
Lumbar & Recliner Module Connector
Pin Number(s) 1 2 3 4 5 6 7 8 9 10 11 12
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Circuit Designation/Description Circuit 1 (Pink/Orange) Backrest Motor Circuit 2 (White/Blue) Lumbar Motor Circuit 3 (Violet/Blue) Lumbar Pot Circuit 4 (Green/Brown) Backrest Circuit 5 (White/Brown) Lumbar Scan Circuit 6 (Orange/Brown) Backrest Pot Circuit 7 (Blue/White) Lumbar Motor Circuit 8 (Violet/Green) Backrest Motor Circuit 9 (Blue/Orange) Lumbar Pot Circuit 10 (Blue/Orange) Lumbar Down Circuit 11 Not Connected Circuit 12 (Orange/Blue) Lumbar Up
Normal Condition/Measurement 0 or 12V 0 or 12V 0 to 20kΩ 0 to 10kΩ 0V Refer to cct4 0 or 12V 0 or 12V Refer to cct 3 open cct or 0V
open cct or 0V
01/2003 2003.0 BA Falcon
501-10-12
Seating
501-10-12
DIAGNOSIS AND TESTING (Continued) Pinpoint Tests PINPOINT TEST A : THE POWER SEAT IS INOPERATIVE Test Step A1
Result / Action to Take
CHECK FOR POWER AT SEAT Measure the voltage between the power pins on connectors CON-1 pins 1 and 2, CON-1 pin 1 and CON-2 pin 6.
Yes
Is the voltage greater than 10 volts?
No
Go to A2
Replace the fuse if CON-1 problem. Check BEM if CON-2 problem.
A2
CHECK CONNECTION AND CIRCUIT CONTINUITY Measure voltage between the power and grounds on the module connector, CON-4 pins 1 and 8 also 1 and 7. Is the voltage within 0.5 of a volt of that measured in A1?
Yes
Replace the harness. Refer to removal and installation instructions in this chapter.
No
Replace seat module. Refer to removal and installation instructions in this chapter.
PINPOINT TEST B : THE POWER SEAT MOVES BUT IS NOISY Test Step B1
Result / Action to Take
VISUAL INSPECTION FOR OBSTRUCTION IN SEAT TRACKS Inspect upper and lower seat track area for any foreign matter such as biros, coins, etc. Was foreign matter or debris found in the seat tracks?
Yes
Remove any obstructions from the seat tracks that could affect seat movement.
No
Go to B2
B2
VISUAL INSPECTION FOR POWER SEAT MOVEMENT OBSTRUCTION Check under the seat for anything that could affect seat movement, such as accessory floor mats, etc.
Yes
Was an obstruction found?
No
Remove all obstructions.
Apply Grease, “SHELL ALVANIA RL2” onto the sliding areas of the seat tracks. NOTE: Care should be taken not to apply excess grease to the tracks as excessive grease could transfer to the carpet.
PINPOINT TEST C : THE POWER SEAT MOVES BUT IS LOOSE Test Step C1
Result / Action to Take
SEAT LOWER TRACK TO FLOOR Yes
Check tightness of the bolts used to retain the seat tracks to the vehicle floor.
Go to C2
Were the bolts tight?
No
Tighten the seat mounting bolts to 35 ± 5 NM.
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Seating
501-10-13
DIAGNOSIS AND TESTING (Continued) Test Step C2
Result / Action to Take
SEAT UPPER TRACK TO SEAT Check the tightness of the nuts used to retain the seat tracks to the seat cushion frame.
Yes
Were the nuts tight?
No
Go to C3
Tighted the nuts to 28 ± 4 NM.
C3
SEAT TRACK CONDITION Carry out a visual inspection using a torch of the seat track assembly for any physical damage. Is damage evident?
Yes
Remove the seat assembly and replace the seat track assembly. Refer to removal and installation instructions in this chapter .
No
Go to C4
C4
SEAT TRACK BALL BEARING CHECK Using an assistant, grasp the seat backrest and move backwards and forwards by hand to check for excessive movement. While the assistant is moving the seat backrest, use a torch to view the seat tracks look for excessive movement between the upper and lower rail.
Yes
Replace the track assembly. Refer to removal and installation instructions in this chapter.
No
Go to C5
NOTE: Carry out this test in 3 positions of the seat, fully forward mid - fully back.
Did your see or feel excessive track movement in any of the 3 positions?
C5
SEAT ASSEMBLY GENERAL MOVEMENT - PART 1 Grasp the seat backrest and move backwards and forwards by hand to check for excessive movement. Is the recliner mechanism loose at the cushion frame?
Yes
Remove the Two (2) plastic side covers and tighten the bolts retaining the seat recliner to the cushion frame. 32 ± 5 Nm.
No
Go to C6
C6
SEAT ASSEMBLY GENERAL MOVEMENT - PART 2 Using an assistant, grasp the seat backrest and move backwards and forwards by hand to check for excessive movement. While the assistant is moving the seat backrest, using a torch to view the under side of the seat to establish at what point the seat movement is happening. Once the movement point is established check for signs of metal fatigue.
Yes
Replace the fatigue affected assembly.
No
The seat, frame and tracks appear to be Okay.
Did you find any signs of metal fatigue?
PINPOINT TEST D : THE POWER SEAT DOES NOT MAKE FULL TRAVEL Test Step D1
Result / Action to Take
UNDER SEAT OBSTRUCTION Check under the seat for an obstruction, such as floor mats, umbrella, Yes first aid kit etc. Remove the obstruction and recheck seat movement. Did you find an obstruction that could cause the seat not to travel the full movement? No Go to D2
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Seating
501-10-14
DIAGNOSIS AND TESTING (Continued) Test Step D2
Result / Action to Take
SEAT TRACK OBSTRUCTION Check in the seat tracks for an obstruction, such as a pen, pencil, coins etc. Did you find an obstruction that could cause the seat tracks not to travel the full movement?
Yes
Remove the obstruction and recheck seat movement.
No
Go to D3
D3
CHECK CIRCUIT CONTINUITY Check for resistance between pot connector and module connector for the effected motor. Track - measure between CON-8 pin 1 and pin 2, also CON-5 pin 3 and pin 4. Front Lift - measure between CON-8 pin 3 and pin 4, also CON-5 pin 1 and pin 15. Rear Lift - measure between CON-8 pin 7 and pin 8, also CON-5 pin 2 and pin 16 Is the difference between readings less than 5 ohms?
Yes
If DTC 23 is active, replace Motor Sensor. If no DTC replace seat module.
No
Replace Harness. Refer to removal and installation instructions in this chapter.
PINPOINT TEST E : THE PEDAL DOES NOT REMEMBER STORED POSITIONS Test Step E1
Result / Action to Take
MEASURE POTENTIOMETER CHANGE AT TWO DIFFERENT PEDAL POSITIONS Remove connector CON-3 and measure the potentiometer resistance at CON-3 between pin 3 and pin 4. Reconnect CON-3 and move the pedal then remove connector CON-3 and re-measure.
Yes
Is the difference in resistance less than 20 ohm’s?
Replace Module. Refer to removal and installation instructions in this chapter.
Replace APM. Section 206-06
No
PINPOINT TEST F : THE POWER SEAT DOES NOT MOVE HORIZONTALLY/VERTICALLY Test Step F1
Result / Action to Take
CONTINUITY MOTOR TO MODULE Yes Measure the harness resistance between the motor and the module. Go to F2 Track - measure between CON-7 pin 1 and CON-4 pin 9, also CON-7 pin 2 and CON-4 pin 5. No Front Lift - measure between CON-6 pin 1 and CON-4 pin 4, Replace Harness. Refer to removal and also CON-7 pin 2 and CON-4 pin 11. installation instructions in this chapter. Rear Lift - measure between CON-7 pin 3 and CON-4 pin 2, also CON-7 pin 4 and CON-4 pin 3. Is the resistance less than 5 ohms?
F2
MEASURE MOTOR OUTPUT VOLTAGES
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Disconnect each motor while measuring voltage push appropriate switch. Track - measure between CON-7 pin 1 and pin 2. Front Lift - measure between CON-6 pin 1 and pin 2.
Yes
Rear Lift - measure between CON-7 pin 3 and pin 4. Is the voltage more than 10 volts?
Go to F3
Replace seat motor. Refer to removal and installation instructions in this chapter.
No
01/2003 2003.0 BA Falcon
501-10-15
Seating
501-10-15
DIAGNOSIS AND TESTING (Continued) Test Step F3
Result / Action to Take
CHECK SWITCH FUNCTION Connect a working switch pack to the harness and try to move the seat horizontally and vertically. Did the seat move the effected motor?
Yes
Replace Switch pack. Refer to removal and installation instructions in this chapter.
No
Replace Seat module. Refer to removal and installation instructions in this chapter.
PINPOINT TEST G : THE POWER SEAT DOES NOT RECLINE Test Step G1
Result / Action to Take
MOVEMENT CHECK FOR GOOD SWITCH PACK Replace the switch pack with a known good switch and test if seat still Yes doesn’t recline. Replace Switch pack. Refer to removal and installation instructions in this chapter. Did the recliner move?
No
Go to G2
G2
VOLTAGE CHECK FOR MOTOR Yes Measuring voltage on the motor pins in the backrest connector while pushing the appropriate switch. Measure between CON-9 pin 1 and 2. Replace seat motor. Refer to removal and installation instructions in this chapter. Is the voltage more than 10 volts? No
Go to G3
G3
CONTINUITY BACKREST CONNECTOR TO MODULE Measure the harness resistance between: CON-9 pin 1 to CON-10 pin 8. CON-9 pin 2 to CON-10 pin 1. Is the resistance less than 5 ohm’s?
Yes
Replace Seat module. Refer to removal and installation instructions in this chapter.
No
Replace Harness. Refer to removal and installation instructions in this chapter.
PINPOINT TEST H : THE POWER LUMBAR IS INOPERATIVE Test Step H1
CONTINUITY CHECK SWITCH AND BACKREST CONNECTOR TO MODULE Measure continuity between CON-10 pin 5 and CON-10 pin 12 and CON-10 pin 10 while operating the lumbar. Is the resistance less than 5 ohm’s between pin 5 and one of the other pins while Lumbar is being operated and open CCT when not being operated?
H2
Result / Action to Take
Yes
Go to H2
No
Replace Switch pack. Refer to removal and installation instructions in this chapter.
VOLTAGE CHECK FOR MOTOR Measuring voltage on the motor pins in the lumbar connector while pushing the appropriate switch.CON-9 pins 3 and 8. Is the voltage more than 10 volts?
Yes
Replace motor. Refer to removal and installation instructions in this chapter .
No
Go to H3
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01/2003 2003.0 BA Falcon
501-10-16
Seating
501-10-16
DIAGNOSIS AND TESTING (Continued) Test Step H3
Result / Action to Take
MEMORY BUTTON MOVEMENT CHECK Measure the harness resistance between: CON-9 pin 3 and CON-10 pin 7 CON-9 pin 8 and CON-10 pin 2 Did the lumbar move?
Yes
Replace Harness. Refer to removal and installation instructions in this chapter.
No
Replace Seat Module. Refer to removal and installation instructions in this chapter.
PINPOINT TEST I : MEMORY RECALL IS INOPERATIVE Test Step I1
Result / Action to Take
CONTINUITY FROM POTENTIOMETER FEEDBACK TO MODULE Measure the harness resistance between the Potentiometer and the module. Track - CON-5 pin 3 and 4. Front Lift - CON-5 pin 1 and 15. Rear Lift - CON-5 pin 2 and 16. Recliner - CON-10 pin 4 and 6.
Yes
If any DTC from 21 to 26 is set replace the pot otherwise. Go to I2.
No
Replace Harness. Refer to removal and installation instructions in this chapter.
Lumbar - CON-10 pin 3 and 9. Is the resistance in the range specified by the connector measurement chart?
I2
CHECK BUTTON BOARD Push all 3 memory buttons one at a time. Did chime sound and seat NOT move?
Yes
Replace seat Module. Refer to removal and installation instructions in this chapter.
No
Replace Button Board. Refer to removal and installation instructions in this chapter.
PINPOINT TEST J : PRIORITY RECALL INOPERATIVE Test Step J1
Result / Action to Take
CONTINUITY FROM BODY INTERFACE TO MODULE Measure the harness resistance between: CON-2 pin 8 and CON-5 pin 5. CON-2 pin 9 and CON-5 pin 6. Is the resistance less than 5 ohms?
Yes
If DTC 13 or 14 is set problem is with the BEM ( Section 419-10) else replace seat module. Refer to removal and installation instructions in this chapter.
No
Replace Harness. Refer to removal and installation instructions in this chapter.
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01/2003 2003.0 BA Falcon
501-10-17
Seating
501-10-17
DIAGNOSIS AND TESTING (Continued) PINPOINT TEST K : MIRROR DIP IS INOPERATIVE Test Step K1
Result / Action to Take
CHECK FOR IGNITION FUNCTION Perform a seat recall and activate ignition before recall is complete. Did the seat stop short of the recall position?
Yes
Go to K3
No
Go to K2
K2
CHECK FOR IGNITION AT THE SEAT CONNECTOR Measure the harness voltage at CON-2 pin 2. Is the Voltage >10V?
Yes
If DTC 15 is set problem is with the Harness else replace seat module.
No
Refer to section 501-10.
K3
CHECK FOR REVERSE FUNCTION With Ignition on and PRNDL in Reverse activate the Mirror Dip button, Yes hold the button for 2 seconds to ensure chime will happen even if the Go to K5 function is currently enabled. Did the seat chime?
K4
No
Go to K4
CHECK FOR REVERSE AT THE SEAT CONNECTOR Measure the harness voltage at CON-2 pin 3. Is the Voltage >10V?
Yes
If DTC 16 is set problem is with the Harness else replace seat module.
No
Refer to PCM section 303-14.
K5
CHECK FOR MIRROR OPERATION Program different mirror locations into the memory buttons and then recall each memory position. Did the mirrors move to the correct location?
Yes
Replace Harness. Refer to removal and installation instructions in this chapter.
No
Refer to the Exterior Mirror section 501-09.
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01/2003 2003.0 BA Falcon
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Seating
501-10-18
REMOVAL AND INSTALLATION
Front Seat Assembly
4. Unplug all electrical connectors from outboard underside of seat.
Removal 1. Set seat back angle to vertical position and set height adjustment to full up position. 2. Disconnect the battery. WARNING: Wait at least one minute after disconnecting the battery ground cable before disconnecting any supplemental restraint system electrical connector. Failure to follow this warning could cause premature deployment and may result in personal injury.
NOTE: Number of connectors depend on seat option and may include seat belt pre-tensioner, side airbag, memory and power connectors on outboard side of seat (Refer to Section 501-20a).
3. Remove front and rear plastic track cover by releasing metal spring.
5. Remove four seat mounting bolts.
6. Carefully remove the seat from the vehicle. Installation 1. To install front seat, reverse the removal procedure.
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Seating
501-10-19
REMOVAL AND INSTALLATION (Continued)
Rear Seat Cushion
2. Press spring clip down to release.
Removal 1. To remove rear seat cushion push each side back and up to release floor clips.
3. Pull bolster forward to remove, disengage plastic hook at bottom. Installation 1. Ensure that rear metal loop is engaged in sheet metal as shown and push each side down to engage floor clip.
Installation 1. To install, reverse the removal procedure.
Rear Seat Back Rear Seat Bolster Removal 1. Insert screw driver down back of bolster.
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Removal 1. Remove seat bolster. Refer to Rear Seat Bolster in this section. 2. Delatch seat back and fold forward.
01/2003 2003.0 BA Falcon
501-10-20
Seating
501-10-20
REMOVAL AND INSTALLATION (Continued) 3. Place narrow screw driver between white cam and bearing.
4. Disengage cam from bearing by levering outboard.
Installation 1. Ensure white cam is in disengaged position and seat back is lying flat.
2. Place cam in holder and raise seat back to engage.
5. Lift seat back up vertically. 3. Check that cam has engaged properly.
6. Remove Rear Seat Back.
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01/2003 2003.0 BA Falcon
501-10-21
Seating
501-10-21
DISASSEMBLY AND ASSEMBLY
Front Head Restraint
Back Cover
Disassembly and Assembly 1. Press locking button next to headrest guide and lift in direction shown.
Disassembly 1. Remove two screws located at bottom edge of back cover.
Item 1 2
Description Press locking button Lift headrest
2. Slide cover down until hooks located at the top are released.
2. Detach trim cover retaining strip by removing the 2 retaining screws.
3. Carefully disengage side clips and lift the back cover away.
3. Peel back the trim cover up and away to remove from head restraint pad. CAUTION: Failure to follow procedure can result in damage to the side retention clip.
Assembly 1. Insert the top retaining/locating tabs and slide cover upwards. 2. Locate and snap in the side clips.
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01/2003 2003.0 BA Falcon
501-10-22
Seating
501-10-22
DISASSEMBLY AND ASSEMBLY (Continued) 3. Replace the 2 lower edge screws.
Lumbar Knob
CAUTION: Failure to follow procedure can result in damage to the side retention clip. Disassembly and Assembly 1. Use a flat tool and remove lumbar knob cover.
Headrest Guides
Disassembly and Assembly 1. Remove headrest (Refer to Headrest in this section). 2. Remove back cover (Refer to Back Cover in this section). 3. Undo top J-clip retainer.
2. Remove screw.
4. Insert your hand between the back rest foam pad and the frame. With your fingers squeeze the head rest guide ends and push upwards.
3. Place hands or fingers behind escutcheon/knob.
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01/2003 2003.0 BA Falcon
501-10-23
Seating
501-10-23
DISASSEMBLY AND ASSEMBLY (Continued) 4. Pull to remove knob and escutcheon together.
Recliner Knob and Outer Side Cover Disassembly and Assembly 1. Remove 2 mounting screws from the outer side cover. CAUTION: Failure to do so may cause cover to crack around cover mounting boss.
Inner Side Cover Disassembly and Assembly 1. Undo screw from inner side cover.
2. Place hands behind side cover.
2. Remove inner side cover.
3. Pull side cover away from seat base to remove the reclining knob and side cover together.
4. Where applicable, disconnect plugs from switch and/or memory buttons.
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01/2003 2003.0 BA Falcon
501-10-24
Seating
501-10-24
DISASSEMBLY AND ASSEMBLY (Continued)
Front Seat Back
9. Unclip yellow plug from connector cradle (where side air bag is fitted).
Disassembly and Assembly 1. Remove seat out of vehicle (Refer to Seats in this section).
2. 3. 4. 5. 6. 7. 8.
WARNING: Wait at least one minute after disconnecting the battery ground cable before disconnecting any supplemental restraint system electrical connector. Failure to follow this warning could cause premature deployment and may result in personal injury. Remove head rest (Refer to Headrest in this section). Remove plastic back cover (Refer to Back Cover in this section). 10. Remove three fir tree clips (where side air bag is Remove back cover (Refer to Back Cover in this fitted). section). Remove lumbar knob (Refer to Lumbar Knob in this section). Remove recliner knob and outer side cover (Refer to Recliner Knob and Outer Side Cover in this section). Remove inner side cover (Refer to Inner Side Cover in this section). Unclip connector cradle cover (where side air bag is fitted). WARNING: Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury.
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01/2003 2003.0 BA Falcon
501-10-25
Seating
501-10-25
DISASSEMBLY AND ASSEMBLY (Continued) 11. Undo four M10 bolts as shown. Outside
15. Unzip side airbag cover (where fitted) and remove it with the foam assembly. WARNING: Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. WARNING: After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of the gas generant combustion that is irritating to the skin. Wash your hands with soap and water afterward.
Inside
12. Place seat back face down on clean work bench. 13. Remove head rest guides (Refer to Headrest in this section). 14. Undo the 4 rear J clip retainer.
16. Remove dummy block where fitted.
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Seating
501-10-26
DISASSEMBLY AND ASSEMBLY (Continued) or side supplemental restraint system (SRS) components and before repairing, installing new, adjusting or striking components near the front or Disassembly side air bag sensors, such as doors, instrument 1. See front seat (Refer to Seats in this section). panel, console, door latches, strikers, seats and WARNING: Wait at least one minute after hood latches. disconnecting the battery ground cable before Please refer to the appropriate workshop manual to determine the location of the front air bag disconnecting any supplemantal restraint sensors. system electrical connector. Failure to follow The side air bag sensors are located at or near the this warning could cause premature deployment and may result in personal injury. base of the B-pillar. To deplete the backup power supply energy, 2. Remove plastic outboard side cover (Refer to disconnect the battery ground cable and wait at Outer Side Cover in this section). least one minute. Be sure to disconnect auxiliary 3. Remove seat back from seat (Refer to Front Seat batteries and power supplies (if equipped). Back in this section). WARNING: The restraint system diagnostic 4. Remove trim cover and foam pad from seat back tool is for restraint system repair only. Remove assembly (Refer to Front Seat Back in this from vehicle prior to road use. Failure to remove section). could result in injury and possible violation of 5. Read warnings below and then remove two M5 vehicle safety standards. nuts from airbag module.
Airbag
WARNING: Always wear safety glasses when repairing an air bag supplemental restraint system (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment.
WARNING: Never power up a seat inside or out of the vehicle except using the in-car connector dedicated to power supply. NOTE: If a seat equipped with a seat mounted side air bag system is being repaired, the air bag system must be deactivated per the deactivation procedure contained in Section 501-20b of the appropriate workshop manual.
WARNING: Carry a live side air bag module with the air bag and tear seam pointed away from your body. This will reduce the risk of injury in the NOTE: Restraint system diagnostic tools must be event of an accidental deployment. installed under the seats in the side air bag to floor connector. WARNING: Do not set a live side air bag NOTE: Diagnostics or repairs are not to be carried out module down on the cover tear seam. This will on a side air bag system or a safety belt pretensioner reduce the risk of injury in the event of an (if equipped) with the seat in the vehicle. accidental deployment. Prior to attempting to diagnose/repair the side air bag system or a safety belt pretensioner (if equipped) the WARNING: After deployment, the air bag seat must be removed from the vehicle and the surface can contain deposits of sodium restraint system diagnostic tool must be installed in hydroxide, a product of the gas generant side air bag connector at the floor connector. The combustion that is irritating to the skin. Wash restraint system diagnostic tool must be removed prior your hands with soap and water afterward. to operating the vehicle. WARNING: Never probe the connectors on NOTE: After diagnosing/repairing a seat system the the air bag module. Doing so can result in air bag restraint system diagnostic tool must be removed deployment, which can result in personal injury. before operating the vehicle. WARNING: Vehicle sensor orientation is critical for correct system operation. If a vehicle equipped with an air bag supplemental restraint system (SRS) is involved in a collision, inspect the sensor mounting bracket and wiring pigtail for deformation. Install and correctly position the new sensor or any other damaged supplemental restraint system (SRS) components whether or not the air bag is deployed. To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or installing a new front G73272 en
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Seating
501-10-27
DISASSEMBLY AND ASSEMBLY (Continued) 6. Carefully remove airbag.
2. Carefully remove cover from foam by placing one finger on the blue hook cover retaining strip and peeling cover from the foam pad, making sure not to pull the blue hook retaing strip the foam pad. WARNING: After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of the gas generant combustion that is irritating to the skin. Wash your hands with soap and water afterward. CAUTION: Failure to do so may result in retaining strip not being held in place securely.
Item 1 2
Description Nut Side Airbag
Assembly 1. Assemble Airbag module to seat frame ensuring front plastic retaining features are located over metal bracket tabs. 2. Install the two M5 nyloc nuts. 3. Check and fit dummy module to inboard side of seat, if required. 4. Fit foam and trim to frame. 5. Pull SIAB covering material (“chute”) through and around SIAB module. 6. Close zip around seat frame.
3. Pull cover and loop (white seam on trim cover) carefully so the blue hook assembly is not pulled out of foam.
CAUTION: Ensure that the zip is closed properly. CAUTION: Trim cover hook and loop must be securely engaged and the trim cover must be aligned in its proper orientation. 7. Reverse installation procedures 5,4,3,2 and 1. NOTE: A repair is made by installing new components only. If a new part is installed and the new part does not correct the condition, install the original part and carry out the diagnostic procedure again. NOTE: If a side air bag deployment took place, new seatback pad, trim cover, and side air bag module must be installed. A new seatback frame should be installed if necessary.
Front Seat Back Trim Cover Disassembly 1. Follow instructions for front seat back disassembly (Refer to Front Seat back in this section).
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4. Repeat for each section of hook and loop strip. Assembly 1. Make sure that you are installing the correct front seat back cover onto the foam seat back. A side airbag cover can be identified by a tag with the words "AIRBAG" sewn into the seam on the outboard side of each seat cover.In addition on the inside of the cover where the "AIRBAG" tag is attached a white airbag chute and trim cover ID bar code will be sewn into the seam. CAUTION: Do not fit a non airbag front seat back cover to a seat that has a side airbag fitted. Doing so may result in a side 01/2003 2003.0 BA Falcon
501-10-28
Seating
501-10-28
DISASSEMBLY AND ASSEMBLY (Continued) airbag deployment failure, which may cause severe or fatal injuiry to the occupant. NOTE: If a side airbag deployment took place, new seatback pad, trim cover, and side airbag module must be installed. A new seatback frame should be installed if necessary.
4. Unclip cover from connector cradle.
NOTE: Do not fit an airbag front seat back cover to a seat that does not have a side airbag fitted. 2. Push the cover loop (white seam on trim cover) onto the blue hook in the foam seat back. The cover loop must be engage along the entire lenght of the seat back blue hook. CAUTION: Failure to secure the cover loop with the seat blue hook may result in a side airbag deployment failure, which may cause severe or fatal injury to the occupant.
5. Unplug grey plug from connector cradle.
6. Remove three fir tree clips.
Pre-tensioner Disassembly and Assembly 1. Where applicable, raise seat electrically to full upright position. 2. Remove seat from vehicle (Refer to Seats in this section). WARNING: Wait at least one minute after disconnecting the battery ground cable before disconnecting any supplemental restraint system electrical connector. Failure to follow this warning could cause premature deployment and may result in personal injury. 3. Turn seat upside down to begin work on under seat.
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01/2003 2003.0 BA Falcon
501-10-29
Seating
501-10-29
DISASSEMBLY AND ASSEMBLY (Continued) 7. Undo pre-tensioner mounting bolt.
3. Disconnect wiring plug(s).
8. Remove pretensioner wiring loom connector through space on top of seat track.
4. Remove switch assembly from side cover housing using a flat bladed instrument to dislodge the switch assembly.
Memory Module Disassembly and Assembly 1. Remove Seat from vehicle (Refer to Seats in this section). 2. Unclip underseat wiring loom retention protecting cover.
9. Remove pretensioner assembly.
Seat Operating Switch Disassembly and Assembly 1. Remove outer side trims.
3. Unplug the white memory module plugs.
2. Remove outer side cover (Refer to Outer Side Cover in this section).
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01/2003 2003.0 BA Falcon
501-10-30
Seating
501-10-30
DISASSEMBLY AND ASSEMBLY (Continued) 4. Undo two retaining mounting screws.
5. Remove memory module. CAUTION: Take care during removal process not to break off top mounting boss.
4. Turn seat over and undo four cushion retaining nuts.
5. Remove front seat cushion from track. 6. Undo three black J clips (rear and sides).
Front Seat Cushion (2-way) Disassembly and Assembly 1. Remove seat from vehicle (Refer to Seats in this section). WARNING: Wait at least one minute after disconnecting the battery ground cable before disconnecting any supplemental restraint system electrical connector. Failure to follow this warning could cause premature deployment and may result in personal injury. 2. Remove pre-tensioner cable fir tree clips. NOTE: Leave pretensioner fitted to track. 7. Undo front white J clip. NOTE: White clip is glued to seat.
3. Remove front seat back (Refer to Front Seat Back in this section). 8. Remove cover from foam as per seat back foam disassembly instructions.
Front Seat Cushion (4-way & 6-way non-memory) Disassembly and Assembly 1. Perform steps 1,2,3 from 2-way front seat cushion disassembly. G73271 en
01/2003 2003.0 BA Falcon
501-10-31
Seating
501-10-31
DISASSEMBLY AND ASSEMBLY (Continued) 2. Remove three fir tree clips.
3. Perform steps 4,5,6,7,8,9 of front seat cushion (2-way) disassembly.
Front Seat Cushion (6-way memory) Disassembly and Assembly 1. Remove seat from vehicle (Refer to Seats in this section). 2. Unclip wiring loom retention nappy. 3. Remove pre-tensioner cable fir tree clips. 4. Remove front seat back (Refer to Front Seat Back in this section). 5. Unclip wiring loom clip from cushion frame using long nose pliers. 6. Undo two memory module mounting screws. 7. Undo the memory module. 8. Per step 3 above on 4-way seat (Refer to Front Seat Back in this section). CAUTION: Be careful not to break off top lug during removal process.
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01/2003 2003.0 BA Falcon
501-11-1
Glass, Frames and Mechanisms
501-11-1
SECTION : 501-11 Glass, Frames and Mechanisms VEHICLE APPLICATION : 2003.0 BA Falcon CONTENTS
PAGE
DESCRIPTION AND OPERATION Glass, Frames and Mechanisms ..........................................................................................501-11-2 DIAGNOSIS AND TESTING Glass, Frames and Mechanisms ..........................................................................................501-11-3 REMOVAL AND INSTALLATION Window Control Switch .........................................................................................................501-11-4 Front Door Window Glass .....................................................................................................501-11-4 Rear Door Window Glass — Moveable ................................................................................501-11-5 Rear Door Quarter Window Glass — Sedan ........................................................................501-11-5 Rear Quarter Glass — Wagon ..............................................................................................501-11-6 Rear Door Quarter Glass — LWB ........................................................................................501-11-7 Rear Door Quarter Glass — Ute ...........................................................................................501-11-7 Front Door Window Regulator ..............................................................................................501-11-8 Rear Door Window Regulator ...............................................................................................501-11-8 Fixed (Stationary) Glass Replacement .................................................................................501-11-9 Front Windshield Glass .........................................................................................................501-11-9 Rear Windshield Glass — Sedan .......................................................................................501-11-12 Liftgate Glass — Wagon .....................................................................................................501-11-13 Rear Windshield Glass — Ute ............................................................................................501-11-13
01/2003 2003.0 BA Falcon
501-11-2
Glass, Frames and Mechanisms
501-11-2
DESCRIPTION AND OPERATION
Glass, Frames and Mechanisms Vehicles may be fitted with front power operated windows (rear windows manually operated) or both front and rear power operated windows. Front only Power Windows The switches located on the front door trims are used to raise/lower the front windows. Depress and hold the up/down switch locations to raise and lower the window. Front and Rear Power Windows The five switches, located on the front driver door trim, control the four windows. Switches are also provided on the other three door trims for operation of that window only. The child lock switch on the front driver door can be used to disable the rear switches. Auto down - the driver’s window switch can be pressed and held for approximately 1 second to automatically fully lower the driver’s window. All electric windows operate with the ignition switch in the ‘ON’ or ‘accessory’ positions. When the key is returned to the ‘OFF’ position, power window operation is available for one hour (or 45 seconds if a door is opened).
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01/2003 2003.0 BA Falcon
501-11-3
Glass, Frames and Mechanisms
501-11-3
DIAGNOSIS AND TESTING
Glass, Frames and Mechanisms Before making any of the following trouble checks, make sure that the battery is fully charged, and turn the ignition switch to the accessory position. Circuit For wiring circuit checks refer to the wiring diagram in Section 000-00. All Power Windows are inoperative 1. Remove 30 amp circuit breaker in fuse panel and check for continuity through contacts.
2. Connect voltmeter or test light between lower circuit breaker terminal and ground to ensure electrical supply at this point. 3. Check operation of accessory relay in relay block by turning the ignition switch on and off and observe the relay operation by sound or feel. If relay is not operating, fit a new relay. Check for current at the switches. A Single Power Window is inoperative 4. Activate the switch and listen for the motor running free. If the motor runs and the window does not move, the glass coupling or gear teeth have failed. 5. If the motor does not run, disconnect the wires at the motor in order to check for voltage attach feed wire while actuating the window switch. If there is no voltage at the motorfeed terminals, check for voltage at the switch feed wire. If there is voltage at the switch, replace the switch. Window inoperative in one direction 6. Check the operation with the individual and master switches. If only one switch is inoperative, replace the faulty switch. 7. If the window will not function correctly from either switch, check for defective wiring between the switch and the motor. If the wiring leads are open, replace the wiring. 8. If the window operates normally in one direction, the motor is not defective. Power window operates sluggishly 9. Check the regulator and window runs for binding. Adjust the runs, repair and lubricate the regulator. Lubricate the runs with silicone lubricant. 10. Check for frayed insulation where the window wires may partially ground. Check for loose connections which will cause high resistance. 11. Check motor current draw during operation (place an ammeter in series with the ground lead of the battery). Motor current draw should not exceed 12 amps during normal operation and should exceed 20 amps at stall. If the current is above 12 amps during operations of the window, readjust the glass mechanism. If the stall current is below 20 amperes at stall, look for poor electrical connections. 12. Motor current draw when disconnected from the regulator plate should not exceed 5 amps.
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01/2003 2003.0 BA Falcon
501-11-4
Glass, Frames and Mechanisms
501-11-4
REMOVAL AND INSTALLATION
Window Control Switch
3. Remove the power window switch from the door trim & disconnect the wiring.
Removal 1. Remove door trim (For additional information refer to Section 501-05). 2. Remove switch panel by depressing locking tabs at rear of door trim and pushing through to front of trim. 3. Disconnect wiring.
Item 1 2
Item 1 2
Description Window control switch Door trim
Item 1 2
Description Window control switch Door trim
Installation 1. Reverse the removal procedure.
Front Door Window Glass Removal 1. Remove the remote mirror interior trim. 2. Remove the interior door handle bezel and window regulator handle.
F56432 en
Description Window control switch Door trim
4. Remove the door trim retaining screws and remove door trim. 5. Remove the door watershield. 6. Raise the door glass until the glass to regulator retaining clips are accessible. Hold the glass at the top edge and use a blade screwdriver to deflect and disengage the vertical legs of both retaining clips. NOTE: If the regulator is jammed preventing access to the retaining clips it may be necessary to cut the cable on the regulator in order to lower the glass.
Item 1 2 3 4 5
Description Front Power Window Regulator Front Door Inner Panel Glass and Clip Assembly Nut Nut Bolt
7. Raise the glass in the door and disengage from the glass run. Tilt the glass forward and withdraw from the outside of the door. 01/2003 2003.0 BA Falcon
501-11-5
Glass, Frames and Mechanisms
501-11-5
REMOVAL AND INSTALLATION (Continued) 5. Raise the door glass until the glass to regulator Installation retaining clips are accessible. Hold the glass at 1. Insert the glass into the door, forward edge the top edge and use a blade screwdriver to downwards from the outside. Lower glass into the deflect and disengage the vertical legs of both door and tilt back to normal position to engage in retaining clips. door glass runs. NOTE: If the regulator is jammed preventing 2. Align the glass to regulator. Push glass access to the retaining clips it may be necessary downwards to ensure engagement of retaining to cut the cable on the regulator in order to lower clips. the glass. 3. Temporarily connect the switch to the wiring to ensure glass moves freely in glass runs. 4. Install door watershield. 5. Position door trim panel and install retaining screws. 6. Install interior door handle bezel and window regulator handle. NOTE: With the glass fully raised, position the window regulator handle pointing rearwards (i.e. 3 o’clock for RHS and 9 o’clock for LHS). 7. Install power window switch whilst connecting wiring to back of switch. Install remote mirror interior trim panel.
Rear Door Window Glass — Moveable Removal 1. Remove interior door handle bezel. Remove window regulator handle. 2. Remove the door trim retaining screws and remove door trim. 3. Remove the power window switch from the door trim and disconnect the wiring.
Item 1 2
Description Window control switch Door trim
4. Remove the door watershield.
Item 1 2 3 4 5
Description Rear Door Inner Panel Glass and Clip Assembly Nut Bolt Rear Power Window regulator
6. Withdraw the moveable door glass from the outside of the door frame. NOTE: It may be found beneficial to lower the window regulator after disengaging the glass to regulator retaining clips. Installation 1. Insert the glass into the door from the outside, tilt the glass forward and lower it into the glass run. 2. Raise the window regulator and align the glass to regulator. Push glass downward and ensure engagement of retaining clips. Check that glass operates freely in glass run. 3. Refit the door watershield. 4. Install door trim panel and retaining screws. 5. Install the interior door handle bezel and window regulator handle. NOTE: With the glass fully raised, position the window regulator handle pointing rearwards (i.e. 3 o’clock for RHS and 9 o’clock for LHS). 6. Install power window switch whilst connecting wiring to back of switch.
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01/2003 2003.0 BA Falcon
501-11-6
Glass, Frames and Mechanisms
501-11-6
REMOVAL AND INSTALLATION (Continued)
Rear Door Quarter Window Glass — Sedan
3. Remove the rear quarter glass lower moulding.
Removal CAUTION: Gloves and protective eyewear should be worn at all times. 1. Prepare to remove the rear door quarter glass by applying masking tape to the body in line with the glass edges. This will help to protect the vehicle paintwork should the cutting tool used in removal slip or cut through the urethane. 2. Remove antenna terminal (left hand side only).
Item 1 2 3
Item 1 2 3 4
Description Rear Door Quarter Window Glass Door Inner Panel Screw Rivet
3. Cut the urethane around the perimeter of the glass using a sharp, long-bladed knife. Remove glass and weatherstrip assembly. Installation 1. Prepare surfaces and apply primer and sealer as described in the windshield long or short installation procedures. 2. Attach glass and weatherstrip assembly to door by first locating the lugs on the lower part of the moulding into the guides on the beltline. 3. Use duct tape or G-clamps to hold assembly to door during curing period. (approx. 1.5 hours).
Description Door Outer Panel Door Inner Panel Seal Assembly
4. Open the liftgate and remove the quarter glass rear moulding. 5. Grasp the rear glass upper moulding by hand and carefully pull the moulding upwards to detach it from the glass. 6. Make antenna terminal connection (left hand glass only). 7. Prepare to remove the quarter glass by applying masking tape to the body in line with the glass edges. This will help to protect the paintwork should the cutting tool used in removal slip or cut through the urethane suddenly. CAUTION: When cutting near the corners of the glass, cut inwards from the corners to avoid bodywork damage.
Rear Quarter Glass — Wagon Removal CAUTION: Gloves and protective eyewear should be worn at all times. 1. Remove interior ‘C’ pillar trim. For additional information refer to Section 501-05. 2. Remove two retaining nuts and remove exterior ‘C’ pillar trim.
F56434 en
Item 1
Description Seal
01/2003 2003.0 BA Falcon
501-11-7
Glass, Frames and Mechanisms
501-11-7
REMOVAL AND INSTALLATION (Continued) 8. Cut the urethane around the perimeter of the glass using a dual handle knife. Continue until all urethane is cut. Thick areas of urethane not cut by the dual handle knife can be cut with a utility knife. 9. Attach suction cups to the quarter glass and lift it clear of the aperture. NOTE: Ensure that no urethane contacts silver paint grid lines.
3. Prise the glass from the panel by cutting the butyl-coated PVC foam sealer.
Item 1 2 3
Item 1 2 3
Description Quarter Panel Quarter Glass Assembly Urethane Sealer
Installation NOTE: For installation refer to the windshield long or short installation procedures. 1. Install the rear quarter glass lower moulding. 2. Install the ‘C’ pillar trim panel.
Rear Door Quarter Glass — LWB Removal CAUTION: Gloves and protective eyewear should be worn at all times. 1. Remove interior C-pillar trim. For additional information refer to Section 501-05. 2. Remove the five nuts from the studs.
F56438 en
Description Rear Door Quarter Glass Stud Nut
4. Remove up butyl/foam from painted sheetmetal. Installation 1. Remove the plastic release liner from the butyl-coated PVC foam of the 6th Lite. Check that the butyl covers the full length to be sealed. 2. Apply and tighten nuts to the five studs. 3. Reinstall interior C-pillar trim.
Rear Door Quarter Glass — Ute Removal CAUTION: Gloves and protective eyewear should be worn at all times. 1. Remove interior C-pillar trim. For additional information refer to Section 501-05. 2. Remove antenna terminal. 3. Remove the two nuts from the studs.
01/2003 2003.0 BA Falcon
501-11-8
Glass, Frames and Mechanisms
501-11-8
REMOVAL AND INSTALLATION (Continued) 4. Prise the glass from the panel by cutting the butyl-coated PVC foam sealer.
Item 1 2 3 4
Description Glass Primer Urethane Panel Assembly Glass and Weatherstrip Assembly Lock Nut
Item 3 4 5
Description Glass and Clip Assembly Nut Nut Bolt
2. Raise the glass by hand and support the glass in the fully raised position. 3. Remove the three nuts and three bolts attaching the regulator to the inner panel. 4. The regulator assembly is a non-serviceable item and must be replaced if faulty. Installation 1. Position the regulator into the door and install the retaining nuts and bolts. 2. Repeat steps 2-8 of Removal and Installation in section Front Door Window Glass.
Rear Door Window Regulator Removal 1. Repeat steps 1-5 of Removal and Installation in section Rear Door Window Glass - Moveable.
5. Remove up butyl/foam from painted sheetmetal. NOTE: Ensure that no urethane contacts silver paint grid lines. Installation 1. Remove the plastic release liner from the butyl-coated PVC foam on the 6th Lite. Check that the butyl covers the full length to be sealed. 2. Apply and tighten nuts to the two studs. 3. Connect antenna terminal. 4. Reinstall interior C-pillar trim.
Front Door Window Regulator Removal 1. Repeat steps 1-5 of Removal and Installation in section Front Door Window Glass.
Item 1 2
Description Front Power Window Regulator Front Door Inner Panel
F56438 en
Item 1 2 3 4 5
Description Rear Door Inner Panel Glass and Clip Assembly Nut Bolt Rear Power Window regulator
2. Raise the glass by hand and support the glass in the fully raised position. 3. Remove the bolts and nuts attaching the regulator to the door inner panel and withdraw the regulator assembly. The regulator assembly is a non serviceable unit and must be replaced as an assembly. Installation 1. Position the regulator assembly into the door and install the retaining bolts and nuts. 2. Repeat steps 2-6 of Removal and Installation in section Rear Door Window Glass - Moveable.
01/2003 2003.0 BA Falcon
501-11-9
Glass, Frames and Mechanisms
501-11-9
REMOVAL AND INSTALLATION (Continued)
Fixed (Stationary) Glass Replacement Special Tool(s) BTB Glass Removal tool WK 10 HD
CAUTION: Do not slam vehicle doors within 24 hours of fixed glass replacement unless vehicle windows are open 150mm. minimum. Vehicles should not be driven until urethane sealant has cured for a minimum of 6 hours. NOTE: The stationary glass, which is bonded to the body aperture flanges by urethane sealant, forms part of the body structure. The replacement of any stationary glass requires that urethane sealant be used to maintain the integrity of the structure. Stationary glass is fitted to: Windshield (laminated with a tinted band). Rear window glass - Sedan. Liftgate glass - Wagon. Rear door quarter glass - Sedan and Wagon. Rear quarter glass - Wagon. Two alternative methods may be used in the replacement of stationary glass, depending on certain criteria. Short method The short method is used where the original urethane adhesive is retained on the body opening flanges after the glass is removed and serves as a base for the replacement glass. The operator should remove the glass ensuring the maximum amount of urethane is retained on the body flanges. This method may be used to replace cracked windscreens or glass which is still intact. Long method In the long method, the urethane adhesive is completely removed from the body aperture flanges and replaced with new adhesive. This method used where the adhesive cannot serve as a base for the replacement glass or body and paint repairs are required. All remaining urethane adhesive must be removed from the body aperture flanges.
1. Place covers on vehicle fenders, seats and instrument panel. Remove interior mirror. 2. Remove the wiper arm and blade assemblies. For additional information refer to Section 501-08. 3. Raise the engine hood and remove the cowl top vent grille panel. For additional information refer to Section 501-08. 4. Prepare to remove the windshield glass by applying masking tape to the body in line with the glass edges. This will protect the vehicle paintwork should the cutting tool used in removal slip or cut through the urethane. 5. Cut paas moulding lip away level with edge of glass.
Item 1
2 3
Front Windshield Glass Removal
4
CAUTION: Gloves and protective eyewear should be worn at all times.
5
F56444 en
Description Primer NOTE: Width of primer at top edges of windshield Primer Overlap Area Paas Moulding NOTE: Width of primer along bottom edge of windshield NOTE: Width of primer at side edge of windshield Primer Overlap Area
01/2003 2003.0 BA Falcon
501-11-10
Glass, Frames and Mechanisms
501-11-10
REMOVAL AND INSTALLATION (Continued) Short Method 6. Clean glass thoroughly to allow visibility of the cutting operation, and trim excess sealant 1. Trim the urethane sealant bed on the windshield material from the edge of glass using a suitable aperture flange until it is relatively smooth, and blade. remove any loose urethane pieces. Exposed body 7. Use BTB glass removal air tool (Part no:WK 10 surfaces should be cleaned with X55 solvent (or HD). Spray into the flange from outside, & as equivalent) and primed with urethane primer. close as possible to the urethane from inside. Use a combination of Baby shampoo & water as this will not stain IP etc. This aids the cutting tool to slide through the urethane. Cut the Sides & Top externally using 90° external blade. Then using the long flat blade from inside the vehicle cut away the Bottom & Free top corners. Take care not to demage sheet metal & the IP Top as it is not replacable. 8. When cutting operation is completed (be sure there are no areas where sealant is still attached to glass, as one such hold-up will cause breakage of the windscreen on removal) attach suction cups to glass and lift clear of aperture. WARNING: Be careful not to damage IP top surface (not replaceable). Installation NOTE: Determine which installation method is appropriate under the circumstances. Refer to the criteria for each method given earlier on this page.
Item 1 2 3
Description Glass asy. windshield Paas moulding Urethane sealant
2. Apply urethane sealant to exposed areas to achieve an even sealant bed. 3. Clean periphery of glass with urethane cleaner (ESB M5B 280 A or equivalent). Wipe cleaner off immediately. 4. Apply urethane glass primer to the glass surface ensuring no light is visible through the primer. Allow the primer to cure. NOTE: Thoroughly shake and stir the urethane glass primer to ensure uniform pigment mixing prior to application. 5. Apply a 13-15 High X 9-11 Wide triangular bead of urethane sealant to the primed surface of the glass for the entire perimeter. Ensure it is positioned within the sealant areas shown.
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01/2003 2003.0 BA Falcon
501-11-11
Glass, Frames and Mechanisms
501-11-11
REMOVAL AND INSTALLATION (Continued) 6. Attach suction cups to the windshield glass and lift 11. Assemble the interior rear view mirror to the into position on primed body flange. bracket and tighten the mirror retaining grub screws. NOTE: Glass must be centred in windshield opening so the side clearances vary by not more Installation than 3mm. Long Method 1. Clean all hardened Urethane from the flange. Remove all dirt, dust etc. and clean flanges with X55 solvent or equivalent to remove grease etc. Wear light cotton gloves to avoid finger prints and apply cleaner with a lint free cloth. 2. Using a clean brush, apply urethane body primer to the flanges ensuring that no paint is visible through the primer. Overlap primer in bottom LH and RH corners. Primer application is sufficient when appearance is glossy and free of streaks. Allow 30 minutes for primer to cure. NOTE: Do not touch primed surfaces or allow surfaces to be contaminated prior to glass fitment. 3. Clean all dirt, dust etc. from windshield glass inner surface. 4. Using a lint free cloth wipe the outer 25mm. of inside windshield perimeter with urethane glass cleaner. NOTE: Remove glass cleaner immediately after application because it flash dries. 5. Using a clean brush, apply urethane glass primer to the glass surface with no light visible through the primer. Allow to dry for 5 minutes. NOTE: Thoroughly shake and stir the urethane glass primer to ensure uniform pigment mixing prior to application.
Item 1 2 3 4 5
Description Rear door fixed glass Screw Bolt Rear door Rivet
6. Apply a bead of urethane sealant around the perimeter of the glass on the primed surface. The sealant bead should be approximately 13-15. high with a base width of 9-11mm. and triangular in shape. 7. Attach suction cups to the windshield glass and lift into position on primed body flange. Use the locating pins to position the glass. NOTE: If any primer and/or urethane adheres to the body or trim, other than where required, it must be removed immediately or the surface may be damaged if removed when dry.
7. Secure the windshield by pressing upward until the upper moulding is firmly contacting the roof rebate. 8. Position the wiper arm and blade assemblies and NOTE: If any primer and/or urethane adheres to install the retaining nuts. the body or trim, other than where required, it must be removed immediately or the surface may 9. Install the cowl top grille panel support brackets. be damaged if removed when dry. 10. Position the cowl top grille panel and install attaching screws. 8. Position the cowl top grille panel and install attaching screws. 11. Attach the interior rear view mirror bracket to the windshield in position as shown in Figure using 9. Position the wiper arm and blade assemblies and the Motorcraft Adhesive Kit or equivalent. install the retaining nuts. 10. Attach the interior rear view mirror bracket to the 12. Assemble the interior rear view mirror to the bracket and tighten the mirror retaining grub windshield in position as shown in Fig. 20 using screw. the Motorcraft Adhesive Kit or equivalent.
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01/2003 2003.0 BA Falcon
501-11-12
Glass, Frames and Mechanisms
501-11-12
REMOVAL AND INSTALLATION (Continued) 13. Clean windshield, remove covers from fenders, seats and instrument panel.
Rear Windshield Glass — Sedan Special Tool(s) BTB Glass Removal Air Tool WK 10HD
NOTE: The rear windshield glass is bonded to the moulding and the two cannot be separated. The moulding will be damaged during the removal process and therefore the glass and mouldings assembly cannot be re-used. Remove Roof Ditch Mouldings to avoid damage. Removal CAUTION: Gloves and protective eyewear should be worn at all times. 1. Place covers on the rear parcel shelf, seats and rear quarter panels. 2. Remove the heated rear glass wiring connectors. 3. Remove rear interior trim panels surrounding rear windscreen. For additional information refer to Section 501-08. 4. Prepare to remove the rear glass by applying masking tape to the body in line with the glass edges. This will help to protect the vehicle paintwork should the cutting tool used in removal slip or cut through the urethane. CAUTION: When cutting the urethane near the corners of the glass, cut inwards from the corners to avoid vehicle bodywork damage when cutting from inside. Be carefull not to demage sheet metal.
F56444 en
Item 1 2 3
Description Rear Windshield Paas Moulding Urethane Sealant
5. Use a lubricant such as Baby shampoo & water applied inside the flange to aid air tool to slide when cutting urethane. Use glass removal air tool to cut all four sides around the perimeter of the glass, externally using external blades. Free top corners using long flat blade & cut from inside the vehicle. 6. Attach suction cups to the rear glass and lift it clear of the aperture. Installation For installation procedures refer to the windshield long or short installation procedures. And also follow these steps: 1. Urethane bead 9-11 wide and 12-14 high. 2. Make electrical connection from rear glass. Fly-Lead to aerial amplifier module box on left hand side. 3. Make electrical connection from earth lead to glass terminal left hand side. 4. Because it will effect on glass antenna performance. NOTE: Ensure that no urethane contacts silver paint grid lines. 01/2003 2003.0 BA Falcon
501-11-13
Glass, Frames and Mechanisms
501-11-13
REMOVAL AND INSTALLATION (Continued)
Liftgate Glass — Wagon Removal CAUTION: Gloves and protective eyewear should be worn at all times. 1. Remove liftgate wiper arm and blade. 2. Remove the heated rear glass wiring connectors. NOTE: The PCV perimeter moulding is bonded to the glass and must be replaced as part of the liftgate rear glass assembly.
4. Cut around the perimeter of the glass using a dual handle knife. Continue until all urethane is cut. Thick areas of urethane not cut by the dual handle knife can be cut with a utility knife.
3. Prepare to remove the liftgate rear glass by applying masking tape to the body in line with the glass edges. This will help to protect the vehicle paintwork should the cutting tool used in removal slip or cut through the urethane. CAUTION: When cutting near the corners of the glass, cut inwards from the corners to avoid bodywork damage.
Item 1 2 3
Description Rear Windshield Glass Prier - Urethane Glass Cleaner - Urethane
Item 1 2 3 4
Description Liftgate outer panel Liftgate inner panel Nut Urethane Sealer
5. Attach suction cups to the liftgate glass and lift it clear of the aperture. Installation NOTE: For installation, refer to the windshield long or short installation procedures, followed by assembly of four retaining nuts. 1. Reconnect the liftgate rear heated glass wiring connectors. 2. Refit the liftgate wiper arm and blade.
Rear Windshield Glass — Ute Removal NOTE: The rear windshield glass is bonded to the moulding and the two cannot be separated.
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01/2003 2003.0 BA Falcon
501-11-14
Glass, Frames and Mechanisms
501-11-14
REMOVAL AND INSTALLATION (Continued) NOTE: The moulding will be damaged during the removal process and therefore the glass and mouldings assembly cannot be re-used. CAUTION: Gloves and protective eyewear should be worn at all times. 1. Place covers on the rear parcel shelf, seats and rear quarter panels. 2. Remove the heated rear glass wiring connectors. 3. Remove rear interior trim panels surrounding rear windscreen. For additional information refer to Section 501-08. 4. Prepare to remove the rear glass by applying masking tape to the body in line with the glass edges. This will help to protect the vehicle paintwork should the cutting tool used in removal slip or cut through the urethane. CAUTION: When cutting the urethane near the corners of the glass, cut inwards from the corners to avoid vehicle bodywork damage. 5. Cut the urethane around the perimeter of the glass, on the inside of the vehicle, using a sharp long-bladed knife. 6. Attach suction cups to the rear glass and lift it clear of the aperture. Installation NOTE: For installation procedures refer to the windshield long or short installation procedures. 1. Reconnect the heater rear glass wiring connectors. NOTE: Ensure that no urethane contacts silver paint grid lines.
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01/2003 2003.0 BA Falcon
501-12-1
Instrument Panel and Console
501-12-1
SECTION : 501-12 Instrument Panel and Console VEHICLE APPLICATION : 2003.0 BA Falcon CONTENTS
PAGE
SPECIFICATIONS Specifications ........................................................................................................................501-12-2 DESCRIPTION AND OPERATION Instrument Panel ....................................................................................................................501-12-3 REMOVAL AND INSTALLATION Instrument Panel ....................................................................................................................501-12-4 Floor Console & Duct Assembly ............................................................................................501-12-6 Overhead Console .................................................................................................................501-12-8 Sun Load Sensor ...................................................................................................................501-12-8 Vent Outlet Registers .............................................................................................................501-12-8 Demist Nozzles ......................................................................................................................501-12-8 Glove Compartment (with damper mechanism) ....................................................................501-12-8 Glove Compartment (without damper mechanism) ...............................................................501-12-9
01/2003 2003.0 BA Falcon
501-12-2
Instrument Panel and Console
501-12-2
SPECIFICATIONS Torque Specifications Description Lower Centre Finish Panel Assembly Screw Instrument Panel Centre Tunnel Retaining Bolt Instrument Panel Footwell Brace Retaining Bolt Instrument Panel Cowl Top Bolt Instrument Panel Outside Retaining Bolt Instrument Panel Inside Retaining Bolt Console Retaining Screw PRNDL Retaining Screw Console Transmission Retaining Screw Console Gearshift Retaining Screw
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Nm 1.2-1.8 25.5-34.5 25.5-34.5 8.9-12.1 25.5-34.5 25.5-34.5 3.1-4.3 1.2-1.8 1.2-1.8 1.2-1.8
01/2003 2003.0 BA Falcon
501-12-3
Instrument Panel and Console
501-12-3
DESCRIPTION AND OPERATION
Instrument Panel The following components are contained within the instrument panel: climate control HVAC (Heating, Ventilation and Air Conditioning) unit glove compartment instrument cluster instrument panel side finish panels passenger airbag module Instrument panel duct (incorporating Demist, Face centre and side ducts) Vent outlet registers Sunload sensor Interior command centre
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01/2003 2003.0 BA Falcon
501-12-4
Instrument Panel and Console
501-12-4
REMOVAL AND INSTALLATION
Instrument Panel Removal 1. Set seat back angle to vertical position and set height adjustment to full up position. 2. Disconnect the battery. WARNING: Wait at least one minute after disconnecting the battery ground cable before disconnecting any supplemental restraint system electrical connector. Failure to follow this warning could cause premature deployment and may result in personal injury. 3. Remove both front seat. Refer to Section 501-10 Seating. 4. Remove park brake handle. Refer to Section 206-05 Parking Brake and Actuation. 5. Remove Floor console as described later in this section. 6. Remove A-pillar trim. Refer to Section 501-05 Interior Trim and Ornamentation. 7. Remove instrument panel end cap mouldings (LH and RH sides).
8. Remove the fuse panel cover. 9. Disconnect the engine hood release cable from the fuse box by pushing down at the rear and sliding it forward.
10. Detach the lever-lock wiring connectors at lower cowl side wiring block retainers (common both sides. RH side shown).
11. Detach wiring block retainers from body. WARNING: The restraints control module (RCM) orientation is critical for proper airbag supplemental restraint system (SRS) operation. If a vehicle equipped with an SRS system has been involved in a collision in which the center tunnel area has been damaged, inspect the mounting and bracket for deformation. If damaged, the RCM must be replaced whether or not the airbags have deployed. In addition, make sure the area of the RCM mounting is restored to its original condition. WARNING: Vehicle sensor orientation is critical for proper system operation. If a vehicle equipped with an airbag supplemental restraint system (SRS) is involved in a collision, inspect the sensor mounting bracket and wiring pigtail for deformation. Replace and properly position the sensor or any other damaged supplemental restraint system (SRS) components whether or not the airbag is deployed. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side airbag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side airbag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage can result.
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01/2003 2003.0 BA Falcon
501-12-5
Instrument Panel and Console
501-12-5
REMOVAL AND INSTALLATION (Continued) 12. Disconnect the large restraints control module 17. Remove instrument panel centre tunnel retaining (RCM) electrical connector. bolt. 1. Pinch the thumb tab and pivot the connector position assurance lever all the way back until it stops. 2. Pull out and disconnect the RCM electrical connector.
18. Remove instrument panel foot well brace retaining bolt.
Item 1 2 3 4
Description Small RCM connector cover Small RCM connector RCM Large RCM connector
13. Disconnect the small RCM electrical connector. 1. Pull out and remove the electrical connector locking wedge. 2. Push down to release the retaining tab. 19. Remove the sunload sensor blank. 3. While releasing the retaining tab, pull out and 20. Loosen Instrument panel cowl top bolt at least disconnect the small RCM electrical 8-10 turns while pushing down firmly on the bolt connector. head. This spreads the two instrument panel 14. Remove steering column. Refer to Section 211-04 tangs so that they can be slid over the mating Steering Column. cowl tang during the disassembly process. 15. ( Column Shift Only) Remove Centre Lower Finish Panel Assembly.
16. Remove the Interior Command Centre. Refer to Section 413-08 Interior Command Centre
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01/2003 2003.0 BA Falcon
501-12-6
Instrument Panel and Console
501-12-6
REMOVAL AND INSTALLATION (Continued) 21. Undo outside instrument panel retaining bolts below upper front door hinge. Do not remove.
8. 9. 10. 11. 12. 13. 14. 15. 16.
Attach sun load sensor trim panel or blank. Attach cowl scuff trims. Attach fuse door. Attach seat belts. Refit console system. Fit hand brake. Fit front seat. Fit seat side lower garnish and scuff plate. Reconnect battery.
Floor Console & Duct Assembly
22. Remove instrument panel side retaining bolts.
Removal 1. Remove front seating. For additional information, refer to Section 501-10. 2. Remove parking brake. For additional information, refer to Section 206-05. 3. Move gear shift to D (Automatic) or 4th (manual). Remove securig screw and handle/knob.
23. Place Gearshift in ’D’ position to provide clearance for instrument panel removal. 24. Remove instrument panel assembly through right hand side of vehicle. Installation NOTE: Prior to installing the instrument panel assembly, its critical that the instrument panel cowl top bolt is loosened at least 8-10 turns while pushing down firmly on the bolt head. This process spreads the two instrument panel tangs so that they can slide over the mating cowl tang during assembly. 1. Position instrument panel assembly into vehicle and secure side, outer, upper cowl, lower tunnel and front floor retaining bolts. 2. Fit wiring retainer blocks to cowl sides. 3. Attach wiring connectors at cowl sides and crash sensor. 4. Attach hood release cable. 5. Refit steering column. 6. Attach A-pillar trim. 7. Attach end caps.
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Item 1 2
Description Selector handle Screw
01/2003 2003.0 BA Falcon
501-12-7
Instrument Panel and Console
501-12-7
REMOVAL AND INSTALLATION (Continued) 4. Remove PRND dial or manual gear shift cover by 7. Remove tissue holder assembly. lifting the cover evenly at the points illustrated below.
5. Remove console wing trims by removing retaining screws.
8. Remove console gearshift retaining screws ( 3 screws for Automatic, 2 screws for Manual ).
9. Remove side screw fixings. 6. Remove console retaining screws at instrument panel interface.
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01/2003 2003.0 BA Falcon
501-12-8
Instrument Panel and Console
501-12-8
REMOVAL AND INSTALLATION (Continued) 10. Detach retaining clips from inside console bin using flat head screwdriver.
Installation 1. Reverse removal procedure.
Sun Load Sensor For removal and installation of sunload sensor, refer to section 412-04.
Vent Outlet Registers For removal and installation of climate control vent outlet registers, refer to section 412-02.
Demist Nozzles
11. Lift console at rear and disconnect wiring lead (where fitted). 12. Remove console and duct assembly. Installation 1. Reverse removal procedure.
Overhead Console Removal 1. Carefully remove the Headliner. Refer to Section 501-05. 2. Disconnect all the wiring to the Interior Dome Lamp, Reading Lamps/Mobile Office Lamps. Refer to Section 417-02. 3. Carefully remove the headliner from the vehicle. (Care should be taken when handling headlining not to bend or crease unnecessarily). WARNING: Take care when handling headlining as skin irritation may result from contact with fiberglass fibers. 4. Remove the 4 screws (Screw 4.2 x 1.4, 1x13 pan washer head tap) connecting the backing plate that is glued to the headliner and Overhead Console.
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Each of the two demist nozzles can be removed from the instrument panel assembly separately. To remove, use a long fine tool (preferably with a hooked end). Push the tool through the slot in each of the 4 spring loaded clips at the rear of the nozzle (closest to the driver/passenger) and lever /the spring clip forwards and upwards from under the edge of the instrument panel while gently prying the nozzle upwards. When all four rear spring clips are disengaged, the nozzle can be slid rearwards and upwards to disengage the four fixed clips (closest to the windscreen). To assemble, the demist nozzle can be pushed directly downwards in to the instrument panel until all four front fixed clips and four rear spring clips are engaged.
Glove Compartment (with damper mechanism) Removal 1. Release and pull the damper pivot clip at the top of the glove compartment by reaching up from the foot well to the left-hand side (passenger’s A-pillar). Release the damper pivot clip by depressing the central tab. NOTE: Do not fully remove the damper pivot clip to avoid difficulty in re-inserting it into the hole. Pull it out only far enough to clear the damper pivot ring.
01/2003 2003.0 BA Falcon
501-12-9
Instrument Panel and Console
501-12-9
REMOVAL AND INSTALLATION (Continued) 2. Fully extend the damper and push toward the runner channel.
Item 1 2
Description Damper Damper pivot clip
Item 1 2 3
Description Damper pivot clip Damper pivot runner Damper
3. Close the glove compartment. The glove compartment stop should engage and the damper pivot should be positioned to allow the damper pivot clip to slide in. 4. Push the damper pivot clip in to secure the damper into position.
Glove Compartment (without damper mechanism) Removal 1. Open the glove compartment and release the stop by pushing the stop downwards. 2. Pull the glove compartment out of the lower hinges. Installation 1. Clip the glove compartment into the lower hinges. 2. Close the glove compartment. The glove compartment stop should engage.
2. Open the glove compartment and release the stop by pushing the stop downwards. 3. Pull the glove compartment out of the lower hinges. NOTE: Avoid removing the damper from the glove compartment moulding as damage to the damper may result. Installation 1. Clip the glove compartment into the lower hinges.
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01/2003 2003.0 BA Falcon
501-14-1
Handles, Locks, Latches and Entry Systems
501-14-1
SECTION : 501-14 Handles, Locks, Latches and Entry Systems VEHICLE APPLICATION : 2003.0 BA Falcon CONTENTS
PAGE
SPECIFICATIONS Specifications ........................................................................................................................501-14-2 DESCRIPTION AND OPERATION Latches .................................................................................................................................501-14-3 GENERAL PROCEDURES Wagon Liftgate Latch ............................................................................................................501-14-4 REMOVAL AND INSTALLATION Hood Latch ............................................................................................................................501-14-5 Front Door Latch ...................................................................................................................501-14-5 Rear Door Latch ....................................................................................................................501-14-5 Door Latch Striker .................................................................................................................501-14-6 Liftgate Latch and Actuator ...................................................................................................501-14-6 Liftgate Latch Striker .............................................................................................................501-14-7 Hood Latch Release Cable ...................................................................................................501-14-7 Decklid Latch and Emergency Release Cable .....................................................................501-14-7 Decklid Latch Striker .............................................................................................................501-14-8 Exterior Front Door Handle ...................................................................................................501-14-8 Exterior Rear Door Handle ...................................................................................................501-14-8 Interior Door Handle ..............................................................................................................501-14-9 Ignition Lock ..........................................................................................................................501-14-9 Interior Lock Button ................................................................................................................501-14-9 Grab Handles — Ute ..........................................................................................................501-14-10 Grab Handles — Sedan ......................................................................................................501-14-10 Fuel Filler ............................................................................................................................501-14-10 Fuel Filler Door Release Switch .........................................................................................501-14-11 DISASSEMBLY AND ASSEMBLY Door and Liftgate Locks ......................................................................................................501-14-12 Ignition Lock ........................................................................................................................501-14-14
01/2003 2003.0 BA Falcon
501-14-2
Handles, Locks, Latches and Entry Systems
501-14-2
SPECIFICATIONS Torque Specifications Description Door Latch striker screws Front door latch screw Exterior rear door handle screws Rear door latch screw Exterior front door handle screws Exterior front door handle lock retaining screw Decklid latch nuts Decklid striker bolts Wagon liftgate latch screws Wagon liftgate actuator nuts Wagon liftgate striker bolts Hood latch bolts Fuel filler
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Nm 8.9 - 12.1 5 5 5 5 5 10 23 15 9 24 23 1.7
01/2003 2003.0 BA Falcon
501-14-3
Handles, Locks, Latches and Entry Systems
501-14-3
DESCRIPTION AND OPERATION
Latches The decklid consists of the following components: Decklid latch Decklid striker Decklid emergency release cable The wagon liftgate consists of the following components: Liftgate latch and actuator Liftgate striker The hood consists of the following components: Hood Latch Hood latch release handle and cable The fuel filler consists of the following components: Solenoid Assembly
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01/2003 2003.0 BA Falcon
501-14-4
Handles, Locks, Latches and Entry Systems
501-14-4
GENERAL PROCEDURES
Wagon Liftgate Latch NOTE: This latch consists of a primary latch position designed to hold the liftgate firmly into the weatherstrip section to preclude water leaks and/or wind noise. 1. Ensure that the primary latch has been activated when the liftgate is fully closed. 2. Adjust the liftgate latch striker pin as required to establish a door-to-weatherstrip seal. 3. The striker can be adjusted fore/aft and sideways by loosening the retaining bolts.
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01/2003 2003.0 BA Falcon
501-14-5
Handles, Locks, Latches and Entry Systems
501-14-5
REMOVAL AND INSTALLATION
Hood Latch Removal 1. Open bonnet. 2. Remove attaching screws and remove latch assembly from vehicle.
Item 1 2
Description Screw Bonnet Latch assembly
3. Disconnect latch operating cable.
Item 1 2 3
Description Latch operating cable Retaining clips Bonnet latch assembly
Installation 1. Reverse removal procedure.
Front Door Latch Removal 1. Remove the interior door handle bezel. 2. Remove grab handle cap.
G31875 en
3. Remove door trim panel retaining screws (4). Remove grab handle screws (2). Pull door trim away from sheetmetal. 4. Remove the door watershield and Hip Bolster. 5. Disengage latch rod from outer door handle and the door locking rod from the lock barrel lever.
Item 1 2
Description Front door latch and actuator assembly Screw
6. Disconnect interior handle cable from latch. 7. Remove the door latch retaining screws (Torx head), remove the latch from the door. Installation 1. With the latch actuating rods attached assemble the latch into the door panel. Install the retaining screws. 2. Connect interior handle cable to latch. 3. Connect the outer door handle and lock barrel rods. 4. Make sure soldier button rod is fitted to latch handle. Make sure soldier button is fitted to rod. 5. Refit the door watershield and Hip Bolster. 6. Install the door trim panel and refit the retaining screws. 7. Install the interior door handle bezel and grab handle cap.
Rear Door Latch Removal 1. Remove interior door handle. Remove window regulator handle (where fitted). 2. Remove grab handle cap (where fitted). 3. Remove door trim retaining screws, pull the door trim panel from the door channel and remove. 4. Remove water shield.
01/2003 2003.0 BA Falcon
501-14-6
Handles, Locks, Latches and Entry Systems
501-14-6
REMOVAL AND INSTALLATION (Continued) 5. Disconnect exterior door handle rod from latch and handle.
Door Latch Striker Removal 1. Remove striker as shown in figure.
Item 1 2
Description Rear door latch and actuator assembly Screw
6. Remove nuts retaining outer door handle, detach handle from door panel and disconnect door latch rod. 7. Remove latch retaining screws (Torx head). Disconnect interior handle cable from latch and remove latch from door. Installation 1. Position latch into door panel, connect interior handle cable. Install retaining screws. 2. Connect latch rod to outer door handle, position handle to door panel and install retaining nuts. 3. Refit door watershield. 4. Refit interior door trim panel and retaining screws. 5. Install interior door handle bezel, window regulator handle and grab handle cap (where fitted).
Item 1 2
Description Striker Assy. (1 per door) Screw - M8x18 Csk Tx (x2 per door)
Installation 1. Reverse removal procedure.
Liftgate Latch and Actuator Removal 1. Remove the liftgate interior trim panel.(Refer to Section 501-05.) 2. Disconnect the wiring plug.
Item 1 2 3 4 5 6
Description Actuator assembly Lock barrel connecting rod Lock barrel Actuator to latch connecting rod Latch assembly Nut
3. Remove the liftgate actuator mechanism retaining nuts and disconnect the lock barrel connecting rod. G31875 en
01/2003 2003.0 BA Falcon
501-14-7
Handles, Locks, Latches and Entry Systems
501-14-7
REMOVAL AND INSTALLATION (Continued) 4. Remove the actuator assembly while disconnecting the latch rod. 5. Remove the latch assembly retaining screws and remove the latch with connecting rod and courtesy lamp wiring lead attached.
Item 1 2 3 4 5
Description Latch assembly Screw Courtesy lamp wiring Connecting rod Liftgate body
Installation 1. Reverse removal procedure.
Liftgate Latch Striker Removal 1. Remove load floor carpet. (Refer to Section 501-05.) 2. Remove liftgate latch striker bolts.
Item 1 2
Description Liftgate striker Bolt
Hood Latch Release Cable Removal 1. Remove hood latch. 2. Disconnect hood release handle from instrument panel.
Item 1
Description Hood release handle
3. Pop out grommet on cowl side attached to cable. Installation 1. Reverse removal procedure.
Decklid Latch and Emergency Release Cable Removal 1. Remove decklid trim if fitted.(Refer to Section 501-05.) 2. Remove decklid latch nuts.
Item 1 2 3
Description Decklid latch assembly Nut Decklid body
Installation 1. Reverse removal procedure.
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01/2003 2003.0 BA Falcon
501-14-8
Handles, Locks, Latches and Entry Systems
501-14-8
REMOVAL AND INSTALLATION (Continued) 3. Disconnect emergency release cable.
Item 1 2 3
Description Emergency release cable Actuating cable end Emergency release pull tab
Exterior Front Door Handle Removal 1. Remove the interior door handle bezel and window regulator handle. 2. Remove door trim. For additional information, refer to Door Trim section. 3. Remove the door trim retaining screws, lift the door trim panel from the door channel and remove. 4. Remove the door watershield sufficiently to gain access to door handle. 5. Remove the two bolts retaining the outer door handle. 6. Unclip the latch rod, remove the door handle from the door panel and remove door handle.
Installation 1. Reverse removal procedure.
Decklid Latch Striker Removal 1. Remove cover lower back.(Refer to Section 501-05.) 2. Remove decklid latch striker bolts. Item 1 2 3 4
Description Front outer door handle Lock retaining screw Lock retainer Screw - M6
Installation 1. Reverse removal procedure.
Exterior Rear Door Handle Item 1 2
Description Decklid striker Bolt
Installation 1. Reverse removal procedure.
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Removal 1. Remove interior door handle bezel. Remove window regulator handle. 2. Remove door trim. For additional information, refer to Door Trim section. 3. Remove door trim retaining screws, lift the door trim panel from the door channel and remove. 4. Remove the door watershield sufficiently to gain access to door handle.
01/2003 2003.0 BA Falcon
501-14-9
Handles, Locks, Latches and Entry Systems
501-14-9
REMOVAL AND INSTALLATION (Continued) 5. Remove bolt retaining outer door handle, detach handle from door panel and unclip door latch rod.
4. Disengage handle assembly from door inner sheet metal by sliding rearwards and withdrawing through trim. Installation 1. Reverse removal procedure.
Ignition Lock
Item 1 2
Description Exterior rear door handle Bolt
Removal 1. Insert the ignition key and turn it to the ’1’ position. 2. Depress the pin in the steering column lock housing and withdraw the lock assembly. 3. Insert the ignition key and turn it to the ’1’ position. 4. Align the lock in the column housing, depress the pin and push the lock into the housing until the pin snaps into its locating hole.
Installation 1. Reverse removal procedure.
Interior Door Handle Removal 1. Remove plug. 2. Remove screw attaching handle assembly to door inner sheet metal.
Item 1 2
Description Solenoid assembly Solenoid retaining screw
Installation 1. Reverse removal procedure.
Interior Lock Button
Item 1 2 3 4
Description Interior door handle Actuating cable Screw Button plug
Removal NOTE: Lock button is not serviceable. Should a new lock rod be required, a new lock button should be fitted. Installation 1. Door trim must be removed to gain access to lock rod.
3. Disconnect cable attaching handle to latch.
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01/2003 2003.0 BA Falcon
501-14-10
Handles, Locks, Latches and Entry Systems
501-14-10
REMOVAL AND INSTALLATION (Continued) 2. Push lock rod button firmly onto lock rod. Ensure locating rib faces out.
Grab Handles — Sedan Removal 1. Remove grab handles as shown in figure.
Item 1
Description Lock button
3. Replace door trim, guiding lock button through hole in door trim. 4. Ensure button is flush with trim in locked position. 5. Check for satisfactory operation of the lock.
Grab Handles — Ute Removal 1. Remove grab handles as shown in figure.
Item 1 2
Item 1 2
Description Grab handle Screw
Installation 1. Reverse removal procedure.
Fuel Filler Removal 1. Open Luggage compartment. 2. Remove quarter trim. 3. Remove the two solenoid-retaining screws via the fuel door.
Description Grab handle Screw
Installation 1. Reverse removal procedure.
Item 1 2
Description Fuel filler flap Solenoid retaining screw
4. Remove solenoid and cable assembly. Installation 1. Reverse removal procedure.
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01/2003 2003.0 BA Falcon
501-14-11
Handles, Locks, Latches and Entry Systems
501-14-11
REMOVAL AND INSTALLATION (Continued)
Fuel Filler Door Release Switch Removal 1. Use a flat plastic spatula similar to a credit card to gently remove switch assembly from crash pad. Clipping points are on the sides of the bezel. NOTE: Using a screw driver or similar may cause damage to the instrument panel.
2. Disconnect electrical connector from rear of switch. 3. To disassemble the switch assembly: Gently depress locking tabs and push switch out from bezel. Installation 1. Reverse removal procedure.
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01/2003 2003.0 BA Falcon
501-14-12
Handles, Locks, Latches and Entry Systems
501-14-12
DISASSEMBLY AND ASSEMBLY
Door and Liftgate Locks Door Lock
Disassembly 1. Drive out the roll pin securing the lever to the magazine. Remove the lever and spring. Item 1 2 3
Description Spacer Wave washer Tumbler
Liftgate Lock
Item 1 2 3
Description Spacer Wave washer Tumbler
NOTE: The same service procedures apply to both locks. If the key code is unknown, it can be read through the lock drain slot as follows: Item Description Position the lock with the drain slot upwards and the operating lever to the right. Starting at the left, read 1 Shutter the code from each tumbler by counting the number of 2. Remove the circlip retaining the magazine. notches on the edge of each tumbler. 3. Withdraw the magazine and tumblers. 1 notch = 1 Assembly 2 notches = 2 1. Open the overhaul kit and select the tumblers 3 notches = 3 required (in our example 1, 4, 3, 4, 2, 3) 4 0 notches = 4 spacers and 1 tumbler pack spring (wave As can be seen, in our example the key code is washer). 143423. G31891 en
01/2003 2003.0 BA Falcon
501-14-13
Handles, Locks, Latches and Entry Systems
501-14-13
DISASSEMBLY AND ASSEMBLY (Continued) 2. Select the correct handed magazine for the lock 7. Holding the magazine upright between finger and being overhauled. An R or L is stamped on the thumb of one hand, lower the lock housing over end of each magazine indicating the “hand” of the the magazine, ensuring that the roller does not fall magazine. out and that it locates in the housing correctly. Left hand door = L magazine Right hand door = R magazine NOTE: A right hand magazine is used for the liftgate application.
NOTE: The roller slot is the narrower of the two slots. NOTE: Use a pencil to insert tumblers. 3. Insert the tumbler into the magazine so that the roller cutout in the tumbler is on the same side as the roller slot in the magazine. The first tumbler inserted should be the last number of the key code, in our example a ‘3’. Follow this with a spacer, again ensuring that the roller cutout aligns with the roller slot.
8. Keeping the magazine in place in the housing, check that the lock operates correctly. Holding the lock face towards you (drain slot facing down): A Left hand lock will have 0° freeplay to lock (turn key to left), 45° freeplay before unlocking (turn key to right). A Right hand lock will have 0° freeplay to lock (turn key to right), 45° freeplay before unlocking (turn key to left).
9. Up-end the assembly so that it rests on its front face. Secure the magazine in the housing by fitting the circlip.
4. The remaining tumblers are inserted in the following order: ‘2’ + spacer, ‘4’ + spacer, ‘3’ + spacer, ‘4’ + pack spring and finally the last tumbler ‘1’. This is our key code example 143423. 5. Using multi-purpose grease, pack the centre of the magazine and lubricate the magazine casing. 6. Lubricate and then insert the roller into the slot in the magazine.
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01/2003 2003.0 BA Falcon
501-14-14
Handles, Locks, Latches and Entry Systems
501-14-14
DISASSEMBLY AND ASSEMBLY (Continued) 10. Refit the lever return spring onto the housing by crossing the legs of the spring about the post on the housing. 11. Refit the lever ensuring that the spring sits correctly about the lever and install the roll pin.
Ignition Lock
Disassembly 1. Remove the large circlip (A) from the end of the magazine.
2. Remove the small circlip (B) and withdraw the magazine assembly from the housing. 3. If the key code is unknown, remove the end cap from the magazine by spreading the castellations and working from left to right, lay out the tumblers in a line as they are removed. 4. Identify the tumblers (by reading the notches on the edge of each tumbler) and write down the key code. NOTE: The housing is serviced as an assembly. Individual components of the housing are not serviced. 1 2 3 0
Item 1 2 3 4
Description Spacer Wave washer Shutter Tumbler
G31891 en
notch = 1 notches = 2 notches = 3 notches = 4
Assembly 1. Open the overhaul kit and select the tumblers required. NOTE: When rebuilding the lock, the first tumbler to be inserted will be the last one removed: using our example, a ‘3’.
01/2003 2003.0 BA Falcon
501-14-15
Handles, Locks, Latches and Entry Systems
501-14-15
DISASSEMBLY AND ASSEMBLY (Continued) 2. Insert the first tumbler into the magazine ensuring that the roller cutout is on the same side as the roller slot in the magazine. Follow this with a spacer, ensuring that the roller cutout aligns with the roller slot. The first tumbler inserted (using our example) should be a ‘3’.
Item A
Description Make sure roller slot and tumbler cut out are on the same side.
3. Again, following our example, the remaining tumblers are inserted in the following order: 2 + spacer, 4 + spacer, 3 + spacer, 4 + pack spring (wave washer) and finally the last tumbler ‘1’. This completes our key code example 143423. 4. Apply powdered graphite to the centre of the magazine and to the magazine casing. At this stage check that the roller descends/rises when the key is inserted and turned, and that there is 0° free play to lock and 45° free play before unlocking. 5. Fit the end cap to the magazine, clamp it in a soft jawed vice and using an automatic centre punch, deform the castellations to secure the assembly. 6. Lubricate and insert the semi-circular shutter into the magazine by holding the thin tapered end of the shutter between the finger and thumb and passing the thicker end under the two side tabs, so that the thicker end of the shutter sits over the centre of the lock. 7. Lubricate the roller and insert it into the roller slot. 8. Assemble the magazine into the housing by aligning the roller to the roller recess in the housing and sliding it in. Secure the magazine in the housing by fitting the smaller circlip. 9. Refit the large circlip to the magazine so that its open end is opposite the small raised tang on the magazine.
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01/2003 2003.0 BA Falcon
501-16-1
Wipers And Washers
501-16-1
SECTION : 501-16 Wipers And Washers VEHICLE APPLICATION : 2003.0 BA Falcon CONTENTS
PAGE
SPECIFICATIONS Specifications ........................................................................................................................501-16-2 DESCRIPTION AND OPERATION Wipers and Washers — Front ..............................................................................................501-16-3 Wipers and Washers — Rear ...............................................................................................501-16-3 DIAGNOSIS AND TESTING Wipers And Washers ............................................................................................................501-16-4 Principles of Operation .........................................................................................................501-16-4 Rear Window Wiper Washer ................................................................................................501-16-4 Connector Circuit Reference ................................................................................................501-16-5 GENERAL PROCEDURES Windshield Wiper Blade and Pivot Arm Adjustment .............................................................501-16-6 Rear Window Wiper Blade and Pivot Arm Adjustment .........................................................501-16-6 Washer Hose Repair .............................................................................................................501-16-6 Windscreen wiper motor test ................................................................................................501-16-6 REMOVAL AND INSTALLATION Windscreen Wiper Blade Insert ............................................................................................501-16-7 Windscreen Wiper Arm and Blade ........................................................................................501-16-7 Windscreen Wiper Motor and Linkage Assembly .................................................................501-16-7 Wiper Motor from W/S Wiper Linkage Assembly .................................................................501-16-8 Washer Pump .......................................................................................................................501-16-8 Low Level Sensor .................................................................................................................501-16-8 Windshield Washer Reservoir — Sedan ..............................................................................501-16-9 Windshield Washer reservoir Sedan — High Series ............................................................501-16-9 Windshield Washer Reservoir Wagon ................................................................................501-16-10 Liftgate Wiper Assembly .....................................................................................................501-16-11 Washer Hose ......................................................................................................................501-16-11 Windshield Wiper/Washer Switch and/or Rear Window Wiper Switch ...............................501-16-11
01/2003 2003.0 BA Falcon
501-16-2
Wipers And Washers
501-16-2
SPECIFICATIONS General Specifications Description Front Driver W/S wiper arm length Passenger W/S wiper arm length Driver W/S wiper blade length * Passenger W/S wiper blade length * Rear Rear liftgate wiper arm length Rear liftgate wiper blade length
Specification 510mm 600mm 550mm 550mm
290mm 400mm
* Driver and passenger blades are common Torque Specifications Description Nm W/S wiper pivot shaft nut (Driver and 19-24 passenger) (F + G) W/S wiper motor bolts (H.J.K) 9-15 W/S wiper motor crank nut (L) 16-20 W/S wiper motor linkage bolts and nuts 5.2-7.2 (ABCDE) Rear wiper motor bracket bolts 8.8-11.5 Rear wiper motor pivot shaft nut 5.4-6.8 Rear wiper motor tower nut (Large) 1.3-1.8 Windshield washer reservoir bolts and 5-7 nut
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01/2003 2003.0 BA Falcon
501-16-3
Wipers And Washers
501-16-3
DESCRIPTION AND OPERATION
Wipers and Washers — Front The W/S wipers and washer system consists of the following: W/S wiper blade (x2) W/S wiper arm - Driver
W/S wiper arm - Passenger
Rear window wiper motor Rear window wiper/washer switch Control through the Body Electronic Module (BEM) Rear washer reservoir Rear window washer pump Rear window washer hose Rear window washer check valve Rear window washer nozzle jet
W/S wiper motor W/S wiper linkage W/S wiper/washer switch Control through Body Electronic Module (BEM) W/S washer reservoir W/S washer pump W/S washer nozzle jet (x2)
Wipers and Washers — Rear The rear W/S wiper and washer system consists of the following: Rear window wiper blade Rear window wiper arm
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01/2003 2003.0 BA Falcon
501-16-4
Wipers And Washers
501-16-4
DIAGNOSIS AND TESTING
Wipers And Washers Refer to Wiring Diagrams Section 501-16 for schematic and connector information. Special Tool(s) 73III Automotive Meter 105-R0057 or equivalent
INT position, the windshield wipers and washers will run as long as the knob is depressed (up to 10 seconds). When the knob is released, the washer will stop immediately, but the windshield wipers will continue to run for two to three sweeps, then return to their previous set operation. Washer engagement does not affect windshield wiper operation when the wiper/washer switch is in the LOW or HIGH position, but the washer will be deactivated if the knob is held for longer than 10 seconds.
Rear Window Wiper Washer Worldwide Diagnostic System (WDS) 418-F224 New Generation STAR (NGS) Tester 418-F052 or equivalent diagnostic tool SABRE Electrical System Tester 010-00736 or equivalent
The body electronic module (BEM) allows operation of the rear window wiper functions when the ignition switch is in the ON or ACC position only. The BEM controls the cycling of the rear window wiper motor through a single relay (rear window wiper relay). There are four modes of operation: off mode, interval mode, on mode and wash mode. NOTE: The BEM does not control the rear window washer, only the rear window wiper. In the off mode, there is no liftgate wiper motor activity and the liftgate wiper motor will be in the PARK position.
Principles of Operation The wiper system has four different operating modes: off mode, low-speed mode, high-speed mode, and speed sensitive interval mode. In the off mode, there is no windshield wiper motor activity, and the windshield wiper motor is in the PARK position. In the ON mode, the windshield wiper motor is set to a low-speed setting. The wiper/washer switch provides voltage to the windshield wiper motor through the low-speed circuit. The windshield wiper motor provides ground through a dedicated ground circuit. In the high-speed mode, the windshield wiper motor is set to a high-speed setting. The wiper/washer switch provides voltage to the windshield wiper motor through the high-speed circuit. The windshield wiper motor provides ground through a dedicated ground circuit. In the interval mode, the windshield wiper motor is set to a low-speed setting. The windshield wiper interval relay is activated at the beginning of each wipe and deactivated when the windshield wiper motor park switch reaches the run position. The interval relay is part of the wiper/washer electrical system. When the wiper/washer switch is in the interval position, the windshield wipers will make a single sweep followed by a pause. The interval frequency can be varied by rotating the control. The frequency will auto adjust to vehicle speed. To engage the windshield washer, pull the knob of (WDS) the wiper/washer switch toward the steering wheel. When the wiper/washer switch is in the OFF or G43533 en
01/2003 2003.0 BA Falcon
501-16-5
Wipers And Washers
501-16-5
DIAGNOSIS AND TESTING (Continued) Connector Circuit Reference C-159 RH High Beam Headlamp
Pin Number(s) 1 3 4 5 6
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Circuit Designation/Description (BR) Common switch (GR) Supply/park switch (RD) Low speed (BLK) Earth (BL) High speed
Normal Condition/Measurement 0V (GRND) +12V 0V (GRND) 0V 0V (GRND)
01/2003 2003.0 BA Falcon
501-16-6
Wipers And Washers
501-16-6
GENERAL PROCEDURES
Windshield Wiper Blade and Pivot Arm Adjustment NOTE: LHD shown, RHD similar. 1. Cycle and park the windshield wipers. 2. Verify that the RH and LH wiper blades are located at the specified position.
2. To check each wiper motor function, apply power to the appropriate plug terminals as described in the following table. Refer to Connector Circuit Reference - Wiper Motor Plug for terminal location. 3. The parking function requires the connections to be made as per the low speed function. Once the motor is running at low speed applying ground (0V) at the brown lead terminal with engage the park function. The motor will remain in park position until either the ground or power is removed. Function High Speed Low Speed Park
Wire Color Green Blue Green Red Green Red Brown
Voltage Supply(V) +12 V 0V (GRND) +12 V 0V (GRND) +12 V 0V (GRND) 0V (GRND) - Park
3. If not within specification, remove the windshield wiper pivot arms and reposition to the proper locations; refer to Wiper Pivot Arm - Front in this section.
Rear Window Wiper Blade and Pivot Arm Adjustment 1. Cycle and park the rear window wiper. 2. Verify that the rear window wiper blade is located at the horizontal position. 3. If not within specification, remove the rear window wiper pivot arm and reposition to the correct location; refer to Wiper Pivot Arm - Front in this section.
Washer Hose Repair 1. Locate and verify the leaking washer hose. 2. Cut the hose cleanly and remove the damaged portion of the washer hose. 3. Install a windshield washer hose adapter between the cut ends of the hose. NOTE: In diffucult cases, replacement of total hose may be required.
Windscreen wiper motor test 1. Using an equivalent vehicle power supply (12V DC), locate and disconnect the wiper motor loom plug from the vehicle electrical system. NOTE: The plug can be accessed in the engine bay. No removal of windscreen wiper or vehicle components is required.
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01/2003 2003.0 BA Falcon
501-16-7
Wipers And Washers
501-16-7
REMOVAL AND INSTALLATION
Windscreen Wiper Blade Insert
4. Cycle wiper motor to correct park position.
Removal 1. Lift (by the tip) the wiper arm away from the screen as far as it will go; it will be held in that position by spring tension. 2. Press to disengage the spring clip on the blade and pull the wiper blade assembly off the wiper arm. 3. Using a small screwdriver, lift the retention lug and slide the cap off the refill. Discard all old refill components.
5. Position the arm on the spindle. 6. Tighten the attaching nut finger tight and rotate the arm to the correct position. 7. Tighten the attaching nut to specified torque. 8. Replace the plastic cover.
Windscreen Wiper Motor and Linkage Assembly Installation 1. The replacement refill is supplied with one end cap and a small retaining clip fitted. Remove the small clip. 2. Carefully slide the end without the cap into the metal support ensuring that the refill passes through each metal claw. 3. Assemble new end cap supplied with the refill onto the end of the refill ensuring that the retention lug on the end cap is securely located behind the two upturned ends of the metal rails. NOTE: Do not reuse any old end caps.
Removal 1. Park the windscreen wiper system. 2. Remove wiper arms from pivots - note positions. 3. Remove black plastic shield which covers the heater plenum and disconnect washer hoses to give access to wiper motor and linkage assembly. 4. Remove the 3 bolts which hold the passenger pivot end of the assembly to the body. 5. Remove the 2 nuts which retain the driver’s side pivot to the body. Push pivot into the plenum.
4. Refit the blade onto the arm ensuring the plastic locking clip snaps into the hole in the arm hook.
Windscreen Wiper Arm and Blade Removal 1. Lift the plastic cover from the spindle end of the wiper arm. 2. Remove the nut attaching the arm to the pivot spindle. 3. Prise the arm from the serrated tapered seat on the spindle.
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6. Disconnect the wiring from the wiper motor. 7. Carefully withdraw the motor and linkage assembly towards the passenger side through the hole in the cowl area. 8. Remove components as necessary from the linkage. Installation 1. Ensure the linkage is in park position. 01/2003 2003.0 BA Falcon
501-16-8
Wipers And Washers
501-16-8
REMOVAL AND INSTALLATION (Continued) 2. Slide the motor and linkage assembly through the 3. Remove washer pump hole where the passenger pivot mounts, locate 1. Disconnect the electrical connector. the driver’s side pivot and hand start the nuts on 2. Disconnect the washer hose from the the securing studs. washer-pump. 3. Locate the 3 mounting screws at the passenger 3. Remove the washer-pump. pivot mounting points. 4. Tighten the 3 screws and the 2 nuts. 5. Connect the wiring to the motor. 6. Operate the motor to ensure park position. 7. Replace cover shield. 8. Replace wiper arm and arm nut covers.
Wiper Motor from W/S Wiper Linkage Assembly Removal and Installation 1. Remove link end from motor crank ball pin. 2. Clamp motor and linkage assembly in vice via motor crank. NOTE: This is to ensure motor crank does not rotate during step 3. 3. Loosen motor crank nut and remove motor crank. (Note motor crank position) 4. Loosen and remove (3) motor mounting bolts. 5. Remove motor from linkage. 6. To install, reverse removal procedure.
Washer Pump
4. Install washer pump CAUTION: Do not operate the windshield washer pump prior to filling the windshield reservoir. 1. Dip washer-pump inlet into water and immediately insert washer-pump into washer reservoir grommet. 2. Dip washer hose in water and immediately push washer hose (10mm) onto washer-pump outlet. 3. Reconnect the electrical connector to washer-pump. Fill the windshield washer reservoir with clean water and Motorcraft R1-47 screen wash solution or equivalent.
Removal and Installation 1. Remove the left front wheel (Refer to Section 204-04). 2. Remove the left front stone guard (Refer to Section 501-08). NOTE: To prevent spilling windshield washer Low Level Sensor fluid, drain the windshield washer reservoir before removal. Removal and Installation 1. Remove the left front wheel (Refer to Section 204-04). 2. Remove the left front stone guard (Refer to Section 501-08). NOTE: To prevent spilling windshield washer fluid, drain the windshield washer reservoir before removal.
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01/2003 2003.0 BA Falcon
501-16-9
Wipers And Washers
501-16-9
REMOVAL AND INSTALLATION (Continued) 3. Remove low level sensor 1. Disconnect the electrical connector. 2. Ease the low level sensor out of the windshield washer reservoir.
5. Install windshield washer reservoir CAUTION: Do not operate the windshield washer pump prior to filling the windshield reservoir. 1. Locate windshield washer reservoir on stud and place nut onto stud. NOTE: Do not tighten. 2. Fit self tapping bolts (2 places) and tighten to 5-7Nm. 3. Tighten nut to 5-7Nm. 4. Dip washer hose in water and immediately push washer hose (10mm) onto washer pump outlet. 5. Reconnect the electrical connector to washer-pump. 6. Fit washer cap to reservoir.
4. Install low level sensor CAUTION: Do not operate the windshield washer pump prior to filling the windshield reservoir. 1. Dip low level sensor (sensor rubber seal portion) into water and immediately insert washer-pump into windshield washer reservoir. 2. Reconnect the electrical connector to low level sensor. Fill the windshield washer reservoir with clean water and Motorcraft R1-47 screen wash solution or equivalent.
Windshield Washer Reservoir — Sedan Removal and Installation 1. Remove the left front wheel (Refer to Section 204-04). 2. Remove the left front stone guard (Refer to Section 501-08). 3. Drain washer fluid from reservoir prior to removing washer reservoir. 4. Remove windshield washer reservoir 1. Disconnect the electrical connector from washer-pump. 2. Remove washer cap from reservoir so that washer cap does not become obstructive at windshield washer reservoir removal stage. 3. Disconnect the washer hose from the washer pump. 4. Remove the two bolts & nut. 5. Lower windshield washer reservoir and remove from vehicle.
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Fill the windshield washer reservoir with clean water and Motorcraft R1-47 screen wash solution or equivalent.
Windshield Washer reservoir Sedan — High Series Removal and Installation 1. Remove the left front wheel (Refer to Section 204-04). 2. Remove the left front stone guard (Refer to Section 501-08). 3. Drain washer fluid from reservoir prior to removing washer reservoir. 4. Remove windshield washer reservoir. 1. Disconnect the electrical connector from washer-pump. 2. Disconnect the electrical connector from low level sensor. 3. Remove washer cap from reservoir so that washer cap does not become obstructive at windshield washer reservoir removal stage. 4. Disconnect the washer hose from the washer pump.
01/2003 2003.0 BA Falcon
501-16-10
Wipers And Washers
501-16-10
REMOVAL AND INSTALLATION (Continued) 5. Remove the two bolts & nut. 6. Lower windshield washer reservoir and remove from vehicle.
4. Remove windshield washer reservoir. 1. Disconnect the electrical connectors from washer-pumps. 2. Remove washer cap from reservoir so that washer cap does not become obstructive at windshield washer reservoir removal stage. 3. Disconnect the washer hoses from the washer pumps. 4. Remove the two bolts & nut. 5. Lower windshield washer reservoir and remove from vehicle.
5. Install windshield washer reservoir CAUTION: Do not operate the windshield washer pump prior to filling the windshield reservoir. 1. Locate windshield washer reservoir on stud and place nut onto stud. NOTE: Do not tighten. 2. Fit self tapping bolts (2 places) and tighten to 5. Install windshield washer reservoir 5-7Nm. CAUTION: Do not operate the windshield 3. Tighten nut to 5-7Nm. washer pump prior to filling the windshield 4. Dip washer hose in water and immediately reservoir. push washer hose (10mm) onto washer pump 1. Locate windshield washer reservoir on stud outlet. and place nut onto stud. 5. Reconnect the electrical connector to NOTE: Do not tighten. washer-pump. 6. Reconnect the electrical connector to low 2. Fit self tapping bolts (2 places) and tighten to level sensor. 5-7Nm. 7. Fit washer cap to reservoir. 3. Tighten nut to 5-7Nm. Fill the windshield washer reservoir with clean 4. Dip washer hose in water and immediately water and Motorcraft R1-47 screen wash push washer hose (10mm) onto washer pump solution or equivalent. outlet. NOTE: Ensure correct washer hose is fitted to Windshield Washer Reservoir Wagon correct washer-pump. Removal and Installation 5. Reconnect the electrical connector to 1. Remove the left front wheel (Refer to Section washer-pump. 204-04). NOTE: Ensure correct electrical connector is fitted to correct washer-pump. 2. Remove the left front stone guard (Refer to Section 501-08). 6. Reconnect the electrical connector to low 3. Drain washer fluid from reservoir prior to removing level sensor. washer reservoir. 7. Fit washer cap to reservoir. Fill the windshield washer reservoir with clean water and Motorcraft R1-47 screen wash solution or equivalent.
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01/2003 2003.0 BA Falcon
501-16-11
Wipers And Washers
501-16-11
REMOVAL AND INSTALLATION (Continued)
Liftgate Wiper Assembly
Washer Hose
Removal 1. Remove trim panel from the inner surface of liftgate. 2. Remove wiper arm and remove the plastic shield off the large mounting nut. 3. Remove the large mounting nut, spacer and shield. 4. Remove the two nuts on the inner panel which mounts the wiper motor. 5. Remove the wiring harness. 6. Remove the wiper assembly.
Removal 1. Follow hose locations as shown in figures and unclip or pull off as necessary.
Installation 1. Reverse order of removal procedure.
Windshield Wiper/Washer Switch and/or Rear Window Wiper Switch The above switches are a component of the steering column multifunction switch. To remove or install the above switches the entire steering column multifunction switch must be removed/installed. Installation Please refer to Section 211-05 for information 1. Fit seal to wiper motor output shaft. regarding installation and removal of steering column 2. Position wiper motor into vehicle and secure using multifunction switch. the two nuts through the inner panel (do not tighten). 3. Fit the seal, spacer and tighten the large mounting nut. 4. Fit the cover shield over the large nut. 5. Tighten the two screws on the inner panel. 6. Attach wiring loom and operate wiper motor to ensure it is in the park position. 7. Fit wiper arm and position appropriately. 8. Reinstall trim panel.
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01/2003 2003.0 BA Falcon
501-17-1
Sunroof
501-17-1
SECTION : 501-17 Sunroof VEHICLE APPLICATION : 2003.0 BA Falcon CONTENTS
PAGE
DESCRIPTION AND OPERATION Roof Opening Panel ..............................................................................................................501-17-2 Operating Instruction ............................................................................................................501-17-4 Wiring Routing ......................................................................................................................501-17-6 DIAGNOSIS AND TESTING Sunroof .................................................................................................................................501-17-7 Inspection and Verification ...................................................................................................501-17-7 Symptom Chart ....................................................................................................................501-17-8 Pinpoint Tests ......................................................................................................................501-17-9 GENERAL PROCEDURES Sunshade Check .................................................................................................................501-17-12 Glass Panel Adjustment ......................................................................................................501-17-12 Glass Panel Seal Adjustment .............................................................................................501-17-12 Ventilation Tray Adjustment ................................................................................................501-17-13 Wind Deflector Adjustment .................................................................................................501-17-13 Mechanism Covers Adjustment ..........................................................................................501-17-13 REMOVAL AND INSTALLATION Motor ...................................................................................................................................501-17-14 Sunroof Control Unit (SCU) ................................................................................................501-17-14 Drive Cables .......................................................................................................................501-17-14 Drive Cables Timing ............................................................................................................501-17-15 Glass Panel Seal ................................................................................................................501-17-16 Retraction Mechanism ........................................................................................................501-17-16 Guide Rail Mechanism ........................................................................................................501-17-16 Blocking Catch ....................................................................................................................501-17-17 Drain Channel .....................................................................................................................501-17-17
01/2003 2003.0 BA Falcon
501-17-2
Sunroof
501-17-2
DESCRIPTION AND OPERATION
Roof Opening Panel
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01/2003 2003.0 BA Falcon
501-17-3
Sunroof
501-17-3
DESCRIPTION AND OPERATION (Continued) Item 1 2 3 4 5 6 7 9 13 14 15 19a 19
Description Glass Panel Rubber Seal Drain Channel Wind Deflector Sunshade Covers set LH/RH Sunshade Handle Mounting Set Mechanism Service Set Locater LH/RH Service Set Mechanism LH/RH Nut Wind Deflector Wire Harness SCU-UI Wire Harness SCU & Rocker Switch (not on drawing) 21 Switch 22 Fuse and Fuse Holder 24 Frame Rubber 25 Service Set Drive Cables 26 Service Set Blocking Catch LH/RH 27 Panel Mounting Set 33 Service Set Retraction Mechanism LH/RH 35 Set Drain Tubes (6 metre) 36 Trim Ring 37 Set Exterior Covers 40 Mounting Set Drain Channel 42 Set Guides Sunshade + Springs 46 Service Set Motor 49 Mounting Set Motor 51 Repair Set SCU 54 54 Set Side Support Brackets 58 Foam 60 Set Side Trimming LH/RH 61 Glue Set For Stratos 700 Unit The STRATOS 700 Glass Panel sunroof is capable of tilting, venting and sliding. The roofs are glass and incorporate an internal sunshade. They are electrically operated by a switch installed in the header panel.
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01/2003 2003.0 BA Falcon
501-17-4
Sunroof
501-17-4
DESCRIPTION AND OPERATION (Continued)
Item 1 2 3 4 5 6 7 8 9 10
Description Kit - Panel Roof Slide Bracket - Rear Cassette Support (x2) Rivet 6.4 x 2.8-4.8 (x10) Bracket - Front Cassette Support (x2) Bracket - Interior Dome Lamp Retainer Roof Headlining (x2) Rivet - 4.8mm Diameter (x4) Filler - Headlining Front Outer (x6) Filler - Roof Headlining Rear (x2) Hose - Flex PVC Diameter 10mm Front (x5 meters) 11 Hose - 10mm Rear (x2 Meters) 12 Grommet Rear Drain (x4) 13 Bracket - Dome Lamp Mounting 14 Screw - AB Tap 4.2x12.5 Dome Bracket (x4) The sunroof is installed in a special steel frame which provides mounting points for the operating mechanism, drain tubes, frame support brackets, drive unit, electrical harness and a wind deflector. A safety feature is incorporated into the system which ensures that the sunroof automatically opens in the event the sunroof encounters an obstruction while it is being closed. A further feature is the interconnection between the sunroof and the vehicle’s ignition system which G39860 en
automatically closes the sunroof from any position when the ignition key is removed. When closed in this manner, the sunroof has automatic jamming protection.
Operating Instruction Opening - tilt positions The sunroof is controlled by its operating switch.
With the ignition on and the sunroof in the closed position, press the switch. The sunroof will open to the maximum tilt position open. By quickly pressing the switch, the sunroof will move down slightly to the second highest tilt position A. The next quick press of the switch will move it down to position B and so on until the sunroof is closed. 01/2003 2003.0 BA Falcon
501-17-5
Sunroof
501-17-5
DESCRIPTION AND OPERATION (Continued) Auto-close
Alternatively, press and hold the switch until the sunroof tilts to the desired open position. When the switch is released or the sunroof reaches the highest tilt position, the opening function will stop. You can press and hold the switch until the sunroof has lowered to the desired position. If the switch is released or the sunroof reaches the closed position, the closing function will stop.
When you turn off the ignition, the sunroof will beep to indicate that auto-close will be activated. After 3 seconds, the sunroof will automatically start to close which will be indicated by 2 beeps. Once the sunroof has started to automatically close, you can stop it from closing fully by briefly pressing the or switch. If you don’t want the sunroof to close from its current open position, press the or switch during the 3 second interval and it will not start to close. You can still close the sunroof when the ignition is off. Always ensure there are no obstructions to ensure the sunroof closes completely when leaving the vehicle.
Sunroof Position Memory
Two preset positions can be stored for the sliding range of the sunroof. To program: 1. Place the panel in the desired position. 2. Press and hold the 1 switch until you hear a beep (approx. 3 seconds). Opening - sliding open 3. Place the panel in the second desired position. With the ignition on, press the switch. The sunroof 4. Press and hold the 2 switch until you hear a beep (approx. 3 seconds). will start to slide open. To stop the movement before it To select either programmed position, press the 1 or 2 opens fully, quickly press the or switch. To switch. By briefly pressing the switch, the sunroof close the sunroof, quickly press the switch. can be opened completely. Alternatively, press and hold the switch until the sunroof slides to the desired open position. When the Cleaning switch is released or the sunroof reaches the fully open position, the opening function will stop. You can Keep the sunroof gutter areas and drain openings free of dirt, dust, leaves etc. Use an air hose twice a year press and hold the switch until the sunroof has to clean gutter areas and drain tubes. Clean the glass closed to the desired position. If the switch is released panel using only a mild non-scratching detergent and or the sunroof reaches the closed position, the closing a moist chamois leather. function will stop.
Closing - from open or tilt position Quickly press the C button to close the panel from any position.
One-touch control The sunroof can be operated by one-touch control. With the ignition on, if the or switch is momentarily pressed (for a maximum of 0.3 seconds) for the required movement (either open or closed) it will travel to the fully open or fully closed position. Movement can be stopped at any intermediate position by again pressing either switch.
Safety operation If the sunroof is closed by either one-touch control or auto-close, jamming protection is provided. The sunroof will automatically re-open if it encounters an obstruction while closing. After reaching the fully open position, the sliding (closing) movement automatically recommences. The sunroof will continuously try to close until the obstruction has been removed. G39861 en
01/2003 2003.0 BA Falcon
501-17-6
Sunroof
501-17-6
DESCRIPTION AND OPERATION (Continued) Wiring Routing
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01/2003 2003.0 BA Falcon
501-17-7
Sunroof
501-17-7
DIAGNOSIS AND TESTING Motor
Sunroof
Disconnect the motor wire (green/black) from the sunroof control unit. Dismount the motor. Use a Wire Harness Sunroof Control Unit to Battery double wire of sufficient length, connect directly to battery and inspect the motor for proper operation in Check if the power supply on the red and red/black both directions. This is accomplished by reversing the wires are OK? Inspect for broken/damaged wires. connection of the double wire. The motor has an Inspect for proper connection to the sunroof control inbuilt thermal cut-out device that automatically unit. The wire harness connector is numbered to aid switches the motor off during periods of overload. in proper installation: After a cooling down period the motor will function Connector Power on wire if Power on wire if properly. ignition is off ignition is on Sunroof Control Unit Wire number 1 12 V 12 V Testing is covered in the electric trouble shooting (red) guide. The following failures could be the a result of a Wire number 2 Ground Ground broken Sunroof Control Unit. (green) Auto close function defective. Wire number 3 0 V 12 V Soft touch operation defective (red/black) Comfort position can not be programmed Wire Harness Sunroof Control Unit to Control 4 step down option defective Panel One way closing defective Inspect for proper power supply to the STRATOS 700 Before exchanging the Sunroof Control unit, the SCU control panel, accomplished by using a voltage meter needs to be calibrated. Proceed with the trouble on the connector pins. Measurements with battery shooting table if the problem is not solved by the voltage of 13 V: calibration.
Inspection and Verification
Connector Wire 1 (red) Wire 2 Wire 3 Wire 4 Wire 5 Wire 6
Power on wire if Power on wire if ignition is off ignition is on 10.9 V 13 V 10.9 V 13 V 0V 0V 0V 0V 0V 0V 0V 0.6 V
Calibration of the SCU The first time the S.C.U. is connected to the power supply, the maximum tilt position must be defined. Proceed as follows: 1. Turn on the ignition. 2. Open the panel to the maximum tilt position till it reaches the mechanical block (continuous control the switch). The maximum tilt position is now stored in the Control Unit and all electrical features are available. 3. To complete the calibration, the panel must be moved to the complete opened position by soft touch operation.
Testing Electrical Components Ensure that during the test of electrical components the TVS unit is connected to a 12 to 14V power source. If the unit is installed, the battery needs to be connected and operable. During testing the ignition/accessory switch should be on. This test can be accomplished with a test light/votage meter. Cable harness and motor inspection requires the removal of the headlining.
Fuse Visually inspect the fuse for damage.
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01/2003 2003.0 BA Falcon
501-17-8
Sunroof
501-17-8
DIAGNOSIS AND TESTING (Continued) Symptom Chart Condition
Source
Action
While cycling the panel from tilt to close it begins sliding rearward.
Replace blocking catch.
Blocking catch is broken.
While cycling fully open panel forward, it begins tilting under roofskin.
Replace blocking catch.
Blocking catch is broken.
Panel is misaligned side to side.
Retime drive cables.
Timing to drive cables incorrect.
Panel sliding too slowly (with 13.5V power supply panel should not take more than 7 sec. to cycle from full retraction to closure).
Weak battery.
Charge or replace.
Misaligned panel creating drag or friction.
Retime drive cables.
Weak motor. Test as indicated in electrical trouble shooting section.
Replace motor.
Dirty mechanism.
Clean and grease mechanism or replace if necessary.
Sunroof control unit adjusted improperly, panel stopping prior to cycle.
Synchronize sunroof control unit.
Obstacle in mechanism or guide track.
Find object and remove.
One or two rear panel nuts not tightened properly.
Tighten panel nuts. Refer Final Assembly and Adjustments section.
Sliding cap (plastic) on long lever not in place or functioning improperly.
Inspect for proper alignment or replace.
Drain channel rattles.
Inspect for insulator tape between drain channel and mechanism.
Add insulator tape.
Squeaking sunshade.
Plastic to metal movement between sunshade and slides.
Grease contact spots.
Sunshade handle rattling on trim finisher.
Curvature of front sunshade incorrect.
Correct curvature, manual adjustment.
Rattling in motor area.
Cover plate on motor has loose screws.
Tighten coverplate screws.
Wind noise: Panel closed, excessive wind noise.
Replace blocking catch.
Correct glass panel adjustment. Refer Final Assembly and Adjustment section.
Blocking catch broken.
Glass panel seal not tight to trim ring.
Panel vented emitting whistling sound.
Vinyl headlining material wrapped around sunshade too thin, creating large wind channel between rail and side of sunshade.
Place insulating tape along either outboard edge of sunshade to close channel.
Water leakage: Water coming through panel opening area.
Blocked drain tubes.
Inspect drain tubes c!ean opening, blow out tubes.
Misaligned or kinked drain tubes.
Correct routing of drain tubes.
Housing frame distorted, seal to rail disconnected.
Correct frame curvature if necessary reseal rail to frame.
Rear rail bracket has broken seal.
Reseal at rear rail seal point. Refer Trimming Repair section.
Frame seam has improper seal.
Reseal at seam.
Blocking of mechanism, glass panel stopping prematurely.
Rattles: Rear of panel rattling in any position.
Headlining wet in front.
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01/2003 2003.0 BA Falcon
501-17-9
Sunroof
501-17-9
DIAGNOSIS AND TESTING (Continued) Condition
Source
Action
Sunshade fails to open when glass panel is opened to tilt position.
Retraction mechanism broken.
Replace retraction mechanism.
Operating of the sunroof is possible, no auto-close, no Soft-touch.
Voltage-drop of power supply (changing battery or bad battery).
Check power-supply Reset programmable preset positions.
Clicking noises of CSU, panel not sliding.
Voltage to low.
Check power-supply/battery.
CSU clicking in open position, roof does not close with continuous pressing of button.
Voltage-drop or power-supply.
Cut off power-supply briefly (pull fuse), reset programmable positions.
Pinpoint Tests PINPOINT TEST A : SUNROOF NOT OPERATING CORRECTLY Test Step A1
Result / Action to Take
PANEL OPERATION Turn the ignition switch on. Does the panel move when holding switch pressed?
Yes
Go to A2
No
Go to A9
A2
PANEL DIRECTION Does the panel move in both directions?
Yes
Go to A3
No
Go to A14
A3
PANEL TILTING Is panel tilting and sliding possible?
Yes
Go to A4
No
Go to A20
A4
SOFT TOUCH OPERATION Is soft touch operational?
Yes
Go to A5
No
Re-program preset stops and retest sunroof.
A5
AUTO-CLOSE FUNCTION Is the auto close function working?
Yes
Go to A6
No
Go to A11
A6
COMFORT POSITION Is the comfort position working?
Yes
Go to A6
No
Replace Sunroof control unit and retest.
G39862 en
01/2003 2003.0 BA Falcon
501-17-10
Sunroof
501-17-10
DIAGNOSIS AND TESTING (Continued) Test Step A7
Result / Action to Take
ONE-WAY CLOSING Is the one-way closing function working?
Yes
Go to A8
No
Replace Sunroof control unit and retest.
A8
MOTOR OPERATION Does the motor stop, SCU click in and position to max slide and max position?
Yes
Sunroof O.K.
No
Replace Sunroof control unit and retest.
A9
SCU OPERATION Does the SCU make a ’click’ sound?
Yes
Go to A10
No
Go to A12
A10
MOTOR Is the motor running properly?
Yes
Solve mechanical failure and retest.
No
Go to A20
A11
POWER ON RED/BLACK WIRE Is the power over red/black wire when the ignition is switched?
Yes
Replace Sunroof control unit and retest.
No
Improve red/black connection and retest.
A12
WIRE VOLTAGE CHECK On the SCU, does the red, red/black and green wires measure 12V?
Yes
Go to A13
No
Go to A15
A13
RED/BLACK WIRE VOLTAGE Is the red/black power line 12V when body is grounded?
Yes
Go to A14
No
Go to A16
A14
SWITCH CHECK Does the switch appear to be O.K?
Yes
Go to A17
No
Replace the switch and retest.
G39862 en
01/2003 2003.0 BA Falcon
501-17-11
Sunroof
501-17-11
DIAGNOSIS AND TESTING (Continued) Test Step A15
Result / Action to Take
SCU POWER LINE VOLTAGE Does the SCU power line measure 12V when the body is grounded?
Yes
Improve ground wire connection and retest.
No
Go to A18
A16
FUSE 15A CHECK (MOBILE OFFICE) Is fuse 15A O.K?
Yes
Go to A19
No
Replace fuse 10A and retest.
A17
WIRE HARNESS CHECK Is the wire harness O.K.?
Yes
Replace Sunroof control unit and retest.
No
Replace wire harness and retest.
A18
FUSE 30A CHECK (SEAT) Is fuse 30A O.K?
Yes
Go to A19
No
Replace fuse 20A and retest.
A19
WIRE HARNESS CHECK Does the wire harness appear to be O.K.?
Yes
Improve power line connection and retest.
No
Replace wire harness and retest.
A20
POWER ON RED WIRE Is there sufficient power supply over the red wire when operating Yes Replace the motor and retest. the switch?
No
Improve red wire connection and retest.
G39862 en
01/2003 2003.0 BA Falcon
501-17-12
Sunroof
501-17-12
GENERAL PROCEDURES
Sunshade Check 1. Slide mechanism full backwards. 2. Push sunshade retraction mechanism, on both sides, completely forwards with a small screwdriver.
6. Adjust the glass panel to the front. Check with for example a business card the tension of the seal against the trim ring at the rear. 7. Tighten both center screws. 8. Adjust height at the front and tighten front screws. 9. Adjust height at the rear by loosening torx screws of the adjustment curve, adjust the glass level with roof-skin and tighten screws (see figure 12). Torque for all M5 screws is 3.5 Nm.
3. Check sunshade for curvature, headlining, for dirt, damage, etc. 4. Push slide blocks on one side into locked position. 5. Place sunshade in position between slide rails, 10. Check functioning of mechanism and unlock slide blocks. adjustments. Repeat operation 6 till 9 to readjust 6. Check for proper functioning. the glass panel if necessary.
Glass Panel Adjustment
Glass Panel Seal Adjustment
1. Slide mechanism to tilt position. 2. Inspect rubber seal and glass panel for damage. 3. Place the height adjustment curve, (which is at the rear of the glass panel), over the mechanism. Place vertical front lips on panel between the RH and LH mechanisms. 4. Lift the mechanism mounting bracket from the inside and install the 2 front and 2 center screws, leaving the 4 screws untightened. 5. Put glass panel in closed position.
The proper positioning of the panel should result in the seal firmly contacting either the EPDM trim ring or flanged metal of the sunroof opening. If the panel fits properly but gaps remain between seal and trim ring it can be corrected as follows: 1. Adjust panel properly against the rear of the trim profile (Refer to Final Assembly and Adjustment Section). 2. With a grease pencil mark the boundaries of insufficient contact on the panel (at the front). 3. Remove panel.
G39863 en
01/2003 2003.0 BA Falcon
501-17-13
Sunroof
501-17-13
GENERAL PROCEDURES (Continued) 4. In the areas marked, a spacer will be inserted 9. Check functioning and adjustments. inside the rubber seal. Use a vinyl tube with outer Wind Deflector Adjustment diameter of 3 mm (0.12 in) for spacer material. 1. Slide panel backwards. 2. Bring deflector in position. 3. Adjust deflector to 4mm between trim profile and deflector. 4. Tighten two capnuts (2 Nm). 5. Check operation of deflector.
Mechanism Covers Adjustment 1. Before mounting mechanism covers, check functioning of completed roof on sunshade, mechanism, wind deflector and adjustments of glass panel. Correct if necessary. 2. Put mechanism in tilt position. 3. Place cover top part over 3 pins on side adjustment brackets and lower part in rail under drain channel.
5. Glue the spacer material to the seal with super glue. 6. Remount panel and adjust.
4. Check functioning.
Ventilation Tray Adjustment 1. Slide the steel panel to tilt position. 2. Slide the ventilation tray completely to the rear (release the 2 springs from the drain channel if necessary). 3. Place the ventilation tray in the rail, starting with the front guides, and slide it to the front. When the ventilation tray slides completely to the front it can occur that the guides come loose from the rail. 4. Place the left and right tumble mechanism over the middle support pin of the steel panel. 5. Tumble the hook of the tumble mechanism into the slot in the ventilation tray and fasten the mechanism with a parker. 6. Place the panel in closed position. 7. Make sure the ventilation tray is parallel to the trim tray. The rear corners of the ventilation tray can be bend slightly if necessary. 8. The springs of the trim tray are automatically locked to the drain channel during sliding open. G39868 en
01/2003 2003.0 BA Falcon
501-17-14
Sunroof
501-17-14
REMOVAL AND INSTALLATION 3. Remove rear of headliner to access motor cover. 4. Remove motor cover, motor now drops down. Removal and Installation 5. Disconnect the motor wire from the sunroof 1. Remove or drop rear of headliner to access motor control unit. cover. 6. Remove the S.C.U. with screw, drop the front, 2. Remove cover, motor now drops down. slide back. 3. Disconnect the motor wire from the sunroof 7. Remove the gearwheel housing by removing the control unit. two screws. 4. Connect new motor to sunroof control unit. 8. Remove gearwheel by inserting screw-driver, push forward, it drops down. 5. Inspect motor for proper operations in both direc-tions. 6. Remount motor and motor cover. 7. Inspect the unit for proper electrical and mechanical functioning. 8. Re-install headliner.
Motor
Sunroof Control Unit (SCU) Removal and Installation 1. Remove or drop rear of headliner to access motor cover. 2. Remove cover, motor now drops down. 3. Disconnect the motor wire from the S.C.U and remove the motor. 4. Disconnect the wire harness from the S.C.U. 5. Remove the S.C.U. with screw, drop the front, slide back. 6. Place the new sunroof control unit by dropping the front of the S.C.U. low enough for cable clearance slide forward, engage lip of cable plate in S.C.U. slot. Straighten S.C.U. horizontally and tighten screw. 7. Reconnect both wire connectors to the S.C.U. and remount motor and cover. 8. Calibrate the SCU: The first time the S.C.U. is connected to the power supply, the maximum tilt position must be defined. Proceed as follows: Turn on the ignition. Open the panel to the maximum tilt position till it reaches the mechanical block (continuous control the switch). The maximum tilt position is now stored in the Control Unit and all electrical features are available. To complete the calibration, the panel must be moved to the complete opened position by soft touch operation. 9. Check proper functioning of sunroof. 10. Mount headliner. 11. Remount the LH mechanism cover.
9. Place a screwdriver in the mechanism as indicated. Push this mechanism rearward into the slide position. Continue pushing backwards by placing hand on front of mechanism, 3 locator screws become accessible.
10. Remove the locator being careful to remember the positioning of screws and the blocking catch. 11. Pull mechanism all the way forward. 12. Push the mechanism into tilt position. Be sure you do not inadvertently dislodge the mechanism. Keep the front of the mechanism down. 13. Remove the front screw and slide the retraction Drive Cables mechanism forward. Do not take out. 14. Slide mechanism in tilt position further forward. Removal and Installation 15. You can now see the cable. Lift out cable and pull 1. Remove covers, panel, drain channel, wind forward out of the guide rail track. deflector and sunshade or trim tray and ventilation tray and adjustment bracket. 2. Place mechanism in closed position. G39869 en
01/2003 2003.0 BA Falcon
501-17-15
Sunroof
501-17-15
REMOVAL AND INSTALLATION (Continued) 16. Inspect for proper length of new cable, grease and slide into rail. Make sure the oval shaped copper head of the cable seats firmly and diagonally across the guide channel.
17.
18. 19. 20. 21. 22. 23.
24. Mount the new gearwheel. Being sure to center it evenly between the walls of the hole in the motor bracket. NOTE: The core or center of the gear has splines (teeth). The splines do not extend completely to one side of the gears inner core. This is the down (bottom) side for mounting
25. Mount the new gearwheel housing. 26. Mount the sunroof control unit. Dropping the front of the S.C.U. low enough for cable clearance slide forward, engage lip of cable plate in S.C.U. slot. Straighten S.C.U. horizontally and tighten screw. 27. Connect the motor to the sunroof control unit (wire one way connector). 28. Remount motor and cover, replace screws. 29. Calibrate the SCU as described in the Electrical Trouble Shooting Section. To check that cable is positioned properly grasp 30. Inspect the sunroof for proper electrical and long lever in tilt position with one hand, the mechanical functioning. pivoting adjustment bracket in the other hand and 31. Remount headliner. slide backwards, it should slide into place (if 32. Remount sunshade or ventilation tray and trim blocked turn cable slightly to reseat copper oval tray, drain channel, panel, wind deflector and head properly). mechanism covers. Push mechanism into slide position as in point 9. 33. Final inspection of unit. Slide whole mechanism rearwards to allow remoun-ting of locator. Drive Cables Timing Slide the retraction rearwards, remount screw and Removal and Installation locator. 1. Fully tilt panel. Repeat points 10 through 22 to replace other cable. 2. Remove LH/RH mechanism covers. Slide both LH/RH mechanisms to the front 3. Fully close panel. position. 4. Drop rear of headliner to access motor cover Push LH/RH mechanisms to closed position. plate. Insert a pin in each 2.5 mm brass hole. (pointed 5. Remove motor cover, motor now drops down. object). Slide mechanism forward until pin stops 6. Disconnect sunroof control unit wires and remove the mechanisms movement at the desired the motor. location. 7. Dismount sunroof control unit with screw, drop the front and slide back. 8. Remove the gearwheel housing by removing the two screws.
G39872 en
01/2003 2003.0 BA Falcon
501-17-16
Sunroof
501-17-16
REMOVAL AND INSTALLATION (Continued) 9. Remove gearwheel by inserting screwdriver, push 2. Remove seal from panel. forward, it drops down. 3. Remove all foreign debris from around glass frame. 4. Install new seal, beginning at center front of glass panel retaining channel. 5. Utilizing your thumbs, insert seal with enough pressure to be sure of flushness (tight to panel). 6. Trim the glass seal length. when cutting excess leave approximately 6 mm extra then work it into retaining channel. 7. Remount the panel. 8. Mount the LH / RH mechanism cover.
Retraction Mechanism Item 1 2
Description SCU spots on gear wheel view finders SCU spots on gear wheel view finders
10. Push mechanisms LH/RH to closed position. Access each 2.5 mm brass hole with a pin (pointed object). Slide mechanism forward until pin stops the mechanisms movement at the desired location. 11. Mount the new gearwheel. Being sure to center it evenly between the walls of the hole in the motor bracket. Note that the core or center of the gear has splines (teeth). The splines do not extend completely to one side of the gears inner core. This is the down (bottom) side for mounting. 12. Mount the new gearwheel housing. 13. Mount the sunroof control unit. Dropping the front of the S.C.U. low enough for cable clearance slide forward, engage lip of cable plate in S.C.U. slot. Straighten S.C.U. horizontally and tighten screw. 14. Connect the motor to the sunroof control unit. (wire one way connector). 15. Remount motor and cover, replace screws. 16. Calibrate the SCU as described in the Electrical Trouble Shooting Section. 17. Inspect the sunroof for proper electrical and mechanical functioning. 18. Remount headliner. 19. Remount the LH mechanism cover. 20. Final inspection of unit.
Glass Panel Seal
Removal and Installation 1. Retract panel completely. 2. Remove the wind deflector. 3. Remove the two screws and take the retraction mechanism forwards out of rail. 4. Install new retraction mechanism in rail. 5. Remount the wind deflector. 6. Inspect for proper functioning.
Guide Rail Mechanism Removal and Installation 1. Remove LH/RH mechanism covers, panel, drain channel, wind deflector and sunshade. 2. Fully retract mechanism. 3. Remove the locator, retraction mechanism and rail screw. 4. Remove wind deflector mounting nuts. 5. Slide rail sideways to unlock, then lift front up. 6. With rail front up, remove retraction mechanism. 7. Fully close mechanism. 8. Lift and pull rail slowly forward over mechanism, as soon as the front of drive cable appears at end of guide, lift out cable, now pull mechanism carefully forward and lift out. Inspect the new replacement mechanism for cleanliness and completeness. 9. Slide the new mechanism rearward out of rail for cable installation access. 10. Install cable, then push mechanism forward on rail (maintain access to rear rail area).
Removal and Installation 1. Dismount LH / RH mechanism covers, glass panel and exterior covers.
G39872 en
01/2003 2003.0 BA Falcon
501-17-17
Sunroof
501-17-17
REMOVAL AND INSTALLATION (Continued) 11. Apply a bend of liquid butyl as indicated.
11. Remount panel, LH/RH mechanism covers. (Refer Final Assembly and Adjustments section).
Drain Channel Removal and Installation 1. Slide mechanism to tilt position. 2. Slide sunshade to half open position. 3. Mount drain channel on mechanism with screws and washers (torque 0.8 Nm). High side at the rear. 4. Check function of mechanism.
12. Slide rail rearward over mechanism and drive cable while holding the front of the mechanism in place. As soon as the rail is fully extended rearward, drop the front to frame and push rail rearward into rail stop. Line up the screw holes for proper positioning. 13. Retract mechanism totally. 14. Lift front of rail to reinstall retraction mechanism. 15. Drop rail down, push inboard until it "locks" in place. 16. Remount all new rail screws starting at front for proper positioning. Use original positioning of screws by size. 17. Replace wind deflector mounting nuts loosely. 18. Tilt mechanism completely. 19. Inspect for proper mechanical functioning of mechanism. 20. Remount sunshade, drain channel, panel and wind deflector. 21. Inspect functioning of sunroof, reinstall LH/RH mechanism covers.
Blocking Catch Removal and Installation 1. Remove LH/RH mechanism covers and panel. (Refer Final Assembly and Adjustments section). 2. Fully retract mechanism. 3. Remove locator, 4. Fully tilt mechanism. 5. Romove blocking catch by lifting out. 6. Locate and clean out broken blocking catch debris. 7. Install new blocking catch in mechanism, insert circular eye stud into mechanism making sure second smaller stud falls cleanly into mechanism slot. 8. Fully retract mechanism. 9. Remount locator. 10. Inspect for proper mechanical functioning. G39877 en
01/2003 2003.0 BA Falcon
501-19-1
Bumpers
501-19-1
SECTION : 501-19 Bumpers VEHICLE APPLICATION : 2003.0 BA Falcon CONTENTS
PAGE
SPECIFICATIONS Specifications ........................................................................................................................501-19-2 DESCRIPTION AND OPERATION Bumpers ................................................................................................................................501-19-3 REMOVAL AND INSTALLATION Front Bumper ........................................................................................................................501-19-4 Rear Bumper — Sedan ........................................................................................................501-19-5 Rear Bumper — Wagon .......................................................................................................501-19-6 Rear Bumper — Ute .............................................................................................................501-19-7
01/2003 2003.0 BA Falcon
501-19-2
Bumpers
501-19-2
SPECIFICATIONS Torque Specifications Description Upper Front Bumper Screw Rear bumper Retaining Nut (Sedan) Rear bumper Retaining Nut (Wagon) Rear bumper Retaining Nut (Ute) Rear bumper Retaining Bolt (Ute)
G32450 en
Nm 10 3 3 35 35
01/2003 2003.0 BA Falcon
501-19-3
Bumpers
501-19-3
DESCRIPTION AND OPERATION
Bumpers The bumper system consists of the following components: Front bumper Rear bumper
G32451 en
01/2003 2003.0 BA Falcon
501-19-4
Bumpers
501-19-4
REMOVAL AND INSTALLATION
Front Bumper
3. Disconnect the electrical connector to each lamp.
Removal 1. Remove the fender splash shield. Remove the retaining scrivets (9 x 6mm), screws and firtree clips. NOTE: There are a total of 2 screws attaching the front lower section of the splashshield. NOTE: Adjust torque specifications at the front of the document.
Item 1 2
Description Wiring Harness Bumper Assy
4. Remove the two plastic push-in rivets from the radiator grille and lift grille to remove.
Item 1 2 3 4 5
Description Fender Splash Shield Firtree clip 6.5x25mm (2 off) Scrivets - 6mm (9 off) Screw - 5mm (1 off) Screw - 5mm (2 off)
2. Remove the "lower air deflector" by removing the eight attaching screws and two plastic push-in rivets and sliding the air deflector rearwards. Item 1 2
Item 1 2 3 4
Description Rivet push in Grille
Description Air deflector Screw Rivet push in Splash shield
G32452 en
01/2003 2003.0 BA Falcon
501-19-5
Bumpers
501-19-5
REMOVAL AND INSTALLATION (Continued) 5. Remove the two screws from the bumper rabbit ears.
Rear Bumper — Sedan Removal 1. Remove the rear splash shield by removing 2 plastic push in rivets, one rivet and a screw.
Item 1 2 3
Description Screws Upper crossmembers Bumper
Item 1 2
Description Front Absorbers Screw and washer assy
Item Description 1 Rivet Aliminium 6. To detach the bumper from the bumper mounting 2 Screw brackets, hold the bumper by the wheel arch 3 Rivet - Push in plastic opening and push up, at the same time slowly pull outboard until the tip of the bumper is clear of the 4 Splash Shield fender. At this point push up, at the same time slowly pull outboard until the bumper "clicks" clear 2. Remove plastic push in rivet in wheel arch. 3. Remove three scrivets from the fording plate. of the bracket. NOTE: Fording plate should be below the wheel 7. The bumper absorbes can be removed by tub tabs. removing the three screws for each side.
4. Disconnect the electrical connector (if applicable). 5. Remove boot trim scuff plate and foldback side carpets to expose the four mounting nuts.
Installation 1. Reverse the procedure for Removal.
G32452 en
01/2003 2003.0 BA Falcon
501-19-6
Bumpers
501-19-6
REMOVAL AND INSTALLATION (Continued) 6. Remove four mounting nuts from inside the boot.
Rear Bumper — Wagon Removal 1. Undo fording plate by drilling out the heads of the two rivets at the bumper lower edge.
Item 1 2 3
Description M5 Nuts Bumper Assy Body
7. To detach the bumper from the bumper mounting brackets, hold the bumper by the wheel arch opening and push up, at the same time slowly pull outboard until the bumper "clicks" clear of the bracket.
Item 1 2 3 4 5
Description Nut & Washer Assy Nylon retainer - Oval Nylon retainer - Round Rivet Scrivet
2. Drill out tow plug rivets if fitted. 3. Remove splash shield “removable rivets”.
Installation 1. Reverse the procedure for removal.
Item 1 2 3
G32452 en
Description Bolt M6 Front cross member Bumper front cover
01/2003 2003.0 BA Falcon
501-19-7
Bumpers
501-19-7
REMOVAL AND INSTALLATION (Continued) 4. Remove the nut from inside the wheel arch on each side.
Item 1 2 3 4 5
Description Nut & Washer Assy Nylon retainer - Oval Nylon retainer - Round Rivet Scrivet
5. Remove scrivets (4) attaching front top edge of bumper. 6. Pull out bumper and stud at the wheel arch and quarter panel. The push-in studs mid way along the side of the bumper will pull out with a small amount of force. 7. Slide bumper rearwards. 8. To remove the splash shields from the vehicle, drill out the two rivet heads if required. Installation 1. Reverse the procedure for Removal.
5. Remove bolt.
Item 1 2 3
Description Nut Bolt Valence Panel
6. Remove bumper assembly. 7. Disconnect wiring. Installation 1. Reverse the procedure for Removal.
Rear Bumper — Ute Removal 1. Remove tail lamps. 2. Remove stone deflector flap. 3. Remove 2 nuts at each end. 4. Remove licence plate.
G32455 en
01/2003 2003.0 BA Falcon
501-20a-1
Occupant Restraints — Active
501-20a-1
SECTION : 501-20a Occupant Restraints — Active VEHICLE APPLICATION : 2003.0 BA Falcon CONTENTS
PAGE
SPECIFICATIONS Specifications ......................................................................................................................501-20a-2 DESCRIPTION AND OPERATION Occupant Restraint System ................................................................................................501-20a-3 Safety Belt Buckle Pretensioner and Switch .....................................................................501-20a-3 Energy Management Retractor ..........................................................................................501-20a-4 Web Grabber Retractor ......................................................................................................501-20a-4 Child Restraint System .......................................................................................................501-20a-4 DIAGNOSIS AND TESTING Occupant Restraint System ................................................................................................501-20a-6 Inspection and Verification .................................................................................................501-20a-6 Symptom Chart ..................................................................................................................501-20a-6 Component Tests ...............................................................................................................501-20a-6 GENERAL PROCEDURES Occupant Restraints — Active ............................................................................................501-20a-7 Belt Minder Deactivation/Activation ....................................................................................501-20a-7 REMOVAL AND INSTALLATION Front Safety Belt Retractor .................................................................................................501-20a-8 Rear Outer Safety Belt Retractor ........................................................................................501-20a-8 Rear Centre Safety Belt Retractor — Sedan ....................................................................501-20a-10 Rear Centre Safety Belt Buckle/Minibuckle — Wagon .....................................................501-20a-11 Rear Centre Safety Belt Rectractor — Wagon .................................................................501-20a-11 Rear Centre Safety Belt Buckles ......................................................................................501-20a-12 Safety Belt Buckle and Pretensioner ................................................................................501-20a-13 Front Centre Seat Safety Belt Retractor — Ute ................................................................501-20a-13
01/2003 2003.0 BA Falcon
501-20a-2
Occupant Restraints — Active
501-20a-2
SPECIFICATIONS Torque Specifications Description Safety belt retractor bolt (all) Safety belt buckle and pretensioner bolt Safety belt lower anchor bolt (all) Safety belt shoulder height adjuster bolt Safety belt sash guide bolt Child safety seat tether anchor bolt Rear safety belt buckle and rear centre safety belt lower anchor nut Rear centre safety belt buckle nut
G32450 en
Nm 33 33 33 20 33 16 33 33
01/2003 2003.0 BA Falcon
501-20a-3
Occupant Restraints — Active
501-20a-3
DESCRIPTION AND OPERATION
Occupant Restraint System
Safety Belt Buckle Pretensioner and Switch
WARNING: All safety belt components include retractors, buckles, shoulder height adjusters, child safety tether bracket, safety belt bezels and attaching hardware must be replaced after they have been subjected to loading by occupants in a collision. Seat belt assemblies not in use during a collision should also be inspected and replaced if either damage or improper operation is noted.
The front seat safety belt buckles incorporate pretensioners and safety belt buckle switches, which both are connected to the restraints control module (RCM) secured to the floor under the instrument panel. If a fault is detected within the buckle system, the RCM will illuminate the air bag warning light in the instrument cluster. Refer to Section 501-20B. The safety belt buckle pretensioners will deploy at the same time with the front air bags in the event of a WARNING: Each seating position in the severe frontal collision. During a frontal collision, a vehicle has a specific safety belt assembly, which mechanism in the safety belt buckle system is consists of one buckle and one tongue. The safety triggered, which causes the buckle to move downward belt assembly is designed to be used as a pair and pull excess webbing from the lap and sash safety and is not to be used across seating positions. belts. The active restraint system consists of the following: The safety belt buckle pretensioner is not triggered in Front outboard seat safety belt energy the event of a minor frontal, side or rear collision. management retractors and shoulder height The safety belt buckle pretensioner is not triggered in adjusters, attached to the body under the B pillar the event of a frontal collision, if the safety belt tongue trim. is not latched in the buckle. Front outboard bucket seat safety belt buckles, After the ignition is switched on and the front driver attached to the inboard side of the seat. seat safety belt buckle is not latched in, the warning On the commercial vehicle fitted with an auto indicator in the instrument cluster will be on for 8 column gear shift, the front centre seat safety belt seconds or until the safety belt buckle is latched in. buckle is attached to the left hand side of the rear Belt Minder centre seat mounting foot. On the commercial vehicle fitted with an auto This feature provides additional reminders to the column gear shift, the front centre seat safety belt driver that the driver’s seat belt is unbuckled by retractor is attached to the rear body panel behind intermittently sounding a chime and illuminating the the trim panel. seat belt warning lamp in the instrument cluster. Rear seat safety belt retractors for the outboard IF.... THEN.... and centre seats, attached to the parcel shelf The driver’s seatbelt is The seatbelt warning light below the parcel shelf trim panel. not buckled when the illuminates for Rear centre and left hand side safety buckles, ignition is ON approximately 8 seconds attached to the floor pan under the seat cushion. or until the seatbelt is Rear centre and right hand side safety buckle, buckled attached to the floor pan under the seat cushion. The driver’s seat belt is The Belt Minder feature The child safety seat tether anchor, attached to not buckled and the is activated - the seatbelt the parcel shelf. vehicle is moving more warning light flashes and than 5km/h after the the warning chime The seat safety belt system utilises three-point lap ignition is switched on. sounds 5 times every 30 and sash safety belt in all seating positions. seconds, repeating for The retractors in all seating positions feature ELR. approximately 5 minutes During any period of sudden deceleration, or under or until the seat belt is torsion load when cornering at speed, a weight within buckled. the safety belt retractor moves a locking pawl against The driver’s seat belt is The Belt Minder feature the teeth on the retractor wheel, which then locks the buckled while the seat will stop activating. retractor preventing any further release of webbing. As soon as the load applied onto the retractor through belt indicator light is illuminated and the seat the safety belt webbing is removed the locking pawl belt warning chime is releases the retractor reel and normal movement is sounding. returned to the retractor. The driver’s seat belt is The Belt Minder feature buckled before the will not activate. ignition switch is turned to the ON position. G32451 en
01/2003 2003.0 BA Falcon
501-20a-4
Occupant Restraints — Active
501-20a-4
DESCRIPTION AND OPERATION (Continued) One time disable Anytime the seat belt is buckled and then unbuckled during an ignition ON cycle, Belt Minder will be disabled for that ignition cycle only.
Energy Management Retractor The front driver and passenger (if a passenger air bag is fitted) seat safety belt retractors, attached to the base of the B pillar, have an energy management feature designed to provide a controlled amount of webbing pay-out in severe frontal crashes. Once activated, the spindle in the retractor deforms so that the belt forces transferred to the occupant’s chest do not rise above a predetermined load. Item 1 The front passenger (if a passenger air bag is not fitted) seat safety belt retractor attached to the base of 2 3 the B pillar is a Web grabber retractor. 4 Child Restraint System 5
Web Grabber Retractor
WARNING: Rear-facing child restraint seat must not be placed in the front seat where a passenger air bag is fitted. Infants and small children should be restrained at all times in an approved child restraint suited to the vehicle and which conforms to AS1754-1991. Be sure to read the instructions provided by the restraint manufacturer, or consult an approved Restraint Fitting Station. Your automobile club or local vehicle registration authority can provide location details of fitting stations. Use the child restraint seat only for the purpose it was intended. Observe the manufacturer’s maximum load or weight specifications. Do not carry other articles in the child seat. A child restraint anchor fitting is installed in the rear centre anchorage position. Illustrations of the restraint attachment clip and anchor fitting are only applicable to child restraint attachment clips conforming to AS1754-1991. If your child restraint does not have an approved latched-hook attachment clip, you should consult an approved Restraint Fitting Station.
WARNING: Child restraint anchorages and fittings are designed to withstand only those loads imposed by correctly fitted child restraints. Under no circumstances are they to be used for adult seat belts or harnesses or for attaching other items or equipment to the vehicle. Incorrectly fitted child restraints may swing, twist, tip or come away causing death or injury. Anchorage points for the installation of child restraint anchor fittings are provided in the specific locations. Sedan
Item 1 2
G32451 en
Description Anchor Fitting Attachment Clip Upper Tether Strap Lock Washer Spacer
Description Plug Bracket Mount
01/2003 2003.0 BA Falcon
501-20a-5
Occupant Restraints — Active
501-20a-5
DESCRIPTION AND OPERATION (Continued) Wagon
plug originally fitted in the hole or seal the hole with a suitable plug or suitable bolt.
Item Description 1 Bracket 2 Screw To gain access to the anchorage points it is necessary to remove the small plug from the anchorage to install the appropriate bolt, lock washer, anchor fitting and spacer. Ute
Ensure the anchor fitting is correctly oriented towards the front of the vehicle, when the bolt is tightened. The components supplied with child restraints conforming to AS1754-1991 must be selected to suit the anchorage point(s) in the vehicle. Additional anchorage components may be obtained from child restraint manufacturers or suppliers. Please read and follow all the instructions supplied with the child restraint. If you have any doubts, contact the child restraint manufacturer or consult an approved Restraint Fitting Station. Child restraint anchorage points are manufactured into the vehicle. Consult the car owner’s manual for the location of the anchorage points. WARNING: If the child restraint attachment bolt is removed from the floor of your vehicle the hole must be effectively sealed to prevent exhaust gases entering the vehicle interior. Reinstall the G32452 en
01/2003 2003.0 BA Falcon
501-20a-6
Occupant Restraints — Active
501-20a-6
DIAGNOSIS AND TESTING
Occupant Restraint System Inspection and Verification 1. Verify the customer concern by operating the safety belts 2. Visually inspect for obvious signs of mechanical and electrical damage. Refer to the Visual Inspection Chart.
Visual Inspection Chart Mechanical Webbing Safety belt retractor and tongue assembly Safety belt buckle and pretensioner Safety belt shoulder height adjuster
Electrical Pretensioner wire Warning indicator bulb on cluster
3. If the concern is not evident, verify the system and proceed to the Symptom Chart.
Symptom Chart Condition
Source
Action
Normal mode - occupant restraint system inoperative
Webbing Safety belt retractor
CARRY OUT the Component Test in this section.
Safety belt warning indicator bulb is inoperative
Safety belt switch Circuitry RCM
Bulb Refer to DTC (Diagnostic Trouble Code) table in Section 501-20B.
1. Select for this test a quiet or private stretch of road. Make sure that the road is clear and that full Poor Retraction visibility is maintained at all times. 2. Both driver and passenger should adopt a normal, If a safety belt does not retract correctly, check that comfortable seating position. Both occupants the trim bezels are correctly installed and not rubbing should wear the safety belts and the safety belt against the safety belt webbing. Where necessary, webbing must be correctly adjusted, with no slack. check that the safety belt webbing is not rubbing at one end of the retractor cover slot and, if so, correct 3. Proceed at a speed of 10 km/h (6 mph). Do not by loosening the retaining bolt, aligning the retractor exceed 10 km/h (6 mph) for this test. to centralize the safety belt webbing and retighten the 4. Apply the foot brake sharply to stop the vehicle. If bolt. both shoulder straps lock up, the safety belt retractor assemblies are functioning properly. Functional Test 5. Conduct the test twice in each front and rear passenger seat position. WARNING: It is important that during this test the driver and passenger allows the safety belts to 6. Any safety belt retractor, which does not restrain provide the restraint and do not attempt to the wearer during this test, must not be reused. A anticipate the sudden deceleration. The steering new complete safety belt must be installed. wheel should not be used as a brace. However, Static Test both drive and passenger should prepare themselves for the possibility that the safety belt With the vehicle stationary and on level ground take will not lock. The passenger should hold their firm hold of the safety belt webbing (on the tongue hands in front of them, just clear of the instrument side of the safety belt upper anchor) and pull out panel or front seat backrest, depending on which quickly. The retractor should lock within 0.25 meter safety belt is being tested. Failure to follow these (10 inches), preventing further webbing payout. Any instructions may result in personal injury. safety belt retractor from which it is possible to extract further webbing, must not be used. A new complete safety belt must be installed.
Component Tests
G32453 en
01/2003 2003.0 BA Falcon
501-20a-7
Occupant Restraints — Active
501-20a-7
GENERAL PROCEDURES
Occupant Restraints — Active Safety Belt Cleaning WARNING: Do not bleach or re-dye the webbing, as the webbing may weaken. Clean the safety belt webbing only with a mild soap solution recommended for cleaning upholstery or carpets. Follow the instruction provided with soap. Safety Belt Procedure After a Collision WARNING: All safety belt assemblies including retractors, buckles, front seat belt buckle support assemblies, shoulder belt height adjusters, if so equipped, child safety seat tether attachments, and attaching hardware should be inspected after any collision. All belt assemblies should be replaced unless a qualified technician finds the assemblies show no damage and operate correctly. Belt assemblies not in use during a collision should also be inspected and replaced if either damage or improper operation is noted. NOTE: Safety belt assemblies should be periodically inspected to make sure they have not become damaged and that they remain in correct operating condition, particularly if they have been subjected to severe stress. Before installing the new safety belt assembly, the safety belt attaching areas must be inspected for damage and distortion. If the attaching points are damaged and distorted, the sheet metal must be reworked back to its original shape and structural integrity.
3. 4. 5. 6.
Buckle the seat belt. Press and hold the hazard button. Unbuckle then buckle the seat belt. Release the hazard switch. This will disable Belt Minder if it is currently enabled, or enable Belt Minder if it is currently disabled. Confirmation of disabling Belt Minder is provided when the seat belt warning light flashes 5 times. Confirmation of enabling Belt Minder is provided by constant illumination of the seat belt warning light for 5 seconds.
Install the new safety belt(s) using the appropriate instructions. Perform the Functional Test.
Belt Minder Deactivation/Activation CAUTION: The Belt Minder feature can be deactivated/activated by performing the following procedure. Before following the procedure, make sure that: the parking brake is on the gearshift is in P (Park) (automatic transmission) or the neutral position (manual transmission) the ignition switch is in the OFF position all vehicle doors are closed the driver’s seat belt is unbuckled the parklights/headlights are OFF WARNING: To reduce the risk of injury, do not deactivate/activate the Belt Minder feature while driving the vehicle. 1. Turn the ignition switch to the ON position. (DO NOT START THE ENGINE) 2. Wait until the seat belt warning light turns off. G32454a en
01/2003 2003.0 BA Falcon
501-20a-8
Occupant Restraints — Active
501-20a-8
REMOVAL AND INSTALLATION
Front Safety Belt Retractor Special Tool(s) Torx Bit T-50
4. Remove the safety belt shoulder height adjuster. Using M10 socket, remove the bolt. Remove the safety belt shoulder height adjuster.
Removal 1. Remove the safety belt anchor. Remove plastic bolt cap Using the special tool, remove the bolt Remove the safety belt anchor
Item 1 2
Item 1 2 3 4
Description Belt & Retractor Asy Frt Bolt 7/16 20 Screw Cap Spacer (UTE Only)
2. Remove the B pillar trim panel. Refer to Section 501-05 3. Remove the front safety belt retractor. Using the special tool, remove the bolt Remove the front safety belt retractor
Description Screw & Washer M8x20 Hex Flng Belt & Rectractor Asy Frt
Installation 1. To install, reverse the removal procedure. NOTE: Make sure to tighten all bolts to specification. NOTE: Make sure the safety belt webbing is not twisted prior to installation. NOTE: Make sure to align and install the safety belt retractor locating ear into the B-pillar sheet metal before installing the bolt. NOTE: Make sure the trim spreader bracket is fitted to the B pillar sheet metal before installing the height adjuster. 2. Check the active restraint system for correct operation.
Rear Outer Safety Belt Retractor Removal 1. Remove the rear seat cushion. Refer to Section 501-10.
Item 1 2
Description Belt & Retractor Asy Frt Screw M10x1.5
G32455 en
01/2003 2003.0 BA Falcon
501-20a-9
Occupant Restraints — Active
501-20a-9
REMOVAL AND INSTALLATION (Continued) 2. Remove the safety belt anchor. Using the special tool, remove the bolt Remove the safety belt anchor
Item 1 2
Description Belt & Rectractor Asy Rr Bolt Corflex (Pt of item 1)
Item 1 2 3 4 5
Description Bolt Corflex (Pt of item 3) Belt & Retractor Asy Rr C Pillar Trim Safety belt trim (Pt of item 2) Bolt 7/16 20
4. Remove the child safety seat tether anchor 3. Remove the safety belt trim (Sedan only) Prise off the safety belt trim from the package Using a 5mm hexagon key, remove the bolt tray trim (Sedan only) Remove the child safety seat tether anchor on Remove the safety belt trim from C pillar the package tray trim (Wagon only) Remove firtree clips
Item 1 2 3 4
Description Safety belt trim (Pt of item 3) Bolt Corflex (Pt of item 3) Belt & Rectractor Asy Rr Pkg Tray Trim
G32456 en
Item 1 2
Description Plug Bracket - Child Seat Back Mount
5. Remove the package tray trim. Refer to Section 501-05. Remove the pillar trim (Wagon only). Refer to Section 501-05.
01/2003 2003.0 BA Falcon
501-20a-10
Occupant Restraints — Active
501-20a-10
REMOVAL AND INSTALLATION (Continued) 6. Remove the rear safety belt retractor. Feed the safety belt webbing through the package trim opening Using the special tool, remove the bolt (s) Remove the rear safety belt retractor Installation 1. To install, reverse the removal procedure. NOTE: Make sure to tighten all bolts to specification.
3. Remove the safety belt trim Prise off the safety belt trim from the package tray trim
NOTE: Make sure the safety belt webbing is not twisted prior to installation. NOTE: Make sure to align and install the safety belt retractor locating tab into the package tray panel before installing the bolt. 2. Check the active restraint system for correct operation.
Rear Centre Safety Belt Retractor — Sedan Removal 1. Remove the rear seat cushion. Refer to Section 501-10. 2. Remove the safety belt buckle and rear center anchor. Remove the nut Remove the safety belt anchor
4. Remove the child safety seat tether anchor (Sedan only) Using a 5mm hexagon key, remove the bolt Remove the child safety seat tether anchor on the package tray trim Remove firtree clips
Item 1 2
Item 1 2
Description Belt & Retrractor Asy Rr Ctr Nut M12
G32456 en
Description Plug Bracket - Child Seat Back Mount
5. Remove the package tray trim. Refer to Section 501-05.
01/2003 2003.0 BA Falcon
501-20a-11
Occupant Restraints — Active
501-20a-11
REMOVAL AND INSTALLATION (Continued) 6. Remove the rear centre safety belt retractor. Feed the safety belt webbing through the package trim opening Using the special tool, remove the bolt Remove the rear center safety belt retractor
3. To install, reverse the removal procedure. NOTE: Make sure to tighten all nuts to specification. NOTE: Make sure the safety belt webbing is not twisted prior to installation. NOTE: Make sure the safety belt buckles are accessible after repositioning the seat.
Item 1 2
Description Bolt Corflex (Pt of item 2) Belt & Retractor Asy Rr Ctr
Installation 1. To install, reverse the removal procedure. NOTE: Make sure to tighten all nuts and bolts to specification. NOTE: Make sure the safety belt webbing is not twisted prior to installation. NOTE: Make sure to align and install the safety belt retractor locating tab into the package tray panel before installing the bolt.
Item 1 2
Description Rear centre safety belt buckle/mini buckle Nut M12
Rear Centre Safety Belt Rectractor — Wagon Removal and Installation 1. Unbuckle mini buckle. 1. Insert a paper clip end into a hole on the under side of the mini buckle.
2. Check the active restraint system for correct operation.
Rear Centre Safety Belt Buckle/Minibuckle — Wagon Removal 1. Remove the rear seat cushion. Refer to Section 501-10. 2. Remove the safety belt buckle and rear center anchor. Remove the nut Remove the rear center safety belt buckle/minibuckle
G32459 en
01/2003 2003.0 BA Falcon
501-20a-12
Occupant Restraints — Active
501-20a-12
REMOVAL AND INSTALLATION (Continued) 2. Remove the safety belt guide. Prise off the safety belt guide from the seat back.
3. Disassemble the rear 60/40 split seat back. Refer to Section 501-10. Remove seat back trim and pad. 4. Remove the safety belt retractor. Remove the nut Remove the rear safety belt retractor
2. Remove the safety belt buckles. Remove the nut. Sedan
Wagon
Item 1 2
Item 1 2
Description Belt & Retractor Asy Rr Nut 7/16 20 Unf Hex Flg
5. To install, reverse the removal procedure. NOTE: Make sure to tighten all nuts and bolts to specification. NOTE: Make sure the safety belt webbing is not twisted prior to installation.
Description Rear centre safety belt buckles Nut M12
Remove the rear center safety belt buckles Installation 1. To install, reverse the removal procedure. NOTE: Make sure to tighten all nuts to specification. NOTE: Make sure the safety belt webbing is not twisted prior to installation. NOTE: Make sure the safety belt buckles are accessible after repositioning the seat.
6. Check the active restraint system for correct operation.
Rear Centre Safety Belt Buckles Removal 1. Remove the rear seat cushion. Refer to Section 501-10.
G32459 en
01/2003 2003.0 BA Falcon
501-20a-13
Occupant Restraints — Active
501-20a-13
REMOVAL AND INSTALLATION (Continued)
Safety Belt Buckle and Pretensioner Removal 1. Disconnect the battery ground cable.
Front Centre Seat Safety Belt Retractor — Ute
Removal 1. Remove the outboard seat bucket assembly from WARNING: Wait at least two minutes after the vehicle. For additional information, refer to disconnecting the battery ground cable, Section 501-10. before disconnecting any supplemental restraint system electrical connectors. Failure 2. Remove the safety belt anchor to follow this warning could cause premature Using the special tool, remove the bolt. deployment and may result in personal injury. Remove the safety belt anchor from the front 2. Wait two minutes. center seat leg. 3. Remove the front seat. For additional information, refer to Section 501-10. CAUTION: Note the position and routing of the wiring harness to aid assembly. An incorrectly routed harness may lead to the wires becoming damaged on the seat mechanism. Detach the seat wiring harness from the underside of the seat. 4. Detach the safety belt pretensioner wiring harness from the conduit.
Item 1 2
Description Belt & Retrector Asy Frt Ctr Bolt Corflex (part of item 1)
3. Remove the safety belt trim Prise off the safety belt trim from the back panel trim. 4. Remove the back panel trim. For additional information, refer to Section 501-05. 5. Remove the safety belt pretensioner Using the special tool, remove the bolt Remove the safety belt buckle and pretensioner Installation 1. To install, reverse the removal procedure. NOTE: Make sure to tighten all nuts and bolts to specification. NOTE: Make sure to align and install the anti-rotational slot of the safety belt buckle and pretensioner to the pin on the seat track before installing the bolt. 2. Deploy the safety belt buckle pretensioner assembly. For additional information, refer to Section 501-20b.
G32460 en
01/2003 2003.0 BA Falcon
501-20a-14
Occupant Restraints — Active
501-20a-14
REMOVAL AND INSTALLATION (Continued) 5. Remove the centre safety belt retractor Using the special tool, remove the bolts. Remove the center safety belt retractor assembly by lifting it up.
Item 1 2 3 4 5 6
Description Bezel (part of item 5) Belt Asy (part of item 5) Cur Asy Bk Pnl Trim Screw M10x1.5 Belt & Retrector Asy Frt Ctr Corflex Bolt (part of item 5)
Installation 1. To install, reverse the removal procedure. NOTE: Make sure to tighten all bolts to specification. NOTE: Make sure the safety belt webbing is not twisted prior to installation. 2. Check the active restraint system for correct operation.
G32460 en
01/2003 2003.0 BA Falcon
501-20b-1
Occupant Restraints — Passive
501-20b-1
SECTION : 501-20b Occupant Restraints — Passive VEHICLE APPLICATION : 2003.0 BA Falcon CONTENTS
PAGE
SPECIFICATIONS Specifications ......................................................................................................................501-20b-3 DESCRIPTION AND OPERATION Airbag and Safety Belt Pretensioner Supplemental Restraint System (SRS) ....................501-20b-4 Side Airbag Bridge Resistor ..............................................................................................501-20b-8 Driver Airbag Module ........................................................................................................501-20b-8 Clockspring .......................................................................................................................501-20b-8 Passenger Airbag Module .................................................................................................501-20b-8 Passenger Airbag Bridge Resistor .....................................................................................501-20b-8 Safety Belt Pretensioners .................................................................................................501-20b-8 Safety Belt Buckle Switches .............................................................................................501-20b-8 Seat Track Position Sensor ..............................................................................................501-20b-8 Restraints Control Module (RCM) .....................................................................................501-20b-8 Electrical System ..............................................................................................................501-20b-9 Sensors .............................................................................................................................501-20b-9 DIAGNOSIS AND TESTING Airbag and Safety Belt Pretensioner Supplemental Restraint System (SRS) ..................501-20b-10 Restraint System Diagnostic Tool Warning .....................................................................501-20b-10 Diagnosing Customer Concerns Without Hard DTCs ......................................................501-20b-10 Diagnosing Customer Concerns with Hard DTCs ...........................................................501-20b-10 Prove Out Procedure .......................................................................................................501-20b-12 Glossary ...........................................................................................................................501-20b-12 Airbag Reconnect Checklist .............................................................................................501-20b-13 Diagnostic Instructions — Airbag and Safety Belt Pretensioner Supplemental Restraint System (SRS) ................................................................................................................................501-20b-13 Diagnostic Test Modes ....................................................................................................501-20b-13 Bit-Mapped Diagnostic Trouble Codes (DTCs) ................................................................501-20b-14 PID/Data Monitor and Record ..........................................................................................501-20b-14 Active Commands ...........................................................................................................501-20b-14 Inspection and Verification ...............................................................................................501-20b-17 Symptom Chart ................................................................................................................501-20b-17 Connector Circuit Reference ............................................................................................501-20b-17 Pinpoint Tests — Airbag and Safety Belt Pretensioner Supplemental Restraint System (SRS) ...........................................................................................................................................501-20b-23 Restraint System Diagnostic Tool Warning .....................................................................501-20b-23 Pinpoint Test A: The Airbag Warning Indicator Is Illuminated Continuously - RCM Disconnected or Inoperative, Loss of Battery Feed, or Loss of Signal Ground .....................................501-20b-24 Pinpoint Test B: DTC B1869 — Lamp Airbag Warning Indicator Circuit Open or Short to Ground .............................................................................................................................501-20b-26 Pinpoint Test C: DTC B1870 — Airbag Warning Indicator Circuit Short to Battery ........501-20b-30 Pinpoint Test D: DTC B1891 — Airbag Warning Indicator Circuit Short to Battery ........501-20b-33 Pinpoint Test E: LFC 53/DTC B1892 — Airbag Tone Warning Indicator Circuit Shorted to Ground or Open ............................................................................................................................501-20b-37
01/2003 2003.0 BA Falcon
501-20b-2
Occupant Restraints — Passive
501-20b-2
(Continued) Pinpoint Test F: LFC 14/DTC B1921 — Airbag Diagnostic Monitor Ground Circuit Open ................................................................................................................................501-20b-40 Pinpoint Test G: LFC 33 and 34/DTC B2292 - Restraint System Safety Belt Pretensioner Status ...............................................................................................................................501-20b-45 Pinpoint Test H: LFC 19 and 21 /DTC B2293 - Restraint System Airbag Status ............501-20b-51 Pinpoint Test I: LFC 22 and 23 / DTC B2295 — Restraint System Side Airbag Module Status ...............................................................................................................................501-20b-62 Pinpoint Test J: LFC 42, 43, 44 and DTC B2296 — Restraint System Impact Sensor Status ...............................................................................................................................501-20b-70 Pinpoint Test K: LFC 51/DTC B2691 - Driver Safety Belt Buckle Switch Circuit Fault ...501-20b-83 Pinpoint Test L: LFC 51/DTC B2434 - Driver Safety Belt Buckle Switch Circuit Short to Ground .............................................................................................................................501-20b-87 Pinpoint Test M: LFC 51/DTC B2435 - Driver Safety Belt Buckle Switch Current Out of Range ...............................................................................................................................501-20b-91 Pinpoint Test N: LFC 52/DTC B2692 - Passenger Safety Belt Buckle Switch Circuit Fault .................................................................................................................................501-20b-95 Pinpoint Test O: LFC 52/DTC B2438 - Passenger Safety Belt Buckle Switch Circuit Short to Ground .............................................................................................................................501-20b-99 Pinpoint Test P: LFC 52/DTC B2439 - Passenger Safety Belt Buckle Switch Resistance Out of Range .............................................................................................................................501-20b-103 Pinpoint Test Q: LFC 15/DTC C1414 - Incorrect Vehicle ID .........................................501-20b-107 Pinpoint Test R: LFC 49/DTC C1947 - Seat Track Position Sensor Circuit Short to Ground ...........................................................................................................................501-20b-109 Pinpoint Test S: LFC 49/DTC C1948 - Seat Track Position Sensor Circuit Resistance Out of Range .............................................................................................................................501-20b-114 Pinpoint Test T: LFC 49/DTC C1982 - Seat Track Position Sensor Circuit Fault .........501-20b-118 Pinpoint Test U: No Communication With The Restraints Control Module (RCM) ........501-20b-122 GENERAL PROCEDURES Inspection and Repair After a Supplemental Restraint System (SRS) Deployment ......501-20b-125 Airbag Disposal — Deployed Airbag ..............................................................................501-20b-125 Airbag Disposal — Undeployed, Inoperative ..................................................................501-20b-125 Airbag Disposal — Driver, Undeployed, Scrapped Vehicle ............................................501-20b-126 Airbag Disposal — Passenger, Undeployed, Scrapped Vehicle ....................................501-20b-127 Airbag Disposal — Side Airbag, Undeployed, Scrapped Vehicle ...................................501-20b-128 Safety Belt Pretensioner Disposal — Deployed .............................................................501-20b-129 Safety Belt Pretensioner Disposal — Undeployed, Inoperative .....................................501-20b-129 Safety Belt Pretensioner Disposal — Undeployed, Scrapped Vehicle ...........................501-20b-129 Supplemental Restraint System (SRS) Deactivation and Reactivation ..........................501-20b-130 Weld Nut Repair — Missing Weld Nut ............................................................................501-20b-134 Weld Nut Repair — Stripped Weld Nut ..........................................................................501-20b-135 REMOVAL AND INSTALLATION Front Impact Severity Sensor .........................................................................................501-20b-136 Side Impact Sensor — First Row, B — Pillar .................................................................501-20b-138 Restraints Control Module (RCM) ...................................................................................501-20b-140 Driver Airbag Module ......................................................................................................501-20b-143 Passenger Airbag Module ...............................................................................................501-20b-148 Clockspring .....................................................................................................................501-20b-150 Side Airbag Bridge Resistor ............................................................................................501-20b-155 Seat Position Sensor ......................................................................................................501-20b-156 Side Airbag Module ..........................................................................................................501-20b-157
01/2003 2003.0 BA Falcon
501-20b-3
Occupant Restraints — Passive
501-20b-3
SPECIFICATIONS Torque Specifications Description Nm Front impact severity sensor 12 ± 1.8 Side impact sensor bolts (B pillar) 12 ± 1.8 Restraints control module-to-floor bolts 12 ± 1.8 Driver air bag module bolts 5±1 Passenger air bag module bolts 9.5* * Refer to the passenger air bag module removal and installation procedure for the torque specification and sequence.
G12340 en
01/2003 2003.0 BA Falcon
501-20b-4
Occupant Restraints — Passive
501-20b-4
DESCRIPTION AND OPERATION
Airbag and Safety Belt Pretensioner Supplemental Restraint System (SRS) The airbag supplemental restraint system (SRS) is designed to provide increased collision protection for front seat and second row outboard occupants in addition to that provided by the three-point safety belt system. Safety belt use is necessary to obtain the best occupant protection and to receive the full advantage of the SRS. The Supplemental Restraint System contains dual stage deployment (advanced restraint system) driver and front passenger airbag modules. These vehicles can also be equipped with optional side airbags that deploy from the seats upon a side impact. In addition, a front impact severity sensor is mounted to the lower radiator support, a seat position sensor is mounted to the driver seat and a usage detection switch is added to the front driver and passenger outboard buckles.
G12341 en
01/2003 2003.0 BA Falcon
501-20b-5
Occupant Restraints — Passive
501-20b-5
DESCRIPTION AND OPERATION (Continued) Airbag and Safety Belt Pretensioner Supplemental Restraint System (SRS) Deployable Components
G12341 en
01/2003 2003.0 BA Falcon
501-20b-6
Occupant Restraints — Passive
501-20b-6
DESCRIPTION AND OPERATION (Continued) Item 1 2 3 4 5
Description Clockspring Driver airbag module Safety belt buckle and pretensioner Side airbag module Passenger airbag module
G12341 en
01/2003 2003.0 BA Falcon
501-20b-7
Occupant Restraints — Passive
501-20b-7
DESCRIPTION AND OPERATION (Continued) Airbag and Safety Belt Pretensioner Supplemental Restraint System (SRS) Sensor Components
G12341 en
01/2003 2003.0 BA Falcon
501-20b-8
Occupant Restraints — Passive
501-20b-8
DESCRIPTION AND OPERATION (Continued) Item 1 2 3 4 5
Description Front impact severity sensor First row, B-pillar side impact sensor Driver seat position sensor First row, B-pillar side impact sensor Restraints control module (RCM)
Side Airbag Bridge Resistor CAUTION: Do not deactivate the side airbag module circuit by removing the bridge resistor from the electrical connector. If the side airbag bridge resistor is removed, an open circuit fault will be generated by the restraints control module (RCM). If a restraint system diagnostic tool is installed at the side airbag electrical connector, a low resistance fault will be generated. The side airbag bridge resistor: is equipped on vehicles without side airbag modules. must not be removed during deactivation. is located on the seat.
Driver Airbag Module The driver airbag module: is installed new as an assembly. is mounted in the center of the steering wheel.
Clockspring The clockspring: is mounted on the steering column, behind the steering wheel. continuously transfers electrical signals from the driver airbag module to the restraints control module (RCM).
Passenger Airbag Module The passenger airbag module: is installed new as an assembly. is mounted in the passenger side of the instrument panel.
Passenger Airbag Bridge Resistor CAUTION: Do not deactivate this passenger airbag module circuit by removing the bridge resistor from the electrical connector. If the passenger airbag bridge resistor is removed, an open circuit fault will be generated by the RCM. If a restraint system diagnostic tool is installed at the PAB electrical connector, a low resistance fault will be generated. The PAB bridge sensor: G12341 en
is equipped on Commercial vehicles without passenger airbag module. must not be removed during deactivation. is located in the passenger airbag cover assembly.
Safety Belt Pretensioners As part of the SRS the safety belt buckles are equipped with pretensioners. The safety belt buckle pretensioners remove excess slack from the safety belt webbing. The pretensioners are activated by the restraints control module (RCM) when the module detects a crash event force exceeding a programmed limit.
Safety Belt Buckle Switches Both driver and front outboard passenger safety belt buckles are equipped with a switch. The safety belt buckle switch indicates to the restraints control module (RCM) whether the driver and front outboard passenger safety belt buckles are connected or disconnected.
Seat Track Position Sensor The seat track position sensor is a hall-effect sensor located on the driver seat track. The seat track position sensor informs the restraints control module (RCM) of the driver seat position. The RCM uses this information in determining the deployment rate of the dual-stage driver airbag module.
Restraints Control Module (RCM) WARNING: The restraints control module (RCM) orientation is critical for correct system operation. If a vehicle equipped with an airbag supplemental restraint system (SRS) has been involved in a collision in which the center tunnel area has been damaged, inspect the mounting and bracket for deformation. If damaged, the RCM must be replaced whether or not the airbags have deployed. In addition, make sure the area of the RCM mounting is restored to its original condition. The restraints control module carries out the following functions: deploys the airbag(s) in the event of a deployable crash. activates the safety belt buckle pretensioners to remove slack from the safety belt. monitors the SRS for faults. illuminates the airbag indicator if a fault is detected. flashes the airbag indicator to indicate the lamp fault code (LFC) detected. communicates through the data link connector (DLC) the current or historical Diagnostic Trouble Codes (DTCs). 01/2003 2003.0 BA Falcon
501-20b-9
Occupant Restraints — Passive
501-20b-9
DESCRIPTION AND OPERATION (Continued) signals the instrument cluster module to activate a chime to remind the driver to buckle up. signals the instrument cluster module to activate a chime if the airbag indicator is not available and another SRS fault exists. The RCM monitors the SRS for possible faults. If a fault is detected while the ignition switch is in the ON position, the RCM will illuminate the airbag indicator located in the instrument cluster. When the ignition is cycled (turned off and then on), the airbag indicator will prove out by lighting for six seconds. After the prove out, the airbag indicator will then flash the two-digit LFC. If a SRS fault exists, the airbag indicator will flash the LFC five times, then it will remain illuminated for the rest of the key cycle. The RCM will also communicate the current and historical DTCs through the DLC, to the scan tool. If the airbag indicator does not function, and the system detects a fault condition, the RCM will signal the instrument cluster module to activate an audible chime. The chime is a series of five sets of five tone bursts. If the chime is heard, the SRS and the airbag indicator require repair. LFCs are prioritized. If two or more faults occur at the same time, the fault having the highest priority will be displayed. After that fault has been corrected, the next highest priority fault will be displayed. The RCM includes a backup power supply. This feature provides sufficient backup power to deploy the airbags in the event that the ignition circuit is lost or damaged during impact. The backup power supply will deplete its stored energy approximately one minute after the battery ground cable is disconnected.
and bracket for deformation. If damaged, the RCM must be replaced whether or not the airbags have deployed. In addition, make sure the area of the RCM mounting is restored to its original condition. WARNING: Vehicle sensor orientation is critical for correct system operation. If a vehicle equipped with an airbag supplemental restraint system (SRS) is involved in a collision, inspect the sensor mounting bracket and wiring pigtail for deformation. Replace and correctly position the sensor or any other damaged supplemental restraint system (SRS) components whether or not the airbag is deployed. The SRS uses up to five sensors. Within the RCM is one safing sensors which is not separately serviced. The RCM has one safing sensor for front impact. The RCM is mounted to the center tunnel beneath the console. All vehicles will have a front impact severity sensor and it is located in the front-center of the vehicle, mounted under the lower radiator support. If the vehicle is equipped with side airbags, there are two additional side impact sensors. The two additional sensors are located on each B-pillar. Mounting orientation is critical for correct operation of all impact sensors.
Electrical System The electrical system that supports the airbag SRS: is powered from the battery through the ignition circuit. provides the electrical path from the restraints control module (RCM) to the SRS components. provides the electrical path from the RCM to the airbag indicator. provides the electrical path from the RCM to the belt minder indicator. provides the electrical path from the RCM to the data link connector (DLC). provides the electrical path from the RCM to the generic electronic module (GEM) or instrument cluster module.
Sensors WARNING: The restraints control module (RCM) orientation is critical for correct system operation. If a vehicle equipped with an airbag supplemental restraint system (SRS) has been involved in a collision in which the center tunnel area has been damaged, inspect the mounting G12341 en
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Occupant Restraints — Passive
501-20b-10
DIAGNOSIS AND TESTING
Airbag and Safety Belt Pretensioner Supplemental Restraint System (SRS) Refer to Wiring Diagram Section 000-00 for schematic and connector information. Special Tool(s) FLUKE 73III Automotive Meter 105-R0057 or equivalent
Restraint System Diagnostic Tool Warning WARNING: Restraint system diagnostic tools are for service only. Remove from vehicle prior to road use. Failure to remove could result in personal injury and possible violation of vehicle safety standards.
Diagnosing Customer Concerns Without Hard DTCs
Diagnostic Tool, Restraint DAB System, (2 Req’d) 418-F395 (014-R1079) 418-F403, (1 Req’d)
Diagnostic Tool, Restraint PAB System, (1 Req’d) 418-F403
If a lamp fault code (LFC) is reported by the customer but is not present when the vehicle comes in for service, follow the Diagnostic Instruction procedures in this section to identify the intermittent DTC. Once the DTC is known, read the Normal Operation section of the pinpoint test for the DTC involved. Follow the deactivation procedure in this section. Determine the location of components involved in creating the DTC. Carry out a thorough visual inspection of: components. connectors. splices and wiring harnesses. insulation on conductors. Refer to the Possible Causes section of the pinpoint test for the DTC involved, which lists the common concerns that relate to the DTC. Concerns are listed according to priority.
Diagnosing Customer Concerns with Hard DTCs Diagnostic Tool, Restraint P/T System, (2 Req’d) 418-F403
Diagnostic Tool, Restraint SAB System 418-F088 (105-R0012) 2 Req’d
Most Supplemental Restraint System (SRS) diagnostic procedures will require deactivation and reactivation of the system. Deactivation and reactivation require the disconnection of most SRS components and the installation of restraint system diagnostic tools. This reduces the risk of inadvertent deployment of SRS components while diagnostic procedures are being carried out. Restraint system diagnostic tools are required for the diagnosis and testing of the SRS. It is not acceptable to short-circuit the airbag module connections with a jumper wire. If a jumper wire is used to short-circuit the airbag module connections, a lamp fault code (LFC) will be displayed.
Deactivation Procedure Worldwide Diagnostic System (WDS) 418-FS317, or equivalent scan tool
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WARNING: If the supplemental restraint system (SRS) is being serviced, the system must be deactivated and restraint system diagnostic tools must be installed. Refer to Airbag and Safety Belt Pretensioner Supplemental Restraint System (SRS) in this section. The airbag restraint system diagnostic tools must 01/2003 2003.0 BA Falcon
501-20b-11
Occupant Restraints — Passive
501-20b-11
DIAGNOSIS AND TESTING (Continued) 3. Attach restraint system diagnostic tools 418-F395 (2 required) to the clockspring side of the driver airbag module electrical connectors. 4. Remove the outboard passenger side air register. NOTE: Do not deactivate the passenger airbag WARNING: Never probe the connectors on module circuit by removing the passenger airbag the airbag module. Doing so can result in airbag bridge resistor from the passenger airbag bridge deployment, which can result in personal injury. resistor electrical connector. If the passenger airbag bridge resistor is WARNING: The safety belt buckle removed, an open circuit fault will be generated pretensioner is a pyrotechnic device. Never probe by the RCM. a pretensioner electrical connector. Doing so If a restraint system diagnostic tool is installed at could result in pretensioner or airbag deployment the PAB electrical connector, a low resistance and could result in personal injury. fault will be generated by the RCM. WARNING: Never probe the connectors on For commercial vehicle w/o PAB, do not the side airbag module. Doing so can result in disconnect the PAB bridge resistor. side airbag deployment. 5. For vehicles with airbags only: 1. Disconnect the passenger airbag module WARNING: To avoid accidental deployment electrical connector. and possible personal injury, the RCM backup power supply must be depleted before repairing 6. Attach restraint system diagnostic tool 418-F403 or replacing any front or side airbag SRS to the harness side of the passenger airbag components and before servicing, replacing, module electrical connector. adjusting or striking components near the front or NOTE: Do not deactivate the side airbag module side airbag sensors, such as doors, instrument circuit by removing the side airbag bridge resistor panel, console, door latches, strikers, seats and from the side airbag bridge resistor electrical hood latches. connector. To deplete the backup power supply energy, If the side airbag bridge resistor is removed, an open disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary circuit fault will be generated by the RCM. If a restraint system diagnostic tool is installed at the batteries and power supplies (if equipped). The side impact sensors (if equipped) are located side airbag electrical connector, a low resistance fault will be generated by the RCM. in the B-pillars below the latch. NOTE: Diagnostics or repairs are not to be performed For vehicles without side airbags, do not disconnect the side airbag bridge resistor. on a seat equipped with a seat side airbag with the seat in the vehicle. Prior to attempting to diagnose or 7. For vehicles with side airbags only: repair a seat concern when equipped with a seat side 1. Disconnect the passenger side airbag airbag, the seat must be removed from the vehicle electrical connector, located on the seat track. and the restraint system diagnostic tools must be 2. Attach a restraint system diagnostic tool installed in the seat side airbag electrical connectors. 418-F088 (105-R0012) to the vehicle harness NOTE: After diagnosing or repairing an SRS, the side of the passenger side airbag electrical restraint system diagnostic tools must be connector. removed before operating the vehicle over the 8. Disconnect the safety belt buckle pretensioner road. electrical connector, located on the seat track. NOTE: After diagnosing or repairing a seat system, 9. Attach Restraint System Diagnostic Tool the restraint system diagnostic tools must be 418-F403 to the passenger front seat safety belt removed before operating the vehicle over the buckle pretensioner vehicle harness side. road. 10. For vehicles with airbags only: NOTE: The SRS must be fully operational and free of 1. Disconnect the driver side airbag electrical faults before releasing the vehicle to the customer. connector, located on the seat track. 1. Disconnect the battery ground cable (14301) and 2. Attach a restraint system diagnostic tool wait for one minute. For additional information, 418-F088 (105-R0012) to the vehicle harness refer to Section 414-01. side of the driver side airbag electrical connector. 2. Remove the driver airbag module. For additional information, refer to Driver Airbag Module in this 11. Disconnect the safety belt buckle pretensioner section. electrical connector, located on the seat track. be removed and the airbag modules reconnected when the system is reactivated to avoid non-deployment in a collision, resulting in possible personal injury.
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501-20b-12
DIAGNOSIS AND TESTING (Continued) 12. Attach Restraint System Diagnostic Tool 418-F403 to the driver front seat safety belt buckle pretensioner vehicle harness side. 13. Reconnect the battery ground cable. For additional information, refer to Section 414-01. 14. Prove out the system.
Reactivation Procedure WARNING: To reduce the risk of serious personal injury, read and follow all warnings, cautions, and notes at the beginning of the deactivation procedure. 1. Disconnect the battery ground cable and wait one minute. For additional information, refer to Section 414-01. 2. Disconnect the restraint system diagnostic tool and connect the driver front seat safety belt buckle pretensioner electrical connector. 3. For vehicles with side airbags only: 1. Remove the restraint system diagnostic tool from the driver side side airbag electrical connector. 2. Connect the driver side side airbag electrical connector. 4. Disconnect the restraint system diagnostic tool and connect the passenger front seat safety belt buckle pretensioner floor electrical connector. 5. For vehicles with side airbags only: 1. Remove the restraint system diagnostic tool from the passenger side airbag electrical connector. 2. Connect the passenger side airbag electrical connector. 6. For vehicles with side airbags only: 1. Remove the restraint system diagnostic tool from the passenger airbag module electrical connector. 7. Connect the passenger airbag module electrical connector. 8. Remove the restraint system diagnostic tools from the driver airbag module electrical connectors. 9. Install the driver airbag module. For additional information, refer to Driver Airbag Module in this section. 10. Reconnect the battery ground cable. For additional information, refer to Section 414-01. 11. Prove out the system.
will either: fail to light. remain lit continuously. flash. The flashing might not occur until approximately 30 seconds after the ignition switch has been turned from the OFF to the RUN position. This is the time required for the restraints control module (RCM) to complete the testing of the SRS. If the airbag indicator is inoperative and an SRS fault exists, a chime will sound in a pattern of five sets of five beeps. If this occurs, the airbag indicator will need to be repaired before diagnosis can continue.
Glossary Secondary Airbag Warning The secondary airbag warning is an audible fault format that consists of five sets of five tone bursts, with each set of five tone bursts separated by a five second quiet period. One tone burst cycle will consist of one second ON and one second OFF. This series of five activations is repeated every 30 minutes.
Airbag/Pretensioner Restraint System Diagnostic Tools Airbag/pretensioner restraint system diagnostic tools are used to simulate the equivalent resistance of an airbag module or safety belt pretensioner during certain diagnostic procedures.
Disconnect the Component Disconnect the component means disconnect the component vehicle harness connector. It does not mean remove the component. Do not reconnect a disconnected component unless instructed to do so.
Deactivate the System Deactivate the system means to carry out a deactivation procedure. For additional information, refer to Deactivation Procedure in this section.
Prove Out the System Prove out the system means to turn the ignition switch from the OFF to the RUN position and visually monitor the airbag indicator with the airbag modules and safety belt pretensioners or restraint system diagnostic tools installed. For additional information, refer to Prove Out Procedure in this section.
Prove Out Procedure Turn the ignition switch from the OFF to the RUN position and visually monitor the airbag indicator with all SRS components connected or restraint system diagnostic tools installed. The airbag indicator will light continuously for approximately six seconds and then turn off. If an SRS fault is present, the airbag indicator G12343 en
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Occupant Restraints — Passive
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DIAGNOSIS AND TESTING (Continued) Reactivate the System
2. Run the On-Demand Self Test to determine what DTCs are currently being sensed by the RCM. Reactivate the system means to carry out the Refer to On-Demand Self Test in this section. reactivation procedure. For additional information, 3. If the stored DTCs are different than the current refer to Reactivation Procedure in this section. DTCs, always repair the current DTCs first. Reconnect the System 4. If memory displays different continuous DTCs than the On-Demand Self Test, carry out in the Reconnect the system means to reconnect all system following order: components. For additional information, refer to Airbag System Reconnect Checklist in this section. On-Demand Self Test Memory (Retrieve/Clear Continuous DTCs) Install a New Component A DTC can indicate several concerns. The DTCs are Install a new component means to remove the to assist in system diagnosis and are not to be existing component and install a new authorized part considered definitive. Always refer to the pinpoint test obtained from Ford Customer Service Division. corresponding to the DTC to determine where the concern lies and to repair the concern correctly. Verify the System The SRS diagnostics can be divided into three Verify the system means to prove out the system with sections: restraint system diagnostic tools installed in place of diagnostic test modes the SRS components. PID/data monitor and record Airbag Reconnect Checklist active command modes The checklist below should be completed following Diagnostic Test Modes diagnosis or repair of any airbag system concern: All restraint system diagnostic tools removed? Two menu options are available under the diagnostic test modes: All in-seat harness connectors connected? Retrieve/Clear Continuous DTCs All airbag modules connected? On-Demand Self Test Safety belt pretensioner connectors connected? Restraints control module (RCM) connected? All sensors (front and side impact sensors) connected?
Retrieve/Clear Continuous DTCs
During vehicle operation the restraints control module (RCM) will detect and store both intermittent and hard failure DTCs in nonvolatile memory. The DTC strategy Battery connected? employed by the RCM incorporates a time-out Diagnostic Instructions — Airbag and scheme for determining when a concern exists in the Safety Belt Pretensioner Supplemental system. This requires a concern to exist for up to one minute in the system before the RCM will detect it. Restraint System (SRS) For the RCM to determine that a concern no longer exists, the concern must be absent for up to one Special Tool(s) minute. The actual detection time-outs vary with each DTC. The DTCs can be retrieved with a scan tool Worldwide Diagnostic System using the retrieve/clear continuous DTCs option. Any (WDS) DTCs stored in the RCM will be displayed on the scan 418-FS317, tool along with a brief description of the DTC. If no or equivelant scan tool DTCs are present, the scan tool will display a SYSTEM PASSED message. This option can also be used to clear DTCs from the RCM memory, as long as the concern no longer exists. Once 128 key cycles The symptom chart can be used to help locate have been recorded since the concern was last supplemental restraint system (SRS) concerns if no detected, the DTC will automatically be removed from diagnostic trouble codes (DTCs) are retrieved and the memory. listed symptoms are observed. Whether or not the To retrieve or clear DTCs, follow these steps: listed symptoms are observed, always carry out the 1. Connect the scan tool to the data link connector following: (DLC). 1. Retrieve all DTCs stored in the restraints control 2. Turn the ignition switch to the RUN position. module (RCM) memory. For additional 3. Follow the manufacturer’s instructions for the information, refer to Retrieve/Clear Continuous scan tool being used. DTCs in this section.
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501-20b-14
DIAGNOSIS AND TESTING (Continued) 4. All continuous DTCs will be displayed on the screen. NOTE: Before proceeding with the clearing operation, make note of the DTCs displayed. Once cleared, DTCs cannot be retrieved.
that DTC, including the status or state that exists (on-demand DTC) or existed (continuous DTC). To view and flag bit-mapped DTCs, follow these steps: 1. Connect the scan tool to the data link connector (DLC). 5. Clear the DTCs. After clearing the DTCs, cycle the key OFF, then ON. 2. Turn the ignition switch to the ON position. Continuous DTCs that have been cleared will 3. Follow the manufacturer’s instructions for the not re-occur as “Continuous” in the same key scan tool being used. cycle. Only new DTCs which were not 4. Carry out an On-Demand Self Test or retrieve present before clearing can occur as continuous DTCs. “Continuous” after clearing. 5. Select the DTC and the “FLAG” option on the On-Demand Self Test scan tool. The On-Demand Self Test option is used to verify that 6. The scan tool will display PIDs for the DTC. Record all flagged faults. no electrical concerns exist with the airbag SRS. Upon entering the self test, the restraints control PID/Data Monitor and Record module (RCM) will make an electrical check of each electrical component in the system. If a concern is The PID/Data Monitor and Record option allows the detected, a DTC is displayed on the scan tool with a scan tool operator to read the state of several brief description of the DTC. Concerns detected parameter IDs (PIDs) to aid in diagnosing the system. during the self test are not stored in memory, unless PIDs are real time measurements of parameters such the same concern was also detected during normal as voltages, resistances, etc., calculated by the vehicle operation. The self test should always be run restraints control module (RCM) and sent to the scan after any repair to verify that the repair was tool for display. Many of the PIDs supported by the successful. RCM are calculated periodically and are, therefore, To run the On-Demand Self Test, follow these steps: not true real time readings. To retrieve PIDs, follow these steps: 1. Connect the scan tool to the data link connector (DLC). 1. Connect the scan tool to the data link connector (DLC). 2. Turn the ignition switch to the RUN position. 2. Turn the ignition switch to the ON position. 3. Follow the manufacturer’s instructions for the scan tool being used. 3. Follow the manufacturer’s instructions for the scan tool being used. 4. The RCM will run the On-Demand Self Test and display on-demand DTCs (reflecting hard system 4. Record all PIDs that are to be retrieved and concerns) on the scan tool. initiate PID retrieval. PIDs are updated continuously on the display.
Bit-Mapped Diagnostic Trouble Codes (DTCs)
Many of the continuous and on-demand DTCs that can be present in the RCM are bit-mapped DTCs that utilize PIDs (flagged faults). Bit-mapped DTCs are conceptually different from the previous style of DTCs. Previously, DTCs identified a specific concern for a given component and pointed to a particular diagnostic path. In the diagnostic path, PIDs are sometimes used to determine the root cause. Bit-mapped DTCs do not identify the specific concern. A bit-mapped DTC identifies the component(s) in which the concern exists. The next level (PIDs or flagged faults) identifies the specific concern. A scan tool must be used to view the PIDs (flagged faults) of a bit-mapped DTC. Once a scan tool has retrieved a bit-mapped DTC, the scan tool will provide the option to “FLAG” that DTC. When the option to “FLAG” the DTC is available, it must be carried out to identify the specific concern that is present. When the option to “FLAG” the DTC has been carried out, the scan tool will then display the PIDs (flagged faults) for G12344 en
Active Commands Instrument Cluster Module These commands allow the technician to verify the operation of instrument cluster module components and sub-systems.
Restraints Control Module (RCM) These commands allow the technician to verify operation of the supplemental restraint system (SRS) indicator lamps.
Lamp Fault Codes When the restraints control module (RCM) detects a system fault, it will cause the airbag indicator to flash a coded sequence; a lamp fault code (LFC). The code is two digits. The first digit is flashed with a 0.5 second interval between pulses. There is a 2 second pause before the second digit is flashed which also has a 0.5 second interval between pulses. There is a 5 second pause between each display of an LFC. 01/2003 2003.0 BA Falcon
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DIAGNOSIS AND TESTING (Continued) Each LFC is flashed five times after which the airbag indictor will remain lit for the remainder of the key-on cycle. If there are multiple LFCs, each LFC will flash in order of priority.
Diagnostic Trouble Codes (DTCs) While the lamp fault codes (LFCs) are an indication of a general concern in the passive restraints system, the diagnostic trouble codes (DTCs) are more specific. The DTCs can be retrieved from the restraints control module (RCM) with a scan tool via the data link connector (DLC). Restraints Control Module (RCM) Diagnostic Trouble Code (DTC) Table DTC * LFC * Description Action To Take — Continuous The Airbag Indicator is GO to Pinpoint Test A. Illuminated Continuously, RCM Disconnected or Inoperative, Loss of Battery Feed, or Loss of Signal Ground B1231 13 Crash Data Memory Full Install a new RCM and impact sensors. REFER to Inspection and Repair After a Supplemental Restraint System (SRS) Deployment. B1317 Continuous Battery Voltage High CHECK battery voltage; to be below 16 volts. REFER to Section 414-00. B1318 Continuous Battery Voltage Low CHECK battery voltage; to be above 9.0 volts. REFER to Section 414-00. B1342 12 RCM Is Faulted Install a new RCM. B1869 NONE Lamp Airbag Warning Indicator GO to Pinpoint Test B. Continuous lamp Circuit Open or Short to Secondary airbag Ground warning sounds if another fault is present B1870 NONE Airbag Warning Indicator GO to Pinpoint Test C. Secondary airbag Circuit Short to Battery warning sounds if another fault is present B1891 53 Airbag Tone Warning Indicator GO to Pinpoint Test D. Circuit Short to Battery B1892 53 Airbag Tone Warning Indicator GO to Pinpoint Test E. Circuit Open or Shorted to Ground B1921 14 Airbag Diagnostic Monitor GO to Pinpoint Test F. Ground Circuit Open B2292 33 Restraint System - Safety Belt GO to Pinpoint Test G. Pretensioner Status (Driver Pretensioner Circuit Fault) B2292 34 Restraint System - Safety Belt GO to Pinpoint Test G. Pretensioner Status (Passenger Pretensioner Circuit Fault) G12344 en
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DIAGNOSIS AND TESTING (Continued) DTC * B2293
LFC * 19
B2293
21
B2295
22
B2295
23
2296
42
B2296
43
B2296
44
B2691
51
B2434
51
B2435
51
B2477
54
B2692
52
B2438
52
B2439
52
C1414 C1947
15 49
C1948
49
C1981
49
—
—
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Description Restraint System - Airbag Status (Driver Front Airbag Circuit Fault) Restraint System - Airbag Status (Passenger Front Airbag Circuit Fault) Restraint System - Side Airbag Module Status (Driver Side Side Airbag Circuit Fault) Restraint System - Side Airbag Module Status (Passenger Driver Side Side Airbag Circuit Fault) Restraint System - Impact Sensor Status (Front Impact Severity Sensor Circuit Fault) Restraint System - Impact Sensor Status (Driver Side Front Row Impact Sensor Circuit Fault) Restraint System - Impact Sensor Status (Passenger Side Front Row Impact Sensor Circuit Fault) Driver Safety Belt Buckle Switch Circuit Fault Driver Safety Belt Buckle Switch Circuit Short To Ground Driver Safety Belt Buckle Switch Circuit Resistance Out Of Range Module Configuration Failure (Not programmed or incorrect) Passenger Safety Belt Buckle Switch Circuit Fault Passenger Safety Belt Buckle Switch Circuit Short to Ground Passenger Safety Belt Buckle Switch Circuit Resistance Out of Range Incorrect Vehicle ID Seat Track Position Sensor Circuit Short to Ground Seat Track Position Sensor Circuit Resistance Out of Range Seat Track Position Sensor Circuit Fault No communication with the restraints control module (RCM).
Action To Take GO to Pinpoint Test H. GO to Pinpoint Test H. GO to Pinpoint Test I. GO to Pinpoint Test I.
GO to Pinpoint Test J. GO to Pinpoint Test J.
GO to Pinpoint Test J.
GO to Pinpoint Test K. GO to Pinpoint Test L. GO to Pinpoint Test M. Install new RCM. GO to Pinpoint Test N. GO to Pinpoint Test O. GO to Pinpoint Test P. GO to Pinpoint Test Q. GO to Pinpoint Test R. GO to Pinpoint Test S. GO to Pinpoint Test T. REFER to Symptom Chart in this section. & GO to Pinpoint Test U.
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Occupant Restraints — Passive
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DIAGNOSIS AND TESTING (Continued) * DTC: Diagnostic trouble code, retrieved using scan tool. * LFC: Lamp fault code, flashed on airbag indicator.
Inspection and Verification 1. Verify the customer concern by checking the airbag indicator in the instrument cluster module. For additional information, refer to Prove Out the System in this section. 2. Visually inspect for obvious signs of mechanical and electrical damage using the following chart.
Visual Inspection Chart Mechanical Damaged restraints control module (RCM) bracket Damaged front crash severity sensor or bracket Damaged side impact sensor or bracket
Electrical Open fuse(s) Damaged wiring harness Loose or corroded connectors Circuitry open/shorted Damaged shorting bars
3. If the concern is not visually evident, use the scan tool to retrieve diagnostic trouble codes (DTCs) and carry out the on-demand self test. 4. If the on-demand self test is passed and no DTCs are retrieved, Go to Symptom Chart. 5. If DTCs are retrieved, refer to the Restraints Control Module (RCM) Diagnostic Trouble Code (DTC) Table.
Symptom Chart Condition
Source
Action
Airbag warning indicator is illuminated continuously
Fuse to RCM. Wiring, terminals, or connectors. Faulty diagnostic connector. RCM.
Go to PinPoint Test M.
Airbag indicator flashing
Airbag/pretensioner supplemental restraint system (SRS) fault.
REFER to DTC Table.
Audible tone — DTCs retrieved
Airbag SRS system fault.
REFER to DTC Table.
No communication with the restraints control module (RCM)
Scan tool. Data link connector (DLC). RCM. Circuitry.
Go to PinPoint Test AG.
Connector Circuit Reference C189a
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DIAGNOSIS AND TESTING (Continued) Pin Number(s) 1 2 3 4 5 6 11 12 13 14 15 16 17 20 22
Circuit Designation/Description Circuit 614 (O/B) Driver Airbag Feed Squib 1 Circuit 615 (GR/W) Driver Airbag Return Squib 1 Circuit 607 (BR) Pass. Airbag Feed Squib 1 Circuit 616 (P/B) Pass. Airbag Return Squib 1 Circuit 1516 (Y/W) Driver Airbag Feed Squib 2 Circuit 1517 (GR/B) Driver Airbag Return Squib 2 Circuit 70B (SB/W) ISO 9141 Circuit 16PA (R/G) Run / Start Ignition Circuit 1518 (R/W) Pass. Airbag Feed Squib 2 Circuit 1519 (LG/R) Pass. Airbag Return Squib 2 Circuit 608 (B/Y) Airbag Indicator Power Supply Circuit 1203A (B/G) Ground Circuit 8109A (P/O) TAS Deployment Signal Circuit 1203C (B/G) Vehicle ID 1 - Ground Circuit 609 (O) Audible Signal Indicator
c189b
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DIAGNOSIS AND TESTING (Continued) Pin Number(s) 3 4 5 6 19 20 23 24 25 26 27 28 29 30 31 32 33 34
Circuit Designation/Description Circuit 1257 (W) Driver Side Airbag Feed Circuit 1258 (BR) Driver Side Airbag Return Circuit 1259 (W/Y) Pass. Side Airbag Return Circuit 1260 (BR/Y) Pass. Side Airbag Return Circuit 617 (P) Front Crash sensor Feed Circuit 618 (V) Front Crash Sensor Return Circuit 8107 (BR/G) Seat Track Sensor Feed Circuit 8108 (B/O) Seat Track Sensor Return Circuit 85 (B/L) Driver Buckle Switch Input Circuit 1514 (R/B) Pass. Buckle Switch Input Circuit 1261 (W/B) Driver Side Sensor Feed Circuit 1262 (W/R) Driver Side Sensor Return Circuit 1263 (G/W) Pass. Side Sensor Feed Circuit 1264 (R) Pass. Side Sensor Return Circuit 1079 (LG/R) Driver Pretensioner Feed Circuit 1080 (LG/B) Driver Pretensioner Return Circuit 1081 (Y/R) Pass. Pretensioner Feed Circuit 1082 (Y/B) Pass. Pretensioner Return
C233
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501-20b-20
DIAGNOSIS AND TESTING (Continued) Pin Number(s) 1 2 3 4
Circuit Designation/Description Circuit 1203D (B) Ground Circuit 85 (B/L) Driver Buckle (Hall Sensor) Switch Input Circuit 1079 (LG/R) Driver Pretensioner Feed Circuit 1080 (LG/B) Driver Pretensioner Return
C234
Pin Number(s) 1 2 3 4
Circuit Designation/Description Circuit 1203B (B) Ground Circuit 1514 (R/B) Pass. Buckle (Hall Sensor) Switch Input Circuit 1081 (Y/R) Pass. Pretensioner Feed Circuit 1082 (Y/B) Pass. Pretensioner Return
C190
Pin Number(s) 1 2 3 4
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Circuit Designation/Description Circuit 614 (O/B) Driver Airbag Feed Squib 1 Circuit 615 (GR/W) Driver Airbag Return Squib 1 Circuit 1516 (Y/W) Driver Airbag Feed Squib 2 Circuit 1517 (GR/B) Driver Airbag Return Squib 2
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DIAGNOSIS AND TESTING (Continued) C146
Pin Number(s) 1 2 3 4
Circuit Designation/Description Circuit 1518 (R/W) Pass. Airbag Feed Squib 2 Circuit 1519 (LG/R) Pass. Airbag Return Squib 2 Circuit 607 (BR) Pass. Airbag Feed Squib 1 Circuit 616 (P/B) Pass. Airbag Return Squib 1
C342
Pin Number(s) 1 2
Circuit Designation/Description Circuit 1258 (BR) Driver Side Airbag Return Circuit 1257 (W) Driver Side Airbag Feed
C344
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DIAGNOSIS AND TESTING (Continued) Pin Number(s) 1 2
Circuit Designation/Description Circuit 1260 (BR/Y) Pass. Side Airbag Return Circuit 1259 (W/Y) Pass. Side Airbag Return
C340
Pin Number(s) 1 2
Circuit Designation/Description Circuit 618 (V) Front Crash Sensor Return Circuit 617 (P) Front Crash sensor Feed
C341
Pin Number(s) 1 2
Circuit Designation/Description Circuit 1262 (W/R) Driver Side Sensor Return Circuit 1261 (W/B) Driver Side Sensor Feed
C345
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DIAGNOSIS AND TESTING (Continued) Pin Number(s) 1 2
Circuit Designation/Description Circuit 1264 (R) Pass. Side Sensor Return Circuit 1263 (G/W) Pass. Side Sensor Feed
C72
Pin Number(s) 1 2
Pinpoint Tests — Airbag and Safety Belt Pretensioner Supplemental Restraint System (SRS)
Circuit Designation/Description Circuit 8108 (B/O) Seat Track Sensor Return Circuit 8107 (BR/G) Seat Track Sensor Feed Special Tool(s) Diagnostic Tool, Restraint System 418-F088 (105-R0012)
Refer to Wiring Diagram Section 000-00 for schematic and connector information. Special Tool(s) FLUKE 73III Automotive Meter 105-R0057 or equivalent
Diagnostic Tool, Restraint System 418-F395 (014-R1079)
Diagnostic Tool, Restraint System 418-F403
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Worldwide Diagnostic System (WDS) 418-FS317 or equivalent scan tool
Restraint System Diagnostic Tool Warning WARNING: Restraint system diagnostic tools are for service only. Tools must be removed prior to operating the vehicle over the road. Failure to remove restraint system diagnostic tools could result in injury and possible violation of vehicle safety standards.
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Occupant Restraints — Passive
501-20b-24
DIAGNOSIS AND TESTING (Continued) Pinpoint Test A: The Airbag Warning Indicator Is Illuminated Continuously RCM Disconnected or Inoperative, Loss of Battery Feed, or Loss of Signal Ground Normal Operation NOTE: During normal operation, the airbag indicator will illuminate continuously for 6 seconds after the ignition switch is placed to the RUN or ON position and after five cycles of a lamp fault code (LFC) if a fault exists. Be sure to cycle the ignition switch and look for a 6 second indicator prove-out without LFCs. The restraints control module (RCM) will communicate diagnostic trouble codes (DTCs) to the scan tool through the diagnostics connector. If the scan tool displays NO COMMUNICATION when retrieving continuous DTCs, Go to PinPoint Test U to troubleshoot the system.
Possible Causes An airbag indicator that is illuminated continuously can be caused by one of the following: damaged ignition circuit. The RCM disconnected from the vehicle harness. A loss of RCM signal ground. a faulted RCM. damaged wiring, terminals, or connectors. loss of RCM battery feed. instrument cluster. PINPOINT TEST A : THE AIR BAG WARNING INDICATOR IS ILLUMINATED CONTINUOUSLY - RCM DISCONNECTED OR INOPERATIVE, LOSS OF BATTERY FEED, OR LOSS OF SIGNAL GROUND Test Step A1
Result / Action to Take
CHECK FOR CONTINUOUS OR ON-DEMAND SELF TEST DTCs Enter the following diagnostic mode on the diagnostic tool: Retrieve Continuous DTCs
Yes
If continuous DTCs were retrieved, Go to A2. If on-demand DTCs were retrieved, GO to the Retrieve and record any continuous DTCs for use later in this pinpoint Restraints Control Module (RCM) Diagnostic test. Trouble Code (DTC) Table in this section for pinpoint test direction. Enter the following diagnostic mode on the diagnostic tool: On-Demand Self Test. No Go to A2. Were any continuous or on-demand self test DTCs retrieved?
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501-20b-25
Occupant Restraints — Passive
501-20b-25
DIAGNOSIS AND TESTING (Continued) Test Step A2
Result / Action to Take
CHECK THE RCM CONNECTION WARNING: If the supplemental restraint system (SRS) is
being serviced, the system must be deactivated and restraint system diagnostic tools must be installed. Refer to Airbag and Safety Belt Pretensioner Supplemental Restraint System (SRS) in this section. The airbag restraint system diagnostic tools must be removed and the airbag modules reconnected when the system is reactivated to avoid non-deployment in a collision, resulting in possible personal injury.
Yes
Go to A3.
No
CONNECT C189a and ENGAGE the locking tabs. Go to A7.
WARNING: Never probe the connectors on the airbag module. Doing so can result in airbag deployment, which can result in personal injury. WARNING: The safety belt buckle pretensioner is a pyrotechnic device. Never probe a pretensioner electrical connector. Doing so could result in pretensioner or airbag deployment and could result in personal injury. WARNING: Never probe the connectors on the side airbag module. Doing so can result in side airbag deployment. NOTE: Diagnostics or repairs are not to be performed on a seat equipped with a seat side airbag with the seat in the vehicle. Prior to attempting to diagnose or repair a seat concern when equipped with a seat side airbag, the seat must be removed from the vehicle and the restraint system diagnostic tools must be installed in the seat side airbag electrical connectors. The restraint system diagnostic tools must be removed prior to operating the vehicle over the road. NOTE: After diagnosing or repairing an SRS, the restraint system
diagnostic tools must be removed before operating the vehicle over the road.
NOTE: After diagnosing or repairing a seat system, the restraint system diagnostic tools must be removed before operating the vehicle over the road. NOTE: The SRS must be fully operational and free of faults before releasing the vehicle to the customer. Key in OFF position. Deactivate the system. Refer to Airbag and Safety Belt Pretensioner Supplemental Restraint System (SRS) in the Diagnosis and Testing portion of this section. Connect RCM C189a. Make sure RCM C189a is connected and fully seated. Is RCM C189a fully connected and the connector locking tabs engaged?
A3
CHECK CIRCUIT 16PA (R/G) FOR AN OPEN Key in ON position. Measure the voltage between RCM C189a pin 12, circuit 16PA (R/G), harness side and ground. Is the voltage between 9 and 16 volts?
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Yes
Go to A4.
No
REPAIR circuit 16PA (R/G). Go to A7.
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Occupant Restraints — Passive
501-20b-26
DIAGNOSIS AND TESTING (Continued) Test Step A4
CHECK CIRCUIT 1203A (B/G) FOR AN OPEN Key in OFF position. Measure the resistance between RCM C189a pin 16, circuit 1203A (B/G), harness side and ground. Is the resistance less than 1 ohm?
A5
Result / Action to Take
Yes
Go to A5.
No
Repair circuit 1203A (B/G). Go to A7.
CHECK CIRCUIT 608 (B/Y) FOR A OPEN Disconnect RCM C189a. Disconnect Instrument Cluster C171a. Measure the resistance between instrument cluster module C171a, circuit 608 (B/Y), harness side and RCM C189a pin 15, circuit 608 (B/Y), harness side.
Yes
Go to A6.
No
REPAIR circuit 608 (B/Y). Go to A7.
Is the resistance less than 5 ohms?
A6
CHECK INDICATOR LAMP OPERATION (DRIVE LAMP OFF) Connect Instrument Cluster C171a. Key in ON position. Connect a fused jumper between the RCM C189a pin 15, circuit 608 (B/Y), harness side and ground. Is the indicator lamp off ?
A7
Yes
INSTALL a new RCM. REFER to Restraints Control Module (RCM) in this section. Go to A7
No
REPAIR or INSTALL a new instrument cluster module. REFER to Section 413-01. Go to A7
CHECK FOR ADDITIONAL DTCs Refer to the continuous DTCs recorded during Step A1. Were any continuous DTCs retrieved during Step A1?
Yes
Do not clear any DTCs until all DTCs have been resolved. GO to the Restraints Control Module (RCM) Diagnostic Trouble Code (DTC) Table in this section for pinpoint test direction.
No
RECONNECT the system. REACTIVATE the system. PROVE OUT the system. REFER to Airbag and Safety Belt Pretensioner Supplemental Restraint System (SRS) in this section. CLEAR all DTCs.
Pinpoint Test B: DTC B1869 — Lamp Airbag Warning Indicator Circuit Open or Short to Ground Normal Operation If the restraints control module (RCM) detects an open or short to ground on the airbag warning indicator circuit, it will store diagnostic trouble code (DTC) B1869 in memory.
Possible Causes An open airbag indicator circuit can be caused by: damaged wiring, terminals, or connectors. a faulted RCM. a faulty indicator bulb. an instrument cluster module internal concern.
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501-20b-27
Occupant Restraints — Passive
501-20b-27
DIAGNOSIS AND TESTING (Continued) PINPOINT TEST B : DTC B1869 — LAMP AIR BAG WARNING INDICATOR CIRCUIT OPEN OR SHORT TO GROUND Test Step B1
Result / Action to Take
CHECK FOR A HARD OR INTERMITTENT DTC Enter the following diagnostic mode on the diagnostic tool: Retrieve Continuous DTCs.
Yes
Enter the following diagnostic mode on the diagnostic tool: On-Demand Self Test.
No
If the airbag indicator lamp does illuminate, Go to B2. Retrieve and record any continuous DTCs for use later in this pinpoint If the airbag indicator does not illuminate, Go to test. B4.
Was DTC B1869 retrieved during the on-demand self test?
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This is an intermittent fault. The fault condition is not present at this time. Go to B5
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Occupant Restraints — Passive
501-20b-28
DIAGNOSIS AND TESTING (Continued) Test Step B2
Result / Action to Take
CHECK INDICATOR LAMP OPERATION (DRIVE LAMP OFF) WARNING: If the supplemental restraint system (SRS) is
being serviced, the system must be deactivated and restraint system diagnostic tools must be installed. Refer to Airbag and Safety Belt Pretensioner Supplemental Restraint System (SRS) in this section. The airbag restraint system diagnostic tools must be removed and the airbag modules reconnected when the system is reactivated to avoid non-deployment in a collision, resulting in possible personal injury.
Yes
INSTALL a new RCM. REFER to Restraints Control Module (RCM) in this section. Go to B6.
No
Go to B3.
WARNING: Never probe the connectors on the airbag module. Doing so can result in airbag deployment, which can result in personal injury. WARNING: The safety belt buckle pretensioner is a pyrotechnic device. Never probe a pretensioner electrical connector. Doing so could result in pretensioner or airbag deployment and could result in personal injury. WARNING: Never probe the connectors on the side airbag module. Doing so can result in side airbag deployment. NOTE: Diagnostics or repairs are not to be performed on a seat equipped with a seat side airbag with the seat in the vehicle. Prior to attempting to diagnose or repair a seat concern when equipped with a seat side airbag, the seat must be removed from the vehicle and the restraint system diagnostic tools must be installed in the seat side airbag electrical connectors. The restraint system diagnostic tools must be removed prior to operating the vehicle over the road. NOTE: After diagnosing or repairing an SRS, the restraint system diagnostic tools must be removed before operating the vehicle over the road. NOTE: After diagnosing or repairing a seat system, the restraint system diagnostic tools must be removed before operating the vehicle over the road. NOTE: The SRS must be fully operational and free of faults before releasing the vehicle to the customer. Deactivate the system. Refer to Airbag and Safety Belt Pretensioner Supplemental Restraint System (SRS) in the Diagnosis and Testing portion of this section. Disconnect RCM C189a. Key in ON position. Connect a fused jumper between the RCM C189a pin 15, circuit 608 (B/Y), harness side and ground. Is the indicator lamp off?
B3
CHECK CIRCUIT 608 (B/Y) FOR AN OPEN Key in OFF position. Disconnect Instrument Cluster Module C220a. Disconnect RCM C189a. Measure the resistance between instrument cluster module C171a, circuit 608 (B/Y), harness side and RCM C189a pin 15, circuit 608 (B/Y), harness side.
Yes
Go to B6.
No
REPAIR circuit 608 (B/Y). Go to B6.
Is the resistance less than 5 ohms?
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501-20b-29
Occupant Restraints — Passive
501-20b-29
DIAGNOSIS AND TESTING (Continued) Test Step B4
CHECK INDICATOR LAMP OPERATION (DRIVE LAMP ON) Key in OFF position. Disconnect RCM 189a. Key in ON position. Is the indicator lamp on?
B5
Result / Action to Take
Yes
INSTALL a new RCM. REFER to Restraints Control Module (RCM) in this section. Go to B6.
No
REPAIR the circuit 608 (B/Y). Go to B6.
CHECK FOR AN INTERMITTENT FAULT WARNING: If the supplemental restraint system (SRS) is
being serviced, the system must be deactivated and restraint system diagnostic tools must be installed. Refer to Airbag and Safety Belt Pretensioner Supplemental Restraint System (SRS) in this section. The airbag restraint system diagnostic tools must be removed and the airbag modules reconnected when the system is reactivated to avoid non-deployment in a collision, resulting in possible personal injury.
Yes
Go to B2.
No
CHECK for causes of intermittent open or short to ground on circuit 608 (B/Y). ATTEMPT to recreate the hard fault by flexing the wire harness and cycling the ignition key frequently. REPAIR any intermittent concerns found. Go to B6.
WARNING: Never probe the connectors on the airbag module. Doing so can result in airbag deployment, which can result in personal injury. WARNING: The safety belt buckle pretensioner is a pyrotechnic device. Never probe a pretensioner electrical connector. Doing so could result in pretensioner or airbag deployment and could result in personal injury. WARNING: Never probe the connectors on the side airbag module. Doing so can result in side airbag deployment. NOTE: Diagnostics or repairs are not to be performed on a seat equipped with a seat side airbag with the seat in the vehicle. Prior to attempting to diagnose or repair a seat concern when equipped with a seat side airbag, the seat must be removed from the vehicle and the restraint system diagnostic tools must be installed in the seat side airbag electrical connectors. The restraint system diagnostic tools must be removed prior to operating the vehicle over the road. NOTE: After diagnosing or repairing an SRS, the restraint system
diagnostic tools must be removed before operating the vehicle over the road.
NOTE: After diagnosing or repairing a seat system, the restraint system diagnostic tools must be removed before operating the vehicle over the road. NOTE: The SRS must be fully operational and free of faults before releasing the vehicle to the customer. Key in OFF position. Deactivate the system. Refer to Airbag and Safety Belt Pretensioner Supplemental Restraint System (SRS) in the Diagnosis and Testing portion of this section. Enter the following diagnostic mode on the diagnostic tool: On-Demand Self Test Was DTC B1869 retrieved during the on-demand self test?
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501-20b-30
Occupant Restraints — Passive
501-20b-30
DIAGNOSIS AND TESTING (Continued) Test Step B6
Result / Action to Take
CHECK FOR ADDITIONAL DTCs Refer to the continuous DTCs recorded during Step B1. Were any continuous DTCs retrieved during Step B1?
Yes
Do not clear any DTCs until all DTCs have been resolved. GO to the Restraints Control Module (RCM) Diagnostic Trouble Code (DTC) Table in this section for pinpoint test direction.
No
RECONNECT the system. REACTIVATE the system. PROVE OUT the system. REFER to Airbag and Safety Belt Pretensioner Supplemental Restraint System (SRS)in this section. CLEAR all DTCs.
Pinpoint Test C: DTC B1870 — Airbag Warning Indicator Circuit Short to Battery Normal Operation If the restraints control module detects an open or short to battery on the airbag warning indicator circuit, it will store diagnostic trouble code (DTC) B1870 in memory. If any other DTCs are detected with this DTC active, the secondary airbag warning will be activated.
Possible Causes An airbag indicator circuit short to battery can be caused by: damaged wiring, terminals, or connectors. a faulted RCM. PINPOINT TEST C : DTC B1870 — AIR BAG INDICATOR CIRCUIT SHORT TO BATTERY Test Step C1
Result / Action to Take
CHECK FOR A HARD OR INTERMITTENT DTC Enter the following diagnostic mode on the diagnostic tool: Retrieve Continuous DTCs
Yes
Go to C2.
Retrieve and record any continuous DTCs for use later in this pinpoint No test. This is an intermittent fault. The fault condition is not present at this time. Go to C4. Enter the following diagnostic mode on the diagnostic tool: On-Demand Self Test Was DTC B1870 retrieved during the on-demand self test?
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501-20b-31
Occupant Restraints — Passive
501-20b-31
DIAGNOSIS AND TESTING (Continued) Test Step C2
Result / Action to Take
CHECK CIRCUIT 608 (B/Y) FOR SHORT TO BATTERY WARNING: If the supplemental restraint system (SRS) is
being serviced, the system must be deactivated and restraint system diagnostic tools must be installed. Refer to Airbag and Safety Belt Pretensioner Supplemental Restraint System (SRS) in this section. The airbag restraint system diagnostic tools must be removed and the airbag modules reconnected when the system is reactivated to avoid non-deployment in a collision, resulting in possible personal injury.
Yes
Go to C3.
No
REPAIR circuit 608 (B/Y). Go to C5.
WARNING: Never probe the connectors on the airbag module. Doing so can result in airbag deployment, which can result in personal injury. WARNING: The safety belt buckle pretensioner is a pyrotechnic device. Never probe a pretensioner electrical connector. Doing so could result in pretensioner or airbag deployment and could result in personal injury. WARNING: Never probe the connectors on the side airbag module. Doing so can result in side airbag deployment. NOTE: Diagnostics or repairs are not to be performed on a seat equipped with a seat side airbag with the seat in the vehicle. Prior to attempting to diagnose or repair a seat concern when equipped with a seat side airbag, the seat must be removed from the vehicle and the restraint system diagnostic tools must be installed in the seat side airbag electrical connectors. The restraint system diagnostic tools must be removed prior to operating the vehicle over the road. NOTE: After diagnosing or repairing an SRS, the restraint system
diagnostic tools must be removed before operating the vehicle over the road.
NOTE: After diagnosing or repairing a seat system, the restraint system diagnostic tools must be removed before operating the vehicle over the road. NOTE: The SRS must be fully operational and free of faults before releasing the vehicle to the customer. NOTE: Any DTCs for airbag indicator faults associated with the instrument cluster module will be logged by the RCM. Key in OFF position. Deactivate the system. Refer to Airbag and Safety Belt Pretensioner Supplemental Restraint System (SRS) in the Diagnosis and Testing portion of this section. Disconnect Instrument Cluster Module C220a. Disconnect RCM C189a. Key in ON position. Measure the voltage between C171a, circuit 608 (B/Y), harness side and ground. Is the voltage less than 0.2 volt?
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501-20b-32
Occupant Restraints — Passive
501-20b-32
DIAGNOSIS AND TESTING (Continued) Test Step C3
Result / Action to Take
CHECK THE RCM Key in OFF position. Connect RCM C189a. Enter the following diagnostic mode on the diagnostic tool: On-Demand Self Test
NOTE: DTC B1869 should be retrieved when carrying out the
Yes
INSTALL a new RCM. REFER to Restraints Control Module (RCM) in this section. Go to C5
No
REPAIR or INSTALL a new instrument cluster module. Go to C5.
on-demand self test due to an open on circuit 608 (B/Y), DTC B1870 should not be retrieved at this time. Was DTC B 1870 retrieved during the on-demand self test?
C4
CHECK FOR AN INTERMITTENT FAULT WARNING: If the supplemental restraint system (SRS) is
being serviced, the system must be deactivated and restraint system diagnostic tools must be installed. Refer to Airbag and Safety Belt Pretensioner Supplemental Restraint System (SRS) in this section. The airbag restraint system diagnostic tools must be removed and the airbag modules reconnected when the system is reactivated to avoid non-deployment in a collision, resulting in possible personal injury.
Yes
Go to C2.
No
CHECK for causes of intermittent short to battery on circuit 608 (B/Y). ATTEMPT to recreate the hard fault by flexing the wire harness and cycling the ignition key frequently. ACTIVATE other systems in the same wire bundle. REPAIR any intermittent concerns found. Go to C5.
WARNING: Never probe the connectors on the airbag module. Doing so can result in airbag deployment, which can result in personal injury. WARNING: The safety belt buckle pretensioner is a pyrotechnic device. Never probe a pretensioner electrical connector. Doing so could result in pretensioner or airbag deployment and could result in personal injury. WARNING: Never probe the connectors on the side airbag module. Doing so can result in side airbag deployment. NOTE: Diagnostics or repairs are not to be performed on a seat equipped with a seat side airbag with the seat in the vehicle. Prior to attempting to diagnose or repair a seat concern when equipped with a seat side airbag, the seat must be removed from the vehicle and the restraint system diagnostic tools must be installed in the seat side airbag electrical connectors. The restraint system diagnostic tools must be removed prior to operating the vehicle over the road. NOTE: After diagnosing or repairing an SRS, the restraint system diagnostic tools must be removed before operating the vehicle over the road. NOTE: After diagnosing or repairing a seat system, the restraint system diagnostic tools must be removed before operating the vehicle over the road. NOTE: The SRS must be fully operational and free of faults before releasing the vehicle to the customer. Key in OFF position. Deactivate the system. Refer to Airbag and Safety Belt Pretensioner Supplemental Restraint System (SRS) in the Diagnosis and Testing portion of this section. Enter the following diagnostic mode on the diagnostic tool: On-Demand Self Test Was DTC B 1870 retrieved during the on-demand self test?
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501-20b-33
Occupant Restraints — Passive
501-20b-33
DIAGNOSIS AND TESTING (Continued) Test Step C5
Result / Action to Take
CHECK FOR ADDITIONAL DTCs Refer to the continuous DTCs recorded during Step C1. Were any continuous DTCs retrieved during Step C1?
Yes
Do not clear any DTCs until all DTCs have been resolved. GO to the Restraints Control Module (RCM) Diagnostic Trouble Code (DTC) Table in this section for pinpoint test direction.
No
RECONNECT the system. REACTIVATE the system. PROVE OUT the system. REFER to Airbag and Safety Belt Pretensioner Supplemental Restraint System (SRS)in this section. CLEAR all DTCs.
Pinpoint Test D: DTC B1891 — Airbag Warning Indicator Circuit Short to Battery Normal Operation The restraints control module (RCM) monitors its connection to the instrument cluster module at C189a pin 22. This connection is used to signal a chime if the airbag indicator is inoperative and another SRS fault exists. If the RCM detects a short to battery on the connection to the instrument cluster module, it will store diagnostic trouble code (DTC) B1891 in memory.
Possible Causes An airbag indicator circuit short to battery can be caused by: damaged wiring, terminals, or connectors. a damaged or inoperative instrument cluster module. a faulted RCM. PINPOINT TEST D : DTC B1891 — AIR BAG TONE WARNING INDICATOR CIRCUIT SHORT TO BATTERY Test Step D1
Result / Action to Take
CHECK FOR A HARD OR INTERMITTENT DTC Enter the following diagnostic mode on the diagnostic tool: Retrieve Continuous DTCs
Yes
Enter the following diagnostic mode on the diagnostic tool: On-Demand Self Test
No
This is a hard fault. The fault condition is still present. This fault cannot be cleared until it is Retrieve and record any continuous DTCs for use later in this pinpoint corrected and the DTC is no longer retrieved test. during the on-demand self test. Go to D2.
Was DTC B1891 retrieved during the on-demand self test?
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This is an intermittent fault. The fault condition is not present at this time. Go to D4
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501-20b-34
DIAGNOSIS AND TESTING (Continued) Test Step D2
Result / Action to Take
CHECK THE AIR BAG TONE WARNING INDICATOR CIRCUIT FOR A SHORT TO BATTERY WARNING: If the supplemental restraint system (SRS) is
being serviced, the system must be deactivated and restraint system diagnostic tools must be installed. Refer to Airbag and Safety Belt Pretensioner Supplemental Restraint System (SRS) in this section. The airbag restraint system diagnostic tools must be removed and the airbag modules reconnected when the system is reactivated to avoid non-deployment in a collision, resulting in possible personal injury.
Yes
Go to D3.
No
REPAIR circuit 609 (O). Go to D5.
WARNING: Never probe the connectors on the airbag module. Doing so can result in airbag deployment, which can result in personal injury. WARNING: The safety belt buckle pretensioner is a pyrotechnic device. Never probe a pretensioner electrical connector. Doing so could result in pretensioner or airbag deployment and could result in personal injury. WARNING: Never probe the connectors on the side airbag module. Doing so can result in side airbag deployment. NOTE: Diagnostics or repairs are not to be performed on a seat equipped with a seat side airbag with the seat in the vehicle. Prior to attempting to diagnose or repair a seat concern when equipped with a seat side airbag, the seat must be removed from the vehicle and the restraint system diagnostic tools must be installed in the seat side airbag electrical connectors. The restraint system diagnostic tools must be removed prior to operating the vehicle over the road. NOTE: After diagnosing or repairing an SRS, the restraint system diagnostic tools must be removed before operating the vehicle over the road. NOTE: After diagnosing or repairing a seat system, the restraint system diagnostic tools must be removed before operating the vehicle over the road. NOTE: The SRS must be fully operational and free of faults before releasing the vehicle to the customer. Key in OFF position. Deactivate the system. Refer to Airbag and Safety Belt Pretensioner Supplemental Restraint System (SRS) in the Diagnosis and Testing portion of this section. Disconnect RCM C189a. Disconnect Instrument Cluster Module C171b. Key in ON position. Measure the voltage between RCM C189a pin 22, circuit 609 (O), harness side and ground. Is the voltage less than 0.2 volt?
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501-20b-35
Occupant Restraints — Passive
501-20b-35
DIAGNOSIS AND TESTING (Continued) Test Step D3
Result / Action to Take
CHECK THE RCM Key in OFF position. Connect RCM C189a. Key in ON position. Enter the following diagnostic mode on the diagnostic tool: On-Demand Self Test
Yes
INSTALL a new RCM. Go to D5
No
INSTALL a new instrument cluster module. Go to D5
NOTE: DTC B1892 should be retrieved when carrying out the
on-demand self test due to an open on circuit 609 (O), DTC B1891 should not be retrieved at this time.
Was DTC B1891 retrieved during the on-demand self test?
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501-20b-36
Occupant Restraints — Passive
501-20b-36
DIAGNOSIS AND TESTING (Continued) Test Step D4
Result / Action to Take
CHECK FOR AN INTERMITTENT FAULT WARNING: If the supplemental restraint system (SRS) is
being serviced, the system must be deactivated and restraint system diagnostic tools must be installed. Refer to Airbag and Safety Belt Pretensioner Supplemental Restraint System (SRS) in this section. The airbag restraint system diagnostic tools must be removed and the airbag modules reconnected when the system is reactivated to avoid non-deployment in a collision, resulting in possible personal injury.
Yes
Go to D2.
No
CHECK for causes of intermittent short to ground or open on circuit 609 (O). ATTEMPT to recreate the hard fault by flexing the wire harness and cycling the ignition key frequently. REPAIR any intermittent concerns found. Go to D5.
WARNING: Never probe the connectors on the airbag module. Doing so can result in airbag deployment, which can result in personal injury. WARNING: The safety belt buckle pretensioner is a pyrotechnic device. Never probe a pretensioner electrical connector. Doing so could result in pretensioner or airbag deployment and could result in personal injury. WARNING: Never probe the connectors on the side airbag module. Doing so can result in side airbag deployment. NOTE: Diagnostics or repairs are not to be performed on a seat equipped with a seat side airbag with the seat in the vehicle. Prior to attempting to diagnose or repair a seat concern when equipped with a seat side airbag, the seat must be removed from the vehicle and the restraint system diagnostic tools must be installed in the seat side airbag electrical connectors. The restraint system diagnostic tools must be removed prior to operating the vehicle over the road. NOTE: After diagnosing or repairing an SRS, the restraint system diagnostic tools must be removed before operating the vehicle over the road. NOTE: After diagnosing or repairing a seat system, the restraint system diagnostic tools must be removed before operating the vehicle over the road. NOTE: The SRS must be fully operational and free of faults before releasing the vehicle to the customer. Key in OFF position. Deactivate the system. Refer to Airbag and Safety Belt Pretensioner Supplemental Restraint System (SRS) in the Diagnosis and Testing portion of this section. Enter the following diagnostic mode on the diagnostic tool: On-Demand Self Test Was DTC B 1891 retrieved during the on-demand self test?
D5
CHECK FOR ADDITIONAL DTCs Refer to the continuous DTCs recorded during Step D1. Were any continuous DTCs retrieved during Step D1?
Yes
Do not clear any DTCs until all DTCs have been resolved. GO to the Restraints Control Module (RCM) Diagnostic Trouble Code (DTC) Table in this section for pinpoint test direction.
No
RECONNECT the system. REACTIVATE the system. PROVE OUT the system. REFER to Airbag and Safety Belt Pretensioner Supplemental Restraint System (SRS)in this section. CLEAR all DTCs.
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501-20b-37
Occupant Restraints — Passive
501-20b-37
DIAGNOSIS AND TESTING (Continued) Pinpoint Test E: LFC 53/DTC B1892 — Airbag Tone Warning Indicator Circuit Shorted to Ground or Open Normal Operation The restraints control module (RCM) monitors its connection to the instrument cluster module at C189a pin 22. This connection is used to signal a chime if the airbag indicator is inoperative and another SRS fault exists. If the RCM detects a short to ground or open on the connection to the cluster, it will store diagnostic trouble code (DTC) B1892 in memory and flash lamp fault code (LFC) 53 (or a higher priority code if one exists) on the airbag indicator.
Possible Causes An airbag tone warning indicator circuit short to ground or open can be caused by: damaged wiring, terminals, or connectors. a damaged or inoperative instrument cluster module. a faulted RCM. PINPOINT TEST E : LFC 53/DTC B1892 — AIR BAG TONE WARNING INDICATOR CIRCUIT SHORTED TO GROUND OR OPEN Test Step E1
Result / Action to Take
CHECK FOR A HARD OR INTERMITTENT DTC Enter the following diagnostic mode on the diagnostic tool: Retrieve Continuous DTCs
Yes
Enter the following diagnostic mode on the diagnostic tool: On-Demand Self Test
No
This is a hard fault. The fault condition is still present. This fault cannot be cleared until it is Retrieve and record any continuous DTCs for use later in this pinpoint corrected and the DTC is no longer retrieved test. during the on-demand self test. Go to E2.
Was DTC B1892 retrieved during the on-demand self test?
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This is an intermittent fault. The fault condition is not present at this time. Go to E5.
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501-20b-38
DIAGNOSIS AND TESTING (Continued) Test Step E2
Result / Action to Take
CHECK THE AIR BAG TONE WARNING INDICATOR CIRCUIT FOR GROUND SHORT WARNING: If the supplemental restraint system (SRS) is
being serviced, the system must be deactivated and restraint system diagnostic tools must be installed. Refer to Airbag and Safety Belt Pretensioner Supplemental Restraint System (SRS) in this section. The airbag restraint system diagnostic tools must be removed and the airbag modules reconnected when the system is reactivated to avoid non-deployment in a collision, resulting in possible personal injury.
Yes
Go to E3.
No
REPAIR circuit 609 (O). Go to E6.
WARNING: Never probe the connectors on the airbag module. Doing so can result in airbag deployment, which can result in personal injury. WARNING: The safety belt buckle pretensioner is a pyrotechnic device. Never probe a pretensioner electrical connector. Doing so could result in pretensioner or airbag deployment and could result in personal injury. WARNING: Never probe the connectors on the side airbag module. Doing so can result in side airbag deployment. NOTE: Diagnostics or repairs are not to be performed on a seat equipped with a seat side airbag with the seat in the vehicle. Prior to attempting to diagnose or repair a seat concern when equipped with a seat side airbag, the seat must be removed from the vehicle and the restraint system diagnostic tools must be installed in the seat side airbag electrical connectors. The restraint system diagnostic tools must be removed prior to operating the vehicle over the road. NOTE: After diagnosing or repairing an SRS, the restraint system diagnostic tools must be removed before operating the vehicle over the road. NOTE: After diagnosing or repairing a seat system, the restraint system diagnostic tools must be removed before operating the vehicle over the road. NOTE: The SRS must be fully operational and free of faults before releasing the vehicle to the customer. Key in OFF position. Deactivate the system. Refer to Airbag and Safety Belt Pretensioner Supplemental Restraint System (SRS) in the Diagnosis and Testing portion of this section. Disconnect RCM C189a. Disconnect Instrument Cluster Module C171b. Measure the resistance between RCM C189a pin 22, circuit 609 (O), harness side and RCM C189a pin 16, circuit 1203A (B/G), harness side. Is the resistance greater than 1,000,000 ohms?
E3
CHECK THE AIR BAG TONE WARNING INDICATOR CIRCUIT FOR AN OPEN Key in OFF position. Measure the resistance between RCM C189a pin 22, circuit 609 (O), harness side and instrument cluster module C171b, circuit 609 (O), harness side.
Yes
Go to E4.
No
REPAIR circuit 609 (O). Go to E6.
Is the resistance less than 5 ohms?
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501-20b-39
Occupant Restraints — Passive
501-20b-39
DIAGNOSIS AND TESTING (Continued) Test Step E4
CHECK THE AIR BAG TONE WARNING INDICATOR Connect Instrument Cluster Module C171b. Key in ON position. Measure the voltage at RCM C189a pin 22, circuit 609 (O). Is the voltage greater than 10 volts?
E5
Result / Action to Take
Yes
INSTALL a new RCM. Go to E6.
No
INSTALL a new instrument cluster module. Go to E6.
CHECK FOR AN INTERMITTENT FAULT WARNING: If the supplemental restraint system (SRS) is
being serviced, the system must be deactivated and restraint system diagnostic tools must be installed. Refer to Airbag and Safety Belt Pretensioner Supplemental Restraint System (SRS) in this section. The airbag restraint system diagnostic tools must be removed and the airbag modules reconnected when the system is reactivated to avoid non-deployment in a collision, resulting in possible personal injury.
Yes
Go to E2.
No
CHECK for causes of an intermittent short to ground or open on circuit 609 (O). ATTEMPT to recreate the hard fault by flexing the wire harness and cycling the ignition key frequently. REPAIR any intermittent concerns found. Go to E6.
WARNING: Never probe the connectors on the airbag module. Doing so can result in airbag deployment, which can result in personal injury. WARNING: The safety belt buckle pretensioner is a pyrotechnic device. Never probe a pretensioner electrical connector. Doing so could result in pretensioner or airbag deployment and could result in personal injury. WARNING: Never probe the connectors on the side airbag module. Doing so can result in side airbag deployment. NOTE: Diagnostics or repairs are not to be performed on a seat equipped with a seat side airbag with the seat in the vehicle. Prior to attempting to diagnose or repair a seat concern when equipped with a seat side airbag, the seat must be removed from the vehicle and the restraint system diagnostic tools must be installed in the seat side airbag electrical connectors. The restraint system diagnostic tools must be removed prior to operating the vehicle over the road. NOTE: After diagnosing or repairing an SRS, the restraint system
diagnostic tools must be removed before operating the vehicle over the road.
NOTE: After diagnosing or repairing a seat system, the restraint system diagnostic tools must be removed before operating the vehicle over the road. NOTE: The SRS must be fully operational and free of faults before releasing the vehicle to the customer. Key in OFF position. Deactivate the system. Refer to Airbag and Safety Belt Pretensioner Supplemental Restraint System (SRS) in the Diagnosis and Testing portion of this section. Enter the following diagnostic mode on the diagnostic tool: On-Demand Self Test Was DTC B 1892 retrieved during the on-demand self test?
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01/2003 2003.0 BA Falcon
501-20b-40
Occupant Restraints — Passive
501-20b-40
DIAGNOSIS AND TESTING (Continued) Test Step E6
Result / Action to Take
CHECK FOR ADDITIONAL DTCs Refer to the continuous DTCs recorded during Step E1. Were any continuous DTCs retrieved during Step E1?
Yes
Do not clear any DTCs until all DTCs have been resolved. GO to the Restraints Control Module (RCM) Diagnostic Trouble Code (DTC) Table in this section for pinpoint test direction.
No
RECONNECT the system. REACTIVATE the system. PROVE OUT the system. REFER to Airbag and Safety Belt Pretensioner Supplemental Restraint System (SRS)in this section. CLEAR all DTCs.
Pinpoint Test F: LFC 14/DTC B1921 — Airbag Diagnostic Monitor Ground Circuit Open Normal Operation WARNING: The tightening torque of the restraints control module (RCM) retaining bolts is critical for correct airbag supplemental restraint system (SRS) operation. REFER to Restraints Control Module (RCM) in this section for correct torque values. NOTE: A resistance difference as low as 10 ohms can set the LFC. The restraints control module (RCM) monitors the resistance between the ground connections at the mounting bracket and the reference ground at C189a pin 16, circuit 1203A (B/G). If the RCM detects a difference in resistance, it will store diagnostic trouble code (DTC) B1921 in memory and flash lamp fault code (LFC) 14 (or higher priority code if one exists) on the airbag indicator.
Possible Causes A resistance difference between the RCM bracket ground and harness ground can be caused by: the RCM or RCM bracket is not securely mounted. damaged wiring, terminals, or connectors. a faulted RCM.
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01/2003 2003.0 BA Falcon
501-20b-41
Occupant Restraints — Passive
501-20b-41
DIAGNOSIS AND TESTING (Continued) PINPOINT TEST F : LFC 14/DTC B1921 — AIR BAG DIAGNOSTIC MONITOR GROUND CIRCUIT OPEN Test Step F1
Result / Action to Take
CHECK FOR A HARD OR INTERMITTENT DTC Enter the following diagnostic mode on the diagnostic tool: Retrieve Continuous DTCs
Yes
This is a hard fault. The fault condition is still present. This fault cannot be cleared until it is Retrieve and record any continuous DTCs for use later in this pinpoint corrected and the DTC is no longer retrieved test. during the on-demand self test. Go to F2 Enter the following diagnostic mode on the diagnostic tool: On-Demand Self Test No This is an intermittent fault. The fault condition is Was DTC B1921 retrieved during the on-demand self test? not present at this time. Go to F5
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01/2003 2003.0 BA Falcon
501-20b-42
Occupant Restraints — Passive
501-20b-42
DIAGNOSIS AND TESTING (Continued) Test Step F2
Result / Action to Take
INSPECT THE RCM MOUNTING, MOUNTING BRACKET AND MOUNTING SURFACE WARNING: If the supplemental restraint system (SRS) is
being serviced, the system must be deactivated and restraint system diagnostic tools must be installed. Refer to Airbag and Safety Belt Pretensioner Supplemental Restraint System (SRS) in this section. The airbag restraint system diagnostic tools must be removed and the airbag modules reconnected when the system is reactivated to avoid non-deployment in a collision, resulting in possible personal injury.
Yes
CLEAN, TIGHTEN bolts or REPAIR the mounting surface as necessary. REINSTALL the RCM and mounting bracket to the mounting surface. Go to F6.
No
Go to F3.
WARNING: Never probe the connectors on the airbag module. Doing so can result in airbag deployment, which can result in personal injury. WARNING: The safety belt buckle pretensioner is a pyrotechnic device. Never probe a pretensioner electrical connector. Doing so could result in pretensioner or airbag deployment and could result in personal injury. WARNING: Never probe the connectors on the side airbag module. Doing so can result in side airbag deployment. NOTE: Diagnostics or repairs are not to be performed on a seat equipped with a seat side airbag with the seat in the vehicle. Prior to attempting to diagnose or repair a seat concern when equipped with a seat side airbag, the seat must be removed from the vehicle and the restraint system diagnostic tools must be installed in the seat side airbag electrical connectors. The restraint system diagnostic tools must be removed prior to operating the vehicle over the road. NOTE: After diagnosing or repairing an SRS, the restraint system diagnostic tools must be removed before operating the vehicle over the road. NOTE: After diagnosing or repairing a seat system, the restraint system diagnostic tools must be removed before operating the vehicle over the road. NOTE: The SRS must be fully operational and free of faults before releasing the vehicle to the customer. Key in OFF position. Deactivate the system. Refer to Airbag and Safety Belt Pretensioner Supplemental Restraint System (SRS) in the Diagnosis and Testing portion of this section. Inspect the RCM mounting and make sure that the retaining bolts are fully seated and tightened correctly. Remove the RCM. Refer to Restraints Control Module (RCM) in this section. Visually inspect the RCM, mounting bracket and mounting surface for damage, corrosion or dirt. Was a significant amount of corrosion or dirt found, the RCM mounting bracket attached to the mounting surface incorrectly or were the RCM bolts not fully seated and tightened correctly?
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01/2003 2003.0 BA Falcon
501-20b-43
Occupant Restraints — Passive
501-20b-43
DIAGNOSIS AND TESTING (Continued) Test Step F3
Result / Action to Take
INSTALL THE RCM AND CARRY OUT THE ON-DEMAND SELF TEST Clean the RCM mounting surfaces and bolts. Install the RCM. Refer to Restraints Control Module (RCM) in this section. Enter the following diagnostic mode on the diagnostic tool: On-Demand Self Test
Yes
Go to F4.
No
Fault corrected. Go to F6.
Was DTC B1921 retrieved during the on-demand self test?
F4
CHECK GROUND CIRCUIT 1203A (B/G) FOR HIGH RESISTANCE Key in OFF position. Measure the resistance between RCM C189a pin 16, circuit 1203A (B/G), harness side and the RCM case ground. Is the resistance less than 5 ohms?
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Yes
INSTALL a new RCM. Go to F6.
No
REPAIR circuit 1203A (B/G). Go to F6.
01/2003 2003.0 BA Falcon
501-20b-44
Occupant Restraints — Passive
501-20b-44
DIAGNOSIS AND TESTING (Continued) Test Step F5
Result / Action to Take
CHECK FOR AN INTERMITTENT FAULT WARNING: If the supplemental restraint system (SRS) is
being serviced, the system must be deactivated and restraint system diagnostic tools must be installed. Refer to Airbag and Safety Belt Pretensioner Supplemental Restraint System (SRS) in this section. The airbag restraint system diagnostic tools must be removed and the airbag modules reconnected when the system is reactivated to avoid non-deployment in a collision, resulting in possible personal injury.
Yes
Go to F2.
No
CHECK for causes of intermittent high resistance on circuit 1203A (B/G) or the chassis ground. ATTEMPT to recreate the hard fault by flexing the wire harness and cycling the ignition key frequently. REPAIR any intermittent concerns found. Go to F6.
WARNING: Never probe the connectors on the airbag module. Doing so can result in airbag deployment, which can result in personal injury. WARNING: The safety belt buckle pretensioner is a pyrotechnic device. Never probe a pretensioner electrical connector. Doing so could result in pretensioner or airbag deployment and could result in personal injury. WARNING: Never probe the connectors on the side airbag module. Doing so can result in side airbag deployment. NOTE: Diagnostics or repairs are not to be performed on a seat equipped with a seat side airbag with the seat in the vehicle. Prior to attempting to diagnose or repair a seat concern when equipped with a seat side airbag, the seat must be removed from the vehicle and the restraint system diagnostic tools must be installed in the seat side airbag electrical connectors. The restraint system diagnostic tools must be removed prior to operating the vehicle over the road. NOTE: After diagnosing or repairing an SRS, the restraint system diagnostic tools must be removed before operating the vehicle over the road. NOTE: After diagnosing or repairing a seat system, the restraint system diagnostic tools must be removed before operating the vehicle over the road. NOTE: The SRS must be fully operational and free of faults before releasing the vehicle to the customer. Key in OFF position. Deactivate the system. Refer to Airbag and Safety Belt Pretensioner Supplemental Restraint System (SRS) in the Diagnosis and Testing portion of this section. Enter the following diagnostic mode on the diagnostic tool: On-Demand Self Test Was DTC B 1921 retrieved during the on-demand self test?
F6
CHECK FOR ADDITIONAL DTCs Refer to the continuous DTCs recorded during Step F1. Were any continuous DTCs retrieved during Step F1?
Yes
Do not clear any DTCs until all DTCs have been resolved. GO to the Restraints Control Module (RCM) Diagnostic Trouble Code (DTC) Table in this section for pinpoint test direction.
No
RECONNECT the system. REACTIVATE the system. PROVE OUT the system. REFER to Airbag and Safety Belt Pretensioner Supplemental Restraint System (SRS)in this section. CLEAR all DTCs.
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01/2003 2003.0 BA Falcon
501-20b-45
Occupant Restraints — Passive
501-20b-45
DIAGNOSIS AND TESTING (Continued) Pinpoint Test G: LFC 33 and 34/DTC B2292 - Restraint System Safety Belt Pretensioner Status Normal Operation The restraints control module (RCM) checks all of the safety belt pretensioners for faults. If the RCM detects one of the following faults on any of the safety belt pretensioner circuits, it will store diagnostic trouble code (DTC) B2292 in memory and flash, depending on the fault indicator, either lamp fault code (LFC) 33 or 34 (or higher priority code if one exists) on the airbag indicator.
Fault Conditions The RCM monitors for the following fault conditions: low resistance. circuit open. circuit short to voltage. circuit short to ground.
Possible Causes A safety belt pretensioner status fault can be caused by: damaged wiring, terminals, or connectors. a faulty pretensioner. a faulted RCM. PINPOINT TEST G : LFC 33 AND 34/DTC B2292 - RESTRAINT SYSTEM SAFETY BELT PRETENSIONER STATUS Test Step G1
Result / Action to Take
CHECK FOR A HARD OR INTERMITTENT DTC Enter the following diagnostic mode on the diagnostic tool: Retrieve/Flag Continuous DTCs Retrieve, flag and record any continuous DTCs for use later in this pinpoint test. Enter the following diagnostic mode on the diagnostic tool: On-Demand Self Test Enter the following diagnostic mode on the diagnostic tool: Flag DTC B2292 Retrieve and record any flagged faults for use later in this pinpoint test.
Yes
This is a hard fault. The fault condition is still present. This fault cannot be cleared until it is corrected and the DTC is no longer retrieved during the on-demand self test. Go to G2.
No
This is an intermittent fault. The fault condition is not present at this time. Go to G18.
Was DTC B2292 retrieved during the on-demand self test?
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01/2003 2003.0 BA Falcon
501-20b-46
Occupant Restraints — Passive
501-20b-46
DIAGNOSIS AND TESTING (Continued) Test Step G2
Result / Action to Take
CHECK THE PRETENSIONER WARNING: If the supplemental restraint system (SRS) is
Yes
This is a hard fault. The fault condition is still present. This fault cannot be cleared until it is corrected and the DTC is no longer retrieved during the on-demand self test. Using the flagged faults recorded in the Step G1, GO to the appropriate pinpoint test step. If a flagged fault of “?” was recorded, multiple faults exist and the entire pinpoint test must be carried out before installing a new RCM. For driver safety belt pretensioner (DF—PRT) with a low resistance (LOWRES) fault, Go to G3. WARNING: Never probe the connectors on the airbag module. Doing so can result in airbag deployment, which can result in For DF—PRT with an open circuit (O—CIR) fault, Go to G4. personal injury. For DF—PRT with a short to battery (STB) fault, Go to G6. For DF—PRT with a short to ground (STG) fault, WARNING: The safety belt buckle pretensioner is a Go to G8. pyrotechnic device. Never probe a pretensioner electrical connector. Doing so could result in pretensioner or airbag deployment and could For passenger safety belt pretensioner (PF—PRT) with a low resistance (LOWRES) result in personal injury. fault, Go to G10. For PF—PRT with an open circuit (O—CIR) WARNING: Never probe the electrical connector on a side fault, Go to G11. airbag module. Doing so can result in side airbag deployment. For PF—PRT with a short to battery (STB) fault, Go to G13. NOTE: Diagnostics or repairs are not to be performed on a seat For PF—PRT with a short to ground (STG) fault, equipped with a seat side airbag with the seat in the vehicle. Prior to Go to G15. attempting to diagnose or repair a seat concern when equipped with a seat side airbag, the seat must be removed from the vehicle and the restraint No system diagnostic tools must be installed in the seat side airbag electrical INSTALL a new driver or passenger safety belt connectors. The restraint system diagnostic tools must be removed pretensioner. Go to G19. prior to operating the vehicle over the road. being serviced, the system must be deactivated and restraint system diagnostic tools must be installed. Refer to Airbag and Safety Belt Pretensioner Supplemental Restraint System (SRS) in this section. The airbag restraint system diagnostic tools must be removed and the airbag modules reconnected when the system is reactivated to avoid non-deployment in a collision, resulting in possible personal injury.
NOTE: After diagnosing or repairing an SRS, the restraint system diagnostic tools must be removed before operating the vehicle over the road. NOTE: After diagnosing or repairing a seat system, the restraint system diagnostic tools must be removed before operating the vehicle over the road. NOTE: The SRS must be fully operational and free of faults before releasing the vehicle to the customer. Deactivate the system. Refer to Airbag and Safety Belt Pretensioner Supplemental Restraint System (SRS) in the Diagnosis and Testing portion of this section. Enter the following diagnostic mode on the diagnostic tool: On-Demand Self Test Was DTC 2292 retrieved during the on-demand self test?
G3
CHECK THE DRIVER SAFETY BELT PRETENSIONER CIRCUIT 1079 (LG/RD) AND CIRCUIT 1080 (LG/BK) FOR LOW RESISTANCE Key in OFF position. Disconnect Driver Safety Belt Pretensioner Restraint System Diagnostic Tool. Disconnect RCM C189b. Measure the resistance between RCM C189b pin 32, circuit 1080 (LG/BK), and pin 31, circuit 1079 (LG/RD), harness side.
Yes
Go to G17.
No
REPAIR circuit 1079 (LG/RD) and circuit 1080 (LG/BK). Go to G19.
Is the resistance greater than 1,000,000 ohms?
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01/2003 2003.0 BA Falcon
501-20b-47
Occupant Restraints — Passive
501-20b-47
DIAGNOSIS AND TESTING (Continued) Test Step G4
Result / Action to Take
CHECK CIRCUIT 1079 (LG/RD) FOR AN OPEN Key in OFF position. Disconnect Driver Safety Belt Pretensioner Restraint System Diagnostic Tool. Disconnect RCM C189b.
Yes
Go to G5.
No
REPAIR circuit 1079 (LG/RD). Go to G19.
Measure the resistance between RCM C189b pin 31, circuit 1079 (LG/RD), harness side and driver safety belt buckle pretensioner C233, circuit 1079 (LG/RD), harness side. Is the resistance less than 0.5 ohm?
G5
CHECK CIRCUIT 1080 (LG/RD) FOR AN OPEN Key in OFF position. Disconnect Driver Safety Belt Pretensioner Restraint System Diagnostic Tool. Disconnect RCM C189b.
Yes
Go to G17.
No
REPAIR circuit 1080 (LG/BK). Go to G19.
Measure the resistance between RCM C189b pin 32, circuit 1080 (LG/BK), harness side and driver safety belt buckle pretensioner C233, circuit 1080 (LG/BK), harness side. Is the resistance less than 0.5 ohm?
G6
CHECK CIRCUIT 1079 (LG/RD) FOR A SHORT TO VOLTAGE Yes
Disconnect Driver Safety Belt Pretensioner Restraint System Diagnostic Tool.
Go to G7.
Disconnect RCM C189b.
No
Key in ON position.
REPAIR circuit 1079 (LG/RD). Go to G19.
Measure the voltage between RCM C189b pin 31, circuit 1079 (LG/RD), harness side and ground. Is the voltage less than 0.2 volt?
G7
CHECK CIRCUIT 1080 (LG/BK) FOR A SHORT TO VOLTAGE Measure the voltage between RCM C189b pin 32, circuit 1080 (LG/BK), harness side and ground.
Yes
Is the voltage less than 0.2 volt?
No
Go to G17.
REPAIR circuit 1080 (LG/BK). Go to G19.
G8
CHECK CIRCUIT 1079 (LG/RD) FOR A SHORT TO GROUND Key in OFF position. Disconnect Driver Safety Belt Pretensioner Restraint System Diagnostic Tool. Disconnect RCM C189b.
Yes
Go to G9.
No
REPAIR circuit 1079 (LG/RD). Go to G19.
Measure the resistance between RCM C189b pin 31, circuit 1079 (LG/RD), harness side and ground. Is the resistance greater than 1,000,000 ohms?
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01/2003 2003.0 BA Falcon
501-20b-48
Occupant Restraints — Passive
501-20b-48
DIAGNOSIS AND TESTING (Continued) Test Step G9
Result / Action to Take
CHECK CIRCUIT 1080 (LG/BK) FOR A SHORT TO GROUND Measure the resistance between RCM C189b pin 32, circuit 1080 (LG/BK), harness side and ground.
Yes
Is the resistance greater than 1,000,000 ohms?
No
Go to G17.
REPAIR circuit 1080 (LG/BK). Go to G19.
G10
CHECK THE PASSENGER SAFETY BELT PRETENSIONER CIRCUIT 1081 (YE/RD) AND CIRCUIT 1082 (YE/BK) FOR LOW RESISTANCE Key in OFF position. Disconnect Passenger Safety Belt Pretensioner Restraint System Diagnostic Tool. Disconnect RCM C189b. Measure the resistance between RCM C189b pin 34, circuit 1082 (YE/BK), and pin 33, circuit 1081 (YE/RD), harness side.
Yes
Go to G17.
No
REPAIR circuit 1082 (YE/BK) and circuit 1081 (YE/RD). Go to G19.
Is the resistance greater than 1,000,000 ohms?
G11
CHECK CIRCUIT 1081 (YE/RD) FOR AN OPEN Key in OFF position. Disconnect Passenger Safety Belt Pretensioner Restraint System Diagnostic Tool. Disconnect RCM C189b.
Yes
Go to G12.
No
REPAIR circuit 1081 (YE/RD). Go to G19.
Measure the resistance between RCM C189b pin 33, circuit 1081 (YE/RD), harness side and passenger safety belt buckle pretensioner C234, circuit 1081 (YE/RD), harness side. Is the resistance less than 0.5 ohm?
G12
G13
CHECK CIRCUIT 1082 (YE/BK) FOR AN OPEN Yes
Measure the resistance between RCM C189b pin 34, circuit 1082 (YE/BK), harness side and passenger safety belt buckle pretensioner C234, circuit 1082 (YE/BK), harness side.
Go to G17.
Is the resistance less than 0.5 ohm?
REPAIR circuit 1082 (YE/BK). Go to G19.
No
CHECK CIRCUIT 1081 (YE/RD) FOR A SHORT TO VOLTAGE Key in OFF position. Disconnect Passenger Safety Belt Pretensioner Restraint System Diagnostic Tool. Disconnect RCM C189b.
Yes
Go to G14.
No
REPAIR circuit 1081 (YE/RD). Go to G19.
Key in ON position. Measure the voltage between RCM C189b pin 33, circuit 1081 (YE/RD), harness side and ground. Is the voltage less than 0.2 volt?
G14
CHECK CIRCUIT 1082 (YE/BK) FOR A SHORT TO VOLTAGE Yes
Measure the voltage between RCM C189b pin 34, circuit 1082 (YE/BK), harness side and ground.
Go to G17.
Is the voltage less than 0.2 volt?
No
REPAIR circuit 1082 (YE/BK). Go to G19.
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01/2003 2003.0 BA Falcon
501-20b-49
Occupant Restraints — Passive
501-20b-49
DIAGNOSIS AND TESTING (Continued) Test Step G15
Result / Action to Take
CHECK CIRCUIT 1081 (YE/RD) FOR A SHORT TO GROUND Key in OFF position. Disconnect Passenger Safety Belt Pretensioner Restraint System Diagnostic Tool. Disconnect RCM C189b.
Yes
Go to G16.
No
REPAIR circuit 1081 (YE/RD). Go to G19.
Measure the resistance between RCM C189b pin 33, circuit 1081 (YE/RD), harness side and ground. Is the resistance greater than 1,000,000 ohms?
G16
CHECK CIRCUIT 1082 (YE/BK) FOR A SHORT TO GROUND Yes
Measure the resistance between RCM C189b pin 34, circuit 1082 (YE/BK), harness side and ground.
Go to G17.
Is the resistance greater than 1,000,000 ohms?
No
REPAIR circuit 1082 (YE/BK). Go to G19.
G17
CONFIRM THE RCM FAULT NOTE: Make sure all restraint system diagnostic tools, sensor electrical
Yes
Key in OFF position.
If a “?” was flagged by the scan tool, CARRY OUT the entire pinpoint test before installing a new RCM. INSTALL a new RCM. REFER to Restraints Control Module (RCM). Go to G19.
Connect Restraint System Diagnostic Tools.
No
connectors and the RCM electrical connector are connected before carrying out the on-demand self test. If not, erroneous DTCs will be recorded.
Connect RCM C189b.
Fault corrected. Go to G19.
Key in ON position. Enter the following diagnostic mode on the diagnostic tool: On-Demand Self Test Enter the following diagnostic mode on the diagnostic tool: Flag DTC B2292 Retrieve and record any flagged faults. Was DTC B2292 retrieved during the on-demand self test?
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01/2003 2003.0 BA Falcon
501-20b-50
Occupant Restraints — Passive
501-20b-50
DIAGNOSIS AND TESTING (Continued) Test Step G18
Result / Action to Take
CHECK FOR AN INTERMITTENT FAULT WARNING: If the supplemental restraint system (SRS) is
Yes
CHECK for causes of the intermittent fault at or near the affected safety belt pretensioner electrical connector. REPAIR any intermittent concern found. If an intermittent concern was found and repaired, Go to G19. If an intermittent concern was not found and repaired, USE the flagged faults recorded and GO to the appropriate pinpoint test step. If a flagged fault of “?” was recorded, multiple faults exist and the entire pinpoint test must be WARNING: Never probe the connectors on the airbag module. Doing so can result in airbag deployment, which can result in carried out before installing a new RCM. For driver safety belt pretensioner (DF—PRT) personal injury. with a low resistance (LOWRES) fault, Go to G3. For DF—PRT with an open circuit (O—CIR) fault, Go to G4. WARNING: The safety belt buckle pretensioner is a For DF—PRT with a short to battery (STB) fault, pyrotechnic device. Never probe a pretensioner electrical connector. Doing so could result in pretensioner or airbag deployment and could Go to G6. For DF—PRT with a short to ground (STG) fault, result in personal injury. Go to G8. For passenger safety belt pretensioner (PF/PRT) WARNING: Never probe the electrical connector on a side with a low resistance (LOWRES) fault, Go to airbag module. Doing so can result in side airbag deployment. G10. For PF—PRT with an open circuit (O—CIR) NOTE: Diagnostics or repairs are not to be performed on a seat fault, Go to G11. equipped with a seat side airbag with the seat in the vehicle. Prior to For PF—PRT with a short to battery (STB) fault, attempting to diagnose or repair a seat concern when equipped with a seat Go to G13. side airbag, the seat must be removed from the vehicle and the restraint For PF—PRT with a short to ground (STG) fault, system diagnostic tools must be installed in the seat side airbag electrical Go to G15. connectors. The restraint system diagnostic tools must be removed prior to operating the vehicle over the road. No CHECK for causes of the intermittent fault. NOTE: After diagnosing or repairing an SRS, the restraint system ATTEMPT to recreate the hard fault by flexing diagnostic tools must be removed before operating the vehicle over the wire harness and cycling the ignition key the road. frequently. REPAIR any intermittent concerns found. Go to G19. NOTE: After diagnosing or repairing a seat system, the restraint system diagnostic tools must be removed before operating the vehicle over the road. being serviced, the system must be deactivated and restraint system diagnostic tools must be installed. Refer to Airbag and Safety Belt Pretensioner Supplemental Restraint System (SRS) in this section. The airbag restraint system diagnostic tools must be removed and the airbag modules reconnected when the system is reactivated to avoid non-deployment in a collision, resulting in possible personal injury.
NOTE: The SRS must be fully operational and free of faults before releasing the vehicle to the customer. Key in OFF position. Deactivate the system. Refer to Airbag and Safety Belt Pretensioner Supplemental Restraint System (SRS) in the Diagnosis and Testing portion of this section. Enter the following diagnostic mode on the diagnostic tool: On-Demand Self Test Enter the following diagnostic mode on the diagnostic tool: Flag DTC B2292 If DTC B2292 is retrieved during the on-demand self test, retrieve and record any flagged faults. Was DTC B2292 retrieved during the on-demand self test?
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01/2003 2003.0 BA Falcon
501-20b-51
Occupant Restraints — Passive
501-20b-51
DIAGNOSIS AND TESTING (Continued) Test Step G19
Result / Action to Take
CHECK FOR ADDITIONAL DTCs Refer to the continuous DTCs recorded during Step G1. Were any continuous DTCs retrieved during Step G1?
Yes
Do not clear any DTCs until all DTCs have been resolved. GO to the Restraints Control Module (RCM) Diagnostic Trouble Code (DTC) Table in this section for pinpoint test direction.
No
RECONNECT the system. REACTIVATE the system. PROVE OUT the system. REFER to Airbag and Safety Belt Pretensioner Supplemental Restraint System (SRS) in this section. CLEAR all DTCs.
Pinpoint Test H: LFC 19 and 21 /DTC B2293 - Restraint System Airbag Status Normal Operation
The restraints control module (RCM) checks all of the front airbag circuits for faults. If the RCM detects one of the following faults on any of the front airbag circuits, it will store diagnostic trouble code (DTC) B2293 in memory and, depending on the fault, flash either lamp fault code (LFC) 19 or 21 (or higher priority code if one exists) on the airbag indicator.
Fault Conditions
The RCM monitors for the following fault conditions: low resistance. circuit open. circuit short to voltage. circuit short to ground.
Possible Causes A driver airbag status fault can be caused by: damaged wiring, terminals, or connectors. driver airbag sub-harness. a faulty clockspring. a faulty driver airbag module. a faulted RCM. A passenger airbag status fault can be caused by: damaged wiring, terminals, or connectors. a faulty passenger airbag module. faulted RCM.
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01/2003 2003.0 BA Falcon
501-20b-52
Occupant Restraints — Passive
501-20b-52
DIAGNOSIS AND TESTING (Continued) PINPOINT TEST H : LFC 19 AND 21/DTC B2293 - RESTRAINT SYSTEM AIR BAG STATUS Test Step H1
Result / Action to Take
CHECK FOR A HARD OR INTERMITTENT DTC Enter the following diagnostic mode on the diagnostic tool: Retrieve/Flag Continuous DTCs Retrieve, flag and record any continuous DTCs for use later in this pinpoint test. Enter the following diagnostic mode on the diagnostic tool: On-Demand Self Test Enter the following diagnostic mode on the diagnostic tool: Flag DTC B2293 Retrieve and record any flagged faults for use later in this pinpoint test.
Yes
This is a hard fault. The fault condition is still present. This fault cannot be cleared until it is corrected and the DTC is no longer retrieved during the on-demand self test. Go to H2.
No
This is an intermittent fault. The fault condition is not present at this time. Go to H38.
Was DTC B2293 retrieved during the on-demand self test?
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01/2003 2003.0 BA Falcon
501-20b-53
Occupant Restraints — Passive
501-20b-53
DIAGNOSIS AND TESTING (Continued) Test Step H2
Result / Action to Take
CHECK THE DRIVER AND PASSENGER AIR BAG MODULES WARNING: If the supplemental restraint system (SRS) is
Enter the following diagnostic mode on the diagnostic tool: On-Demand Self Test Was DTC B2293 retrieved during the on-demand self test?
No
being serviced, the system must be deactivated and restraint system diagnostic tools must be installed. Refer to Airbag and Safety Belt Pretensioner Supplemental Restraint System (SRS) in this section. The airbag restraint system diagnostic tools must be removed and the airbag modules reconnected when the system is reactivated to avoid non-deployment in a collision, resulting in possible personal injury.
WARNING: Never probe the connectors on the airbag module. Doing so can result in airbag deployment, which can result in personal injury. WARNING: The safety belt buckle pretensioner is a pyrotechnic device. Never probe a pretensioner electrical connector. Doing so could result in pretensioner or airbag deployment and could result in personal injury. WARNING: Never probe the electrical connector on a side airbag module. Doing so can result in side airbag deployment. NOTE: Diagnostics or repairs are not to be performed on a seat equipped with a seat side airbag with the seat in the vehicle. Prior to attempting to diagnose or repair a seat concern when equipped with a seat side airbag, the seat must be removed from the vehicle and the restraint system diagnostic tools must be installed in the seat side airbag electrical connectors. The restraint system diagnostic tools must be removed prior to operating the vehicle over the road. NOTE: After diagnosing or repairing an SRS, the restraint system
diagnostic tools must be removed before operating the vehicle over the road.
NOTE: After diagnosing or repairing a seat system, the restraint system diagnostic tools must be removed before operating the vehicle over the road. NOTE: The SRS must be fully operational and free of faults before releasing the vehicle to the customer. Key in OFF position. Deactivate the system. REFER to Airbag and Safety Belt Pretensioner Supplemental Restraint System (SRS) in the Diagnosis and Testing portion of this section. Key in ON position.
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Yes
This is a hard fault. The fault condition is still present. This fault cannot be cleared until it is corrected and the DTC is no longer retrieved during the on-demand self test. Using the flagged faults recorded in the Step H1, GO to the appropriate pinpoint test step. If a flagged fault of “?” was recorded, multiple faults exist and the entire pinpoint test must be carried out before installing a new RCM. For driver airbag module squib 1 (D—ABAG) with a short to ground (STG) fault, Go to H3. For driver airbag module squib 1 (D—ABAG) with a short to battery (STB) fault, Go to H5. For driver airbag module squib 1 (D—ABAG) with an open circuit (O—CIR) fault, Go to H7. For driver airbag module squib 1 (D—ABAG) with a low resistance (LOWRES) fault, Go to H11. For passenger airbag module squib 1 (P—ABAG) with a short to ground (STG) fault, Go to H14. For passenger airbag module squib 1 (P—ABAG) with a short to battery (STB) fault, Go to H15. For passenger airbag module squib 1 (P—ABAG) with an open circuit (O—CIR) fault, Go to H16. For passenger airbag module squib 1 (P—ABAG) with a low resistance (LOWRES) fault, Go to H18. For driver airbag module squib 2 (D—ABAG2) with a short to ground (STG) fault, Go to H20. For driver airbag module squib 2 (D—ABAG2) with a short to battery (STB) fault, Go to H22. For driver airbag module squib 2 (D—ABAG2) with an open circuit (O—CIR) fault, Go to H24. For driver airbag module squib 2 (D—ABAG2) with a low resistance (LOWRES) fault, Go to H28. For passenger airbag module squib 2 (P—ABAG2) with a short to ground (STG) fault, Go to H31. For passenger airbag module squib 2 (P—ABAG2) with a short to battery (STB) fault, Go to H32. For passenger airbag module squib 2 (P—ABAG2) with an open circuit (O—CIR) fault, Go to H33. For passenger airbag module squib 2 (P—ABAG2) with a low resistance (LOWRES) fault, Go to H35. If a flagged fault of “?” was recorded in Step H1, multiple faults exist and the entire pinpoint test must be carried out before installing a new driver or passenger airbag module. If a fault was flagged against driver airbag module in Step H1, INSTALL a new driver airbag module. REFER to Driver Airbag Module in this section. Go to H39. If a fault was flagged against passenger airbag module in Step H1, INSTALL a new passenger airbag module. REFER to Passenger Airbag Module in this section. Go to H39.
01/2003 2003.0 BA Falcon
501-20b-54
Occupant Restraints — Passive
501-20b-54
DIAGNOSIS AND TESTING (Continued) Test Step H3
Result / Action to Take
CHECK CIRCUIT 614 (O/B) AND CIRCUIT 615 (GY/WH) FOR A SHORT TO GROUND BETWEEN THE RCM AND THE DRIVER AIR BAG MODULE Key in OFF position. Disconnect RCM C189a. Disconnect Driver Airbag Module Squib 1 Restraint System Diagnostic Tool.
Yes
Go to H37.
No
Go to H4.
Measure the resistance between RCM C189a pin 1, circuit 614 (O/B), harness side and ground; and between RCM C189a pin 2, circuit 615 (GY/WH), harness side and ground. Are the resistances greater than 1,000,000 ohms?
H4
CHECK CIRCUIT 614 (O/B) AND CIRCUIT 615 (GY/WH) FOR A SHORT TO GROUND BETWEEN THE RCM AND THE CLOCKSPRING Disconnect Clockspring C190. Measure the resistance between RCM C189a pin 1, circuit 614 (O/B), harness side and ground; and between RCM C189a pin 2, circuit 615 (GY/WH), harness side and ground. Are the resistances greater than 1,000,000 ohms?
H5
Yes
INSTALL a new clockspring. REFER to Clockspring in this section. Go to H39.
No
Due to the shorting bar feature in the electrical connector, the fault can exist in either circuit. Do not remove or defeat the shorting bar. REPAIR circuit 614 (O/B) or circuit 615 (GY/WH). Go to H39.
CHECK CIRCUIT 614 (O/B) AND CIRCUIT 615 (GY/WH) FOR A SHORT TO VOLTAGE BETWEEN THE RCM AND THE DRIVER AIR BAG MODULE Key in OFF position. Disconnect Driver Airbag Module Squib 1 Restraint System Diagnostic Tool. Disconnect RCM C189a.
Yes
Go to H37.
No
Go to H6.
Key in ON position. Measure the voltage between RCM C189a pin 1, circuit 614 (O/B), harness side and ground; and between RCM C189a pin 2, circuit 615 (GY/WH), harness side and ground. Are the voltages less than 0.2 volt?
H6
CHECK CIRCUIT 614 (O/B) AND CIRCUIT 615 (GY/WH) FOR A SHORT TO VOLTAGE BETWEEN THE RCM AND THE CLOCKSPRING Key in OFF position. Disconnect Clockspring C190. Key in ON position. Measure the voltage between RCM C189a pin 1, circuit 614 (O/B), harness side and ground; and between RCM C189a pin 2, circuit 615 (GY/WH), harness side and ground. Are the voltages less than 0.2 volt?
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Yes
INSTALL a new clockspring. REFER to Clockspring in this section. Go to H39.
No
Due to the shorting bar feature in the electrical connector, the fault can exist in either circuit. Do not remove or defeat the shorting bar. REPAIR circuit 614 (O/B) or circuit 615 (GY/WH). Go to H39.
01/2003 2003.0 BA Falcon
501-20b-55
Occupant Restraints — Passive
501-20b-55
DIAGNOSIS AND TESTING (Continued) Test Step H7
Result / Action to Take
CHECK CIRCUIT 614 (O/B) AND CIRCUIT 615 (GY/WH) FOR AN OPEN BETWEEN THE RCM AND THE DRIVER AIR BAG MODULE Key in OFF position. Disconnect Driver Airbag Module Squib 1 Restraint System Diagnostic Tool Disconnect RCM C189a.
Yes
Go to H9.
No
Go to H8.
Measure the resistance between RCM C189a pin 1, circuit 614 (O/B), harness side and driver airbag module, circuit 614 (O/B), harness side. Is the resistance less than 0.5 ohm?
H8
CHECK CIRCUIT 614 (O/B) FOR AN OPEN BETWEEN THE RCM AND THE CLOCKSPRING Disconnect Clockspring C190. Measure the resistance between RCM C189a pin 1, circuit 614 (O/B), harness side and clockspring C190, circuit 614 (O/B), harness side. Is the resistance less than 0.5 ohm?
H9
H10
INSTALL a new clockspring. REFER to Clockspring. Go to H39.
No
REPAIR circuit 614 (O/B). Go to H39.
CHECK CIRCUIT 615 (GY/WH) FOR AN OPEN BETWEEN THE RCM AND THE DRIVER AIR BAG MODULE Yes
Measure the resistance between RCM C189a pin 2, circuit 615 (GY/WH), harness side and driver airbag module, circuit 615 (GY/WH), harness side.
Go to H37.
Is the resistance less than 0.5 ohm?
Go to H10.
No
CHECK CIRCUIT 615 (GY/WH) FOR AN OPEN BETWEEN THE RCM AND THE CLOCKSPRING Disconnect Clockspring C190. Measure the resistance between RCM C189a pin 2, circuit 615 (GY/WH), harness side and clockspring C190, circuit 615 (GY/WH), harness side. Is the resistance less than 0.5 ohm?
H11
Yes
Yes
INSTALL a new clockspring. REFER to Clockspring in this section. Go to H39.
No
REPAIR circuit 615 (GY/WH). Go to H39.
CHECK CIRCUIT 614 (O/B) AND CIRCUIT 615 (GY/WH) FOR LOW RESISTANCE BETWEEN THE DRIVER AIR BAG MODULE AND THE RCM Key in OFF position. Disconnect Driver Airbag Module Squib 1 Restraint System Diagnostic Tool. Measure the resistance between driver airbag module, circuit 614 (O/B) and circuit 615 (GY/WH), harness side.
Yes
Go to H37.
No
Go to H12.
Is the resistance greater than 10,000 ohms?
H12
MEASURE THE RESISTANCE BETWEEN RCM CIRCUIT 614 (O/B) AND CIRCUIT 615 (GY/WH) Disconnect RCM C189a. Measure the resistance between RCM C189a pin 1, circuit 614 (O/B), and pin 2, circuit 615 (GY/WH), component side. Is the resistance greater than 10,000 ohms?
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Yes
Go to H13.
No
Go to H37.
01/2003 2003.0 BA Falcon
501-20b-56
Occupant Restraints — Passive
501-20b-56
DIAGNOSIS AND TESTING (Continued) Test Step H13
CHECK CIRCUIT 614 (O/B) AND CIRCUIT 615 (GY/WH) FOR LOW RESISTANCE BETWEEN THE CLOCKSPRING AND THE RCM Connect RCM C189a.
Yes
Disconnect Clockspring C190.
INSTALL a new clockspring. REFER to Clockspring in this section. Go to H39.
Measure the resistance between clockspring C190, circuit 614 (O/B) and, circuit 615 (GY/WH), harness side.
No
Is the resistance greater than 10,000 ohms?
H14
Result / Action to Take
REPAIR circuit 614 (O/B) and circuit 615 (GY/WH). Go to H39.
CHECK CIRCUIT 607 (BR) AND CIRCUIT 616 (PK/BK) FOR A SHORT TO GROUND BETWEEN THE RCM AND THE PASSENGER AIR BAG MODULE Key in OFF position. Disconnect Passenger Airbag Module Restraint System Diagnostic Tool. Disconnect RCM C189a. Measure the resistance between RCM C189a pin 3, circuit 607 (BR), harness side and ground; and between RCM C189a pin 4, circuit 616 (PK/BK), harness side and ground.
Yes
Go to H37.
No
Due to the shorting bar feature in the electrical connector, the fault can exist in either circuit. Do not remove or defeat the shorting bar. REPAIR circuit 607 (BR) or circuit 616 (PK/BK). Go to H39.
Are the resistances greater than 1,000,000 ohms?
H15
CHECK CIRCUIT 607 (BR) AND CIRCUIT 616 (PK/BK) FOR A SHORT TO BATTERY BETWEEN THE RCM AND THE PASSENGER AIR BAG MODULE Key in OFF position. Disconnect Passenger Airbag Module Restraint System Diagnostic Tool. Disconnect RCM C189a. Key in ON position. Measure the voltage between RCM C189a pin 3, circuit 607 (BR), harness side and ground; and between RCM C189a pin 4, circuit 616 (PK/BK), harness side and ground.
Yes
Go to H37.
No
Due to the shorting bar feature in the electrical connector, the fault can exist in either circuit. Do not remove or defeat the shorting bar. REPAIR circuit 607 (BR) or circuit 616 (PK/BK). Go to H39.
Are the voltages less than 0.2 volt?
H16
CHECK CIRCUIT 607 (BR) FOR AN OPEN BETWEEN THE RCM AND THE PASSENGER AIR BAG MODULE Key in OFF position. Disconnect Passenger Airbag Module Restraint System Diagnostic Tool. Disconnect RCM C189a.
Yes
Go to H17.
No
REPAIR circuit 607 (BR). Go to H39.
Measure the resistance between RCM C189a pin 3, circuit 607 (BR), harness side and passenger airbag module C146, circuit 607 (BR), harness side. Is the resistance less than 0.5 ohm?
H17
CHECK CIRCUIT 616 (PK/BK) FOR AN OPEN BETWEEN THE RCM AND THE PASSENGER AIR BAG MODULE
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Yes
Measure the resistance between RCM C189a pin 4, circuit 616 (PK/BK), harness side and passenger airbag module C146, circuit 616 (PK/BK), harness side.
Go to H37.
Is the resistance less than 0.5 ohm?
REPAIR circuit 616 (PK/BK). Go to H39.
No
01/2003 2003.0 BA Falcon
501-20b-57
Occupant Restraints — Passive
501-20b-57
DIAGNOSIS AND TESTING (Continued) Test Step H18
Result / Action to Take
CHECK CIRCUIT 607 (BR) AND CIRCUIT 616 (PK/BK) FOR LOW RESISTANCE BETWEEN THE PASSENGER AIR BAG MODULE AND THE RCM Key in OFF position. Disconnect Passenger Airbag Module Restraint System Diagnostic Tool. Measure the resistance between passenger airbag module C146, circuit 607 (BR), and pin 2, circuit 616 (PK/BK), harness side.
Yes
Go to H37.
No
Go to H19.
Is the resistance greater than 10,000 ohms?
H19
MEASURE THE RESISTANCE BETWEEN RCM CIRCUIT 607 (BR) AND CIRCUIT 616 (PK/BK) Disconnect RCM C189a. Measure the resistance between RCM C189a pin 3, circuit 607 (BR), and pin 4, circuit 616 (PK/BK), component side. Is the resistance greater than 10,000 ohms?
H20
Yes
REPAIR circuit 607 (BR) and circuit 616 (PK/BK) Go to H22.
No
Go to H37.
CHECK CIRCUIT 1516 (YE/WH) AND CIRCUIT 1517 (GR/B) FOR A SHORT TO GROUND BETWEEN THE RCM AND THE DRIVER AIR BAG MODULE Disconnect RCM C189a. Disconnect Driver Airbag Module Squib 2 Restraint System Diagnostic Tool. Measure the resistance between RCM C189a pin 5, circuit 1516 (YE/WH), harness side and ground; and between RCM C189a pin 6, circuit 1517 (GR/B), harness side and ground.
Yes
Go to H37.
No
Go to H21.
Are the resistances greater than 1,000,000 ohms?
H21
CHECK CIRCUIT 1516 (YE/WH) AND CIRCUIT 1517 (GR/B) FOR A SHORT TO GROUND BETWEEN THE RCM AND THE CLOCKSPRING Disconnect Clockspring C190. Measure the resistance between RCM C189a pin 5, circuit 1516 (YE/WH), harness side and ground; and between RCM C189a pin 6, circuit 1517 (GR/B), harness side and ground. Are the resistances greater than 1,000,000 ohms?
H22
Yes
INSTALL a new clockspring. REFER to Clockspring in this section. Go to H39.
No
Due to the shorting bar feature in the electrical connector, the fault can exist in either circuit. Do not remove or defeat the shorting bar. REPAIR circuit 1516 (YE/WH) or circuit 1517 (GR/B). Go to H39.
CHECK CIRCUIT 1516 (YE/WH) AND CIRCUIT 1517 (GR/B) FOR A SHORT TO VOLTAGE BETWEEN THE RCM AND THE DRIVER AIR BAG MODULE Yes
Disconnect Driver Airbag Module Squib 2 Restraint System Diagnostic Tool.
Go to H37.
Disconnect RCM C189a.
No
Key in ON position.
Go to H23.
Measure the voltage between RCM C189a pin 5, circuit 1516 (YE/WH), harness side and ground; and between RCM C189a pin 6, circuit 1517 (GR/B), harness side and ground. Are the voltages less than 0.2 volt?
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01/2003 2003.0 BA Falcon
501-20b-58
Occupant Restraints — Passive
501-20b-58
DIAGNOSIS AND TESTING (Continued) Test Step H23
CHECK CIRCUIT 1516 (YE/WH) AND CIRCUIT 1517 (GR/B) FOR A SHORT TO VOLTAGE BETWEEN THE RCM AND THE CLOCKSPRING Key in OFF position. Disconnect Clockspring C190. Key in ON position. Measure the voltage between RCM C189a pin 5, circuit 1516 (YE/WH), harness side and ground; and between RCM C189a pin 6, circuit 1517 (GR/B), harness side and ground. Are the voltages less than 0.2 volt?
H24
Result / Action to Take
Yes
INSTALL a new clockspring. REFER to Clockspring in this section. Go to H39.
No
Due to the shorting bar feature in the electrical connector, the fault can exist in either circuit. Do not remove or defeat the shorting bar. REPAIR circuit 1516 (YE/WH) or circuit 1517 (GR/B). Go to H39.
CHECK CIRCUIT 1516 (YE/WH) FOR AN OPEN BETWEEN THE RCM AND THE DRIVER AIR BAG MODULE Key in OFF position. Disconnect Driver Airbag Module Squib 2 Restraint System Diagnostic Tool. Disconnect RCM C189a.
Yes
Go to H26.
No
Go to H25.
Measure the resistance between RCM C189a pin 5, circuit 1516 (YE/WH), harness side and the driver airbag module squib 2, circuit 1516 (YE/WH), harness side. Is the resistance less than 0.5 ohm?
H25
CHECK CIRCUIT 1516 (YE/WH) FOR AN OPEN BETWEEN THE RCM AND THE CLOCKSPRING Disconnect Clockspring C190. Measure the resistance between RCM C189a pin 5, circuit 1516 (YE/WH), harness side and clockspring C190, circuit 1516 (YE/WH), harness side. Is the resistance less than 0.5 ohm?
H26
H27
Yes
INSTALL a new clockspring. REFER to Clockspring in this section. Go to H39.
No
REPAIR circuit 1516 (YE/WH). Go to H39.
CHECK CIRCUIT 1517 (GR/B) FOR AN OPEN BETWEEN THE RCM AND THE DRIVER AIR BAG MODULE Yes
Measure the resistance between RCM C189a pin 6, circuit 1517 (GR/B), harness side and driver airbag module squib 2, circuit 1517 (GR/B), harness side.
Go to H37.
Is the resistance less than 0.5 ohm?
Go to H27.
No
CHECK CIRCUIT 1517 (GR/B) FOR AN OPEN BETWEEN THE RCM AND THE CLOCKSPRING Disconnect Clockspring C190. Measure the resistance between RCM C189a pin 6, circuit 1517 (GR/B), harness side and clockspring C190, circuit 1517 (GR/B), harness side. Is the resistance less than 0.5 ohm?
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Yes
INSTALL a new clockspring. REFER to Clockspring in this section. Go to H39.
No
REPAIR circuit 1517 (GR/B). Go to H39.
01/2003 2003.0 BA Falcon
501-20b-59
Occupant Restraints — Passive
501-20b-59
DIAGNOSIS AND TESTING (Continued) Test Step H28
Result / Action to Take
CHECK FOR LOW RESISTANCE ON CIRCUIT 1516 (YE/WH) AND CIRCUIT 1517 (GR/B) BETWEEN THE RCM AND THE DRIVER AIR BAG MODULE Key in OFF position. Disconnect Driver Airbag Module Squib 2 Restraint System Diagnostic Tool. Measure the resistance between driver airbag module squib 2, circuit 1516 (YE/WH), harness side and circuit 1517 (GR/B), harness side.
Yes
Go to H37.
No
Go to H29.
Is the resistance greater than 10,000 ohms?
H29
MEASURE THE RESISTANCE BETWEEN RCM CIRCUIT 1516 (YE/WH) AND CIRCUIT 1517 (RD/OG) Disconnect RCM C189a. Measure the resistance between RCM C189a pin 5, circuit 1516 (YE/WH), component side and pin 6, circuit 1517 (RD/OG), component side.
Yes
Go to H30.
No
Go to H37.
Is the resistance greater than 10,000 ohms?
H30
CHECK FOR LOW RESISTANCE ON CIRCUIT 1516 (YE/WH) AND CIRCUIT 1517 (GR/B) BETWEEN THE DRIVER AIR BAG MODULE AND THE CLOCKSPRING Connect RCM C189a.
INSTALL a new clockspring. REFER to Clockspring in this section. Go to H39.
Measure the resistance between clockspring C190, circuit 1516 (YE/WH), harness side and pin 1, circuit 1517 (GR/B), harness side.
No
Is the resistance greater than 10,000 ohms?
H31
Yes
Disconnect Clockspring C190.
REPAIR circuit 1516 (YE/WH) and circuit 1517 (GR/B). Go to H39.
CHECK CIRCUIT 1518 (RD/WH) AND CIRCUIT 1519 (LG/RD) FOR A SHORT TO GROUND BETWEEN THE RCM AND THE PASSENGER AIR BAG MODULE Yes
Disconnect Passenger Airbag Module Restraint System Diagnostic Tool.
Go to H37.
Disconnect RCM C189a.
No
Due to the shorting bar feature in the electrical Measure the resistance between RCM C189a pin 13, circuit 1518 (RD/WH), harness side and ground; and between RCM C189a pin 14, connector, the fault can exist in either circuit. REPAIR circuit 1518 (RD/WH) or circuit 1519 circuit 1519 (LG/RD), harness side and ground. (LG/RD). Go to H39. Are the resistances greater than 1,000,000 ohms?
H32
CHECK CIRCUIT 1518 (RD/WH) AND CIRCUIT 1519 (LG/RD) FOR A SHORT TO VOLTAGE BETWEEN THE RCM AND THE PASSENGER AIR BAG MODULE Yes
Disconnect Passenger Airbag Module Restraint System Diagnostic Tool.
Go to H37.
Disconnect RCM C189a.
No
Due to the shorting bar feature in the electrical connector, the fault can exist in either circuit. Measure the voltage between RCM C189a pin 13, circuit 1518 REPAIR circuit 1518 (RD/WH) or circuit 1519 (RD/WH), harness side and ground; and between RCM C189a pin 14, (LG/RD). Go to H39. circuit 1519 (LG/RD), harness side and ground. Key in ON position.
Are the voltages less than 0.2 volt?
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01/2003 2003.0 BA Falcon
501-20b-60
Occupant Restraints — Passive
501-20b-60
DIAGNOSIS AND TESTING (Continued) Test Step H33
Result / Action to Take
CHECK CIRCUIT 1518 (RD/WH) FOR AN OPEN BETWEEN THE RCM AND THE PASSENGER AIR BAG MODULE Key in OFF position. Disconnect Passenger Airbag Module Restraint System Diagnostic Tool. Disconnect RCM C189a.
Yes
Go to H34.
No
REPAIR circuit 1518 (RD/WH). Go to H39.
Measure the resistance between RCM C189a pin 13, circuit 1518 (RD/WH), harness side and passenger airbag module C146, circuit 1518 (RD/WH), harness side. Is the resistance less than 0.5 ohm?
H34
H35
CHECK CIRCUIT 1519 (LG/RD) FOR AN OPEN BETWEEN THE RCM AND THE PASSENGER AIR BAG MODULE Yes
Measure the resistance between RCM C189a pin 14, circuit 1519 (LG/RD), harness side and passenger airbag module C146, circuit 1519 (LG/RD), harness side.
Go to H37.
Is the resistance less than 0.5 ohm?
REPAIR circuit 1519 (LG/RD). Go to H39.
No
CHECK FOR LOW RESISTANCE ON CIRCUIT 1518 (RD/WH) AND CIRCUIT 1519 (LG/RD) BETWEEN THE RCM AND THE PASSENGER AIR BAG MODULE Key in OFF position. Disconnect Passenger Airbag Module Restraint System Diagnostic Tool. Measure the resistance between passenger airbag module C146, circuit 1518 (RD/WH), harness side and, circuit 1519 (LG/RD), harness side.
Yes
Go to H37.
No
Go to H36.
Is the resistance greater than 10,000 ohms?
H36
MEASURE THE RESISTANCE BETWEEN RCM CIRCUIT 1518 (RD/WH) AND CIRCUIT 1519 (LG/RD) Disconnect RCM C189a. Measure the resistance between RCM C189a pin 13, circuit 1518 (RD/WH), component side and pin 14, circuit 1519 (LG/RD), component side. Is the resistance greater than 10,000 ohms?
H37
Yes
REPAIR circuit 1518 (RD/WH) and circuit 1519 (LG/RD). Go to H39.
No
Go to H37.
CONFIRM THE RCM FAULT NOTE: Make sure all restraint system diagnostic tools, sensor electrical connectors and the RCM electrical connector are connected before carrying out the on-demand self-test. If not, erroneous DTCs will be recorded. Key in OFF position. Connect Restraint System Diagnostic Tools. Connect RCM C189a. Enter the following diagnostic mode on the diagnostic tool: On-Demand Self Test Retrieve and record any flagged faults.
Yes
If a “?” was flagged by the scan tool, CARRY OUT the entire pinpoint test before installing a new RCM. INSTALL a new RCM. REFER to Restraints Control Module (RCM) in this section. Go to H39.
No
Fault corrected. Go to H39.
Was DTC B2293 retrieved during the on-demand self test?
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01/2003 2003.0 BA Falcon
501-20b-61
Occupant Restraints — Passive
501-20b-61
DIAGNOSIS AND TESTING (Continued) Test Step H38
Result / Action to Take
CHECK FOR AN INTERMITTENT FAULT WARNING: If the supplemental restraint system (SRS) is
being serviced, the system must be deactivated and restraint system diagnostic tools must be installed. Refer to Airbag and Safety Belt Pretensioner Supplemental Restraint System (SRS) in this section. The airbag restraint system diagnostic tools must be removed and the airbag modules reconnected when the system is reactivated to avoid non-deployment in a collision, resulting in possible personal injury.
WARNING: Never probe the connectors on the airbag module. Doing so can result in airbag deployment, which can result in personal injury. WARNING: The safety belt buckle pretensioner is a pyrotechnic device. Never probe a pretensioner electrical connector. Doing so could result in pretensioner or airbag deployment and could result in personal injury. WARNING: Never probe the electrical connector on a side airbag module. Doing so can result in side airbag deployment. NOTE: Diagnostics or repairs are not to be performed on a seat equipped with a seat side airbag with the seat in the vehicle. Prior to attempting to diagnose or repair a seat concern when equipped with a seat side airbag, the seat must be removed from the vehicle and the restraint system diagnostic tools must be installed in the seat side airbag electrical connectors. The restraint system diagnostic tools must be removed prior to operating the vehicle over the road. NOTE: After diagnosing or repairing an SRS, the restraint system
diagnostic tools must be removed before operating the vehicle over the road.
NOTE: After diagnosing or repairing a seat system, the restraint system diagnostic tools must be removed before operating the vehicle over the road. NOTE: The SRS must be fully operational and free of faults before releasing the vehicle to the customer. Key in OFF position. Deactivate the system. Refer to Airbag and Safety Belt Pretensioner Supplemental Restraint System (SRS) in the Diagnosis and Testing portion of this section. Enter the following diagnostic mode on the diagnostic tool: On-Demand Self Test Enter the following diagnostic mode on the diagnostic tool: Flag DTC B2293 If the DTC B2293 is retrieved during the on-demand self test, retrieve and record any flagged faults. Was the DTC B2293 retrieved during the on-demand self test?
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Yes
CHECK for causes of the intermittent fault at or near the affected airbag module connector. REPAIR any intermittent concerns found. If an intermittent concern was found and repaired, Go to H39. If an intermittent concern was not found and repaired, USE the flagged faults recorded and GO to the appropriate pinpoint test step. If a flagged fault of “?” was recorded in Step H1, multiple faults exist and the entire pinpoint test must be carried out before installing a new RCM. For driver airbag module squib 1 (D—ABAG) with a short to ground (STG) fault, Go to H3. For driver airbag module squib 1 (D—ABAG) with a short to battery (STB) fault, Go to H5. For driver airbag module squib 1 (D—ABAG) with an open circuit (O—CIR) fault, Go to H7. For driver airbag module squib 1 (D—ABAG) with a low resistance (LOWRES) fault, Go to H11. For passenger airbag module squib 1 (P—ABAG) with a short to ground (STG) fault, Go to H14. For passenger airbag module squib 1 (P—ABAG) with a short to battery (STB) fault, Go to H15. For passenger airbag module squib 1 (P—ABAG) with an open circuit (O—CIR) fault, Go to H16. For passenger airbag module squib 1 (P—ABAG) with a low resistance (LOWRES) fault, Go to H18. For driver airbag module squib 2 (D—ABAG2) with a short to ground (STG) fault, Go to H20. For driver airbag module squib 2 (D—ABAG2) with a short to battery (STB) fault, Go to H22. For driver airbag module squib 2 (D—ABAG2) with an open circuit (O—CIR) fault, Go to H24. For driver airbag module squib 2 (D—ABAG2) with a low resistance (LOWRES) fault, Go to H28. For passenger airbag module squib 2 (P—ABAG2) with a short to ground (STG) fault, Go to H31. For passenger airbag module squib 2 (P—ABAG2) with a short to battery (STB) fault, Go to H32. For passenger airbag module squib 2 (P—ABAG2) with an open circuit (O—CIR) fault, Go to H33. For passenger airbag module squib 2 (P—ABAG2) with a low resistance (LOWRES) fault, Go to H35.
No
CHECK for causes of the intermittent fault. ATTEMPT to recreate the hard fault by flexing the wire harness and cycling the ignition key frequently. REPAIR any intermittent concerns found. Go to H39.
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501-20b-62
Occupant Restraints — Passive
501-20b-62
DIAGNOSIS AND TESTING (Continued) Test Step H39
Result / Action to Take
CHECK FOR ADDITIONAL DTCs Refer to the continuous DTCs recorded during Step H1. Were any continuous DTCs retrieved during Step H1?
Yes
Do not clear any DTCs until all DTCs have been resolved. GO to the Restraints Control Module (RCM) Diagnostic Trouble Code (DTC) Table in this section for pinpoint test direction.
No
RECONNECT the system. REACTIVATE the system. PROVE OUT the system. REFER to Airbag and Safety Belt Pretensioner Supplemental Restraint System (SRS). CLEAR all DTCs.
Pinpoint Test I: LFC 22 and 23 / DTC B2295 — Restraint System Side Airbag Module Status Normal Operation
The restraints control module (RCM) checks all side airbag module circuits for faults. If the RCM detects one of the following faults on any of the side airbag module circuits, it will store diagnostic trouble code (DTC) B2295 in memory and flash, depending on the fault, either lamp fault code (LFC) 22 or 23 (or higher priority code if one exists) on the airbag indicator.
Fault Conditions
The RCM monitors for the following fault conditions: low resistance. circuit open. circuit short to voltage. circuit short to ground.
Possible Causes
A side airbag module status fault can be caused by: damaged wiring, terminals, or connectors. a faulty side airbag module. faulted RCM. PINPOINT TEST I : LFC 22 AND 23/DTC B2295 - RESTRAINT SYSTEM SIDE AIRBAG MODULE STATUS Test Step I1
Result / Action to Take
CHECK FOR A HARD OR INTERMITTENT DTC Enter the following diagnostic mode on the diagnostic tool: Retrieve Continuous DTCs Retrieve, flag and record any continuous DTCs for use later in this pinpoint test. Enter the following diagnostic mode on the diagnostic tool: On-Demand Self Test Enter the following diagnostic mode on the diagnostic tool: Flag B2295 Retrieve and record any flagged faults for use later in this pinpoint test. Was DTC B2295 retrieved during the on-demand self test?
G12345 en
Yes
Vehicles with side airbag modules: This is a hard fault, the fault condition is still present. This fault cannot be cleared until it is corrected and the DTC is no longer retrieved during the on-demand self test. Go to I3. Vehicles without side airbag modules: This is a hard fault, the fault condition is still present. This fault cannot be cleared until it is corrected and the DTC is no longer retrieved during the on-demand self test. Go to I2.
No
This is an intermittent fault. The fault condition is not present at this time. Go to I17.
01/2003 2003.0 BA Falcon
501-20b-63
Occupant Restraints — Passive
501-20b-63
DIAGNOSIS AND TESTING (Continued) Test Step I2
Result / Action to Take
CHECK THE SIDE AIRBAG MODULE BRIDGE RESISTOR WARNING: If the supplemental restraint system (SRS) is
Yes
Using the flagged faults recorded in Step I1, GO to the appropriate pinpoint test step. If a flagged fault of “?” was recorded in Step I1, multiple faults exist and the entire pinpoint test must be carried out before installing a new RCM. For driver side airbag module (DFCURTN) with a short to battery (STB) fault, Go to I4. For driver side airbag module (DFCURTN) with a short to ground (STG) fault, Go to I5. For driver side airbag module (DFCURTN) with WARNING: Never probe the connectors on the airbag module. Doing so can result in airbag deployment, which can result in an open circuit (O—CIR) fault, Go to I6. For driver side airbag module (DFCURTN) with personal injury. a low resistance (LOWRES) fault, Go to I8.
being serviced, the system must be deactivated and restraint system diagnostic tools must be installed. Refer to Airbag and Safety Belt Pretensioner Supplemental Restraint System (SRS) in this section. The airbag restraint system diagnostic tools must be removed and the airbag modules reconnected when the system is reactivated to avoid non-deployment in a collision, resulting in possible personal injury.
No WARNING: The safety belt buckle pretensioner is a Fault Corrected. Go to I18. pyrotechnic device. Never probe a pretensioner electrical connector. Doing so could result in pretensioner or airbag deployment and could result in personal injury. WARNING: Never probe the electrical connector on a side airbag module. Doing so can result in side airbag deployment. NOTE: Diagnostics or repairs are not to be performed on a seat equipped with a seat side airbag with the seat in the vehicle. Prior to attempting to diagnose or repair a seat concern when equipped with a seat side airbag, the seat must be removed from the vehicle and the restraint system diagnostic tools must be installed in the seat side airbag electrical connectors. The restraint system diagnostic tools must be removed prior to operating the vehicle over the road. NOTE: After diagnosing or repairing an SRS, the restraint system
diagnostic tools must be removed before operating the vehicle over the road.
NOTE: After diagnosing or repairing a seat system, the restraint system diagnostic tools must be removed before operating the vehicle over the road. NOTE: The SRS must be fully operational and free of faults before releasing the vehicle to the customer. Key in OFF position. Deactivate the system. Refer to Airbag and Safety Belt Pretensioner Supplemental Restraint System (SRS) in the Diagnosis and Testing portion of this section. Disconnect RH Side Airbag Bridge Resistor. Install a known good side airbag bridge resistor. Enter the following diagnostic mode on the diagnostic tool: On-Demand Self Test Enter the following diagnostic mode on the diagnostic tool: Flag DTC B2295 Was DTC B2295 retrieved during the on-demand self test?
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01/2003 2003.0 BA Falcon
501-20b-64
Occupant Restraints — Passive
501-20b-64
DIAGNOSIS AND TESTING (Continued) Test Step I3
Result / Action to Take
CHECK THE DRIVER AND PASSENGER SIDE AIRBAG MODULES WARNING: If the supplemental restraint system (SRS) is
Yes
Using the flagged faults recorded in Step I1, GO to the appropriate pinpoint test step. If a flagged fault of “?” was recorded in Step I1, multiple faults exist and the entire pinpoint test must be carried out before installing a new RCM. For driver side airbag module (DFCURTN) with a short to battery (STB) fault, Go to I4. For driver side airbag module (DFCURTN) with a short to ground (STG) fault, Go to I5. For driver side airbag module (DFCURTN) with WARNING: Never probe the connectors on the airbag module. Doing so can result in airbag deployment, which can result in an open circuit (O—CIR) fault, Go to I6. For driver side airbag module (DFCURTN) with personal injury. a low resistance (LOWRES) fault, Go to I8. For passenger side airbag module (PFCURTN) with a short to battery (STB) fault, Go to I10. WARNING: The safety belt buckle pretensioner is a For passenger side airbag module (PFCURTN) pyrotechnic device. Never probe a pretensioner electrical connector. Doing so could result in pretensioner or airbag deployment and could with a short to ground (STG) fault, Go to I11. For passenger side airbag module (PFCURTN) result in personal injury. with an open circuit (O/CIR) fault, Go to I12. For passenger side airbag module (PFCURTN) WARNING: Never probe the electrical connector on a side with a low resistance (LOWRES) fault, Go to airbag module. Doing so can result in side airbag deployment. I14.
being serviced, the system must be deactivated and restraint system diagnostic tools must be installed. Refer to Airbag and Safety Belt Pretensioner Supplemental Restraint System (SRS) in this section. The airbag restraint system diagnostic tools must be removed and the airbag modules reconnected when the system is reactivated to avoid non-deployment in a collision, resulting in possible personal injury.
NOTE: Diagnostics or repairs are not to be performed on a seat
equipped with a seat side airbag with the seat in the vehicle. Prior to attempting to diagnose or repair a seat concern when equipped with a seat side airbag, the seat must be removed from the vehicle and the restraint system diagnostic tools must be installed in the seat side airbag electrical connectors. The restraint system diagnostic tools must be removed prior to operating the vehicle over the road.
No
If a flagged fault of “?” was recorded in Step I1, multiple faults exist and the entire pinpoint test must be carried out before installing a new side airbag module. If a fault was flagged against driver side airbag module in Step I1, INSTALL a new driver side airbag module. REFER to Side Airbag Module in NOTE: After diagnosing or repairing an SRS, the restraint system this section. Go to I18. diagnostic tools must be removed before operating the vehicle over If a fault was flagged against passenger side the road. airbag module in Step I1, INSTALL a new passenger side airbag module. REFER to Side NOTE: After diagnosing or repairing a seat system, the restraint system Airbag Module in this section. Go to I18. diagnostic tools must be removed before operating the vehicle over the road.
NOTE: The SRS must be fully operational and free of faults before releasing the vehicle to the customer. Key in OFF position. Deactivate the system. Refer to Airbag and Safety Belt Pretensioner Supplemental Restraint System (SRS) in the Diagnosis and Testing portion of this section. Key in ON position. Enter the following diagnostic mode on the diagnostic tool: On-Demand Self Test Was DTC B2295 retrieved during the on-demand self test?
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01/2003 2003.0 BA Falcon
501-20b-65
Occupant Restraints — Passive
501-20b-65
DIAGNOSIS AND TESTING (Continued) Test Step I4
Result / Action to Take
CHECK CIRCUIT 1257 (WH) AND CIRCUIT 1258 (BR) FOR A SHORT TO BATTERY BETWEEN THE RCM AND THE DRIVER SIDE AIRBAG MODULE NOTE: Vehicles without side airbags are equipped with a side airbag bridge resistor on the seat. Key in OFF position. Disconnect Driver Side Side Airbag Module Restraint System Diagnostic Tool. Vehicles with side airbags.
Yes
Go to I16.
No
Due to the shorting bar feature in the electrical connector, the fault can exist in either circuit. REPAIR circuit 1257 (WH) or circuit 1258 (BR). Go to I18.
Disconnect RH Side Side Airbag Bridge Resistor. Vehicles without side airbags. Disconnect RCM C189b. Key in ON position. Measure the voltage between RCM C189b pin 3, circuit 1257 (WH), harness side and ground; and between RCM C189b pin 4, circuit 1258 (BR), harness side and ground. Are the voltages less than 0.2 volt?
I5
CHECK CIRCUIT 1257 (WH) AND CIRCUIT 1258 (BR) FOR A SHORT TO GROUND BETWEEN THE RCM AND THE DRIVER SIDE AIRBAG MODULE Key in OFF position. Disconnect Driver Side Airbag Module Restraint System Diagnostic Tool. Vehicles with side airbags. Disconnect RH Side Side Airbag Bridge Resistor. Vehicles without side airbags.
Yes
Go to I16.
No
Due to the shorting bar feature in the electrical connector, the fault can exist in either circuit. REPAIR circuit 1257 (WH) or circuit 1258 (BR). Go to I18.
Disconnect RCM C189b. Measure the resistance between RCM C189b pin 3, circuit 1257 (WH), harness side and ground; and between RCM C189b pin 4, circuit 1258 (BR), harness side and ground. Is the resistance greater than 1,000,000 ohms?
I6
CHECK CIRCUIT 1257 (WH) FOR AN OPEN BETWEEN THE RCM AND THE DRIVER SIDE AIRBAG MODULE Key in OFF position. Disconnect Driver Side Airbag Module Restraint System Diagnostic Tool. Vehicles with side airbags.
Yes
Go to I7.
No
REPAIR circuit 1257 (WH). Go to I18.
Disconnect RH Side Airbag Module Bridge Resistor. Vehicles without side airbags. Disconnect RCM C189b. For vehicles with side airbags, measure the resistance between RCM C189b pin 3, circuit 1257 (WH), harness side and driver side airbag module C342, circuit 1257 (WH), harness side. For vehicles without side airbags, measure the resistance between RCM C189b pin 3, circuit 1257 (WH), harness side and RH side airbag bridge resistor C342, circuit 1257 (WH), harness side. Is the resistance less than 0.5 ohm?
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01/2003 2003.0 BA Falcon
501-20b-66
Occupant Restraints — Passive
501-20b-66
DIAGNOSIS AND TESTING (Continued) Test Step I7
Result / Action to Take
CHECK CIRCUIT 1258 (BR) FOR AN OPEN BETWEEN THE RCM AND THE DRIVER SIDE AIRBAG MODULE For vehicles with side airbags, measure the resistance between RCM C189b pin 4, circuit 1258 (BR), harness side and driver side airbag module C342, circuit 1258 (BR), harness side.
Yes
Go to I16.
No
For vehicles without side airbags, measure the resistance between REPAIR circuit 1258 (BR). Go to I18. RCM C189b pin 4, circuit 1258 (BR), harness side and RH side airbag bridge resistor C342, circuit 1258 (BR), harness side. Is the resistance less than 0.5 ohm?
I8
CHECK FOR LOW RESISTANCE ON CIRCUIT 1257 (WH) AND CIRCUIT 1258 (BR) BETWEEN THE DRIVER SIDE AIRBAG MODULE AND THE RCM Key in OFF position. Disconnect Driver Side Airbag Module Restraint System Diagnostic Tool. Vehicles with side airbags.
Yes
Go to I16.
No
Go to I9.
Disconnect RH Side Side Airbag Bridge Resistor. Vehicles without side airbags. For vehicles with side airbags, measure the resistance between driver side airbag module C342, circuit 1257 (WH) and 1258 (BR), harness side. For vehicles without side airbags, measure the resistance between RH side airbag bridge resistor C342, circuit 1257 (WH) and circuit 1258 (BR), harness side. Is the resistance greater than 10, 000 ohms?
I9
MEASURE THE RESISTANCE BETWEEN RCM CIRCUIT 1257 (WH) AND CIRCUIT 1258 (BR) Disconnect RCM C189b. Measure the resistance between RCM C189b pin 3, circuit 1257 (WH), and pin 4, circuit 1258 (BR), component side. Is the resistance greater than 10,000 ohms?
I10
Yes
REPAIR circuit 1257 (WH) and circuit 1258 (BR). Go to I18.
No
Go to I16.
CHECK CIRCUIT 1259 (W/Y) AND CIRCUIT 1260 (BN/YE) FOR A SHORT TO BATTERY BETWEEN THE RCM AND THE PASSENGER SIDE AIRBAG MODULE Key in OFF position. Disconnect Passenger Side Airbag Restraint System Diagnostic Tool. Disconnect RCM C189b. Key in ON position. Measure the voltage between RCM C189b pin 5, circuit 1259 (W/Y), harness side and ground; and between RCM C189b pin 6, circuit 1260 (BN/YE), harness side and ground.
Yes
Go to I16.
No
Due to the shorting bar feature in the electrical connector, the fault can exist in either circuit. REPAIR circuit 1259 (W/Y) or circuit 1260 (BN/YE). Go to I18.
Are the voltages less than 0.2 volt?
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01/2003 2003.0 BA Falcon
501-20b-67
Occupant Restraints — Passive
501-20b-67
DIAGNOSIS AND TESTING (Continued) Test Step I11
Result / Action to Take
CHECK CIRCUIT 1259 (W/Y) AND CIRCUIT 1260 (BN/YE) FOR A SHORT TO GROUND BETWEEN THE RCM AND THE PASSENGER SIDE AIRBAG MODULE Key in OFF position. Disconnect Passenger Side Airbag Module Restraint System Diagnostic Tool. Disconnect RCM C189b. Measure the resistance between RCM C189b pin 5, circuit 1259 (W/Y), harness side and ground; and between RCM C189b pin 6, circuit 1260 (BN/YE), harness side and ground.
Yes
Go to I16.
No
Due to the shorting bar feature in the electrical connector, the fault can exist in either circuit. REPAIR circuit 1259 (W/Y) or circuit 1260 (BN/YE). Go to I18.
Is the resistance greater than 1,000,000 ohms?
I12
CHECK CIRCUIT 1259 (W/Y) FOR AN OPEN BETWEEN THE RCM AND THE PASSENGER SIDE AIRBAG MODULE Key in OFF position. Disconnect Passenger Side Airbag Module Restraint System Diagnostic Tool. Disconnect RCM C189b.
Yes
Go to I13.
No
REPAIR circuit 1259 (W/Y). Go to I18.
Measure the resistance between RCM C189b pin 5, circuit 1259 (W/Y), harness side and passenger side airbag module C344, circuit 1259 (W/Y), harness side. Is the resistance less than 0.5 ohm?
I13
I14
CHECK CIRCUIT 1260 (BN/YE) FOR AN OPEN BETWEEN THE RCM AND THE PASSENGER SIDE AIRBAG MODULE Yes
Measure the resistance between RCM C189b pin 6, circuit 1260 (BN/YE), harness side and passenger side airbag module C344, circuit 1260 (BN/YE), harness side.
Go to I14.
Is the resistance less than 0.5 ohm?
REPAIR circuit 1260 (BN/YE). Go to I18.
No
CHECK FOR LOW RESISTANCE ON CIRCUIT 1259 (W/Y) AND CIRCUIT 1260 (BN/YE) BETWEEN THE PASSENGER SIDE AIRBAG MODULE AND THE RCM Key in OFF position. Disconnect Passenger Side Airbag Module Restraint System Diagnostic Tool.
Yes
Go to I16.
No
Measure the resistance between passenger side airbag module C344, Go to I15. circuit 1259 (W/Y), and, circuit 1260 (BN/YE), harness side. Is the resistance greater than 10,000 ohms?
I15
MEASURE THE RESISTANCE BETWEEN RCM CIRCUIT 1259 (W/Y) AND CIRCUIT 1260 (BN/YE) Disconnect RCM C189b. Measure the resistance between RCM C189b pin 5, circuit 1259 (W/Y), and pin 6, circuit 1260 (BN/YE), component side. Is the resistance greater than 10,000 ohms?
G12345 en
Yes
REPAIR circuit 1259 (W/Y) and circuit 1260 (BN/YE). Go to I18.
No
Go to I16.
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501-20b-68
Occupant Restraints — Passive
501-20b-68
DIAGNOSIS AND TESTING (Continued) Test Step I16
Result / Action to Take
CONFIRM THE RCM FAULT NOTE: Make sure all restraint system diagnostic tools, sensor electrical connectors and the RCM electrical connector are connected before carrying out the on-demand self test. If not, erroneous DTCs will be recorded. Key in OFF position. Connect Restraint System Diagnostic Tools. Vehicles with side airbags.
Yes
If a “?” was flagged by the scan tool, CARRY OUT the entire pinpoint test before installing a new RCM. INSTALL a new RCM. Go to I18.
No
Fault corrected. Go to I18.
Connect RH Side Side Airbag Bridge Resistor C342. Vehicles without side airbags. Connect RCM C189b. Enter the following diagnostic mode on the diagnostic tool: On-Demand Self Test Retrieve and record any flagged faults. Was DTC B2295 retrieved during the on-demand self test?
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01/2003 2003.0 BA Falcon
501-20b-69
Occupant Restraints — Passive
501-20b-69
DIAGNOSIS AND TESTING (Continued) Test Step I17
Result / Action to Take
CHECK FOR AN INTERMITTENT FAULT WARNING: If the supplemental restraint system (SRS) is
Yes
CHECK for causes of the intermittent fault at or near the affected side airbag module connector. REPAIR any intermittent concerns found. If an intermittent concern was found and repaired, Go to I18. If an intermittent concern was not found and repaired, USE the flagged faults recorded and GO to the appropriate pinpoint test step. If a flagged fault of “?” was recorded in Step I1, multiple faults exist and the entire pinpoint test must be carried out before installing a new WARNING: Never probe the connectors on the airbag module. Doing so can result in airbag deployment, which can result in RCM. For driver side airbag module with a short to personal injury. battery (STB) fault, Go to I4. For driver side airbag module with a short to ground (STG) fault, Go to I5. WARNING: The safety belt buckle pretensioner is a For driver side airbag module with an open pyrotechnic device. Never probe a pretensioner electrical connector. Doing so could result in pretensioner or airbag deployment and could circuit (O—CIR) fault, Go to I6. For driver side airbag module with a low result in personal injury. resistance (LOWRES) fault, Go to I8. For passenger side airbag module with a short WARNING: Never probe the electrical connector on a side to battery (STB) fault, Go to I10. airbag module. Doing so can result in side airbag deployment. For passenger side airbag module with a short to ground (STG) fault, Go to I11. NOTE: Diagnostics or repairs are not to be performed on a seat For passenger side airbag module with an open equipped with a seat side airbag with the seat in the vehicle. Prior to circuit (O—CIR) fault, Go to I12. attempting to diagnose or repair a seat concern when equipped with a seat For passenger side airbag module with a low side airbag, the seat must be removed from the vehicle and the restraint resistance (LOWRES) fault, Go to I14. system diagnostic tools must be installed in the seat side airbag electrical connectors. The restraint system diagnostic tools must be removed No prior to operating the vehicle over the road. CHECK for causes of the intermittent fault. ATTEMPT to recreate the hard fault by flexing NOTE: After diagnosing or repairing an SRS, the restraint system the wire harness and cycling the ignition key diagnostic tools must be removed before operating the vehicle over frequently. REPAIR any intermittent concerns the road. found. Go to I18. being serviced, the system must be deactivated and restraint system diagnostic tools must be installed. Refer to Airbag and Safety Belt Pretensioner Supplemental Restraint System (SRS) in this section. The airbag restraint system diagnostic tools must be removed and the airbag modules reconnected when the system is reactivated to avoid non-deployment in a collision, resulting in possible personal injury.
NOTE: After diagnosing or repairing a seat system, the restraint system diagnostic tools must be removed before operating the vehicle over the road. NOTE: The SRS must be fully operational and free of faults before releasing the vehicle to the customer. Key in OFF position. Deactivate the system. Refer to Airbag and Safety Belt Pretensioner Supplemental Restraint System (SRS) in the Diagnosis and Testing portion of this section. Key in ON position. Enter the following diagnostic mode on the diagnostic tool: On-Demand Self Test Enter the following diagnostic mode on the diagnostic tool: Flag DTC B2295 If the DTC B2295 is retrieved during the on-demand self test, retrieve and record any flagged faults. Was DTC B2295 retrieved during the on-demand self test?
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01/2003 2003.0 BA Falcon
501-20b-70
Occupant Restraints — Passive
501-20b-70
DIAGNOSIS AND TESTING (Continued) Test Step I18
Result / Action to Take
CHECK FOR ADDITIONAL DTCs Refer to the continuous DTCs recorded during Step I1. Were any continuous DTCs retrieved during Step I1?
Yes
Do not clear any DTCs until all DTCs have been resolved. GO to the Restraints Control Module (RCM) Diagnostic Trouble Code (DTC) Table in this section for pinpoint test direction.
No
RECONNECT the system. REACTIVATE the system. PROVE OUT the system. REFER to Airbag and Safety Belt Pretensioner Supplemental Restraint System (SRS) in this section. CLEAR all DTCs.
Pinpoint Test J: LFC 42, 43, 44 and DTC B2296 — Restraint System Impact Sensor Status Normal Operation
The restraints control module (RCM) checks all of the impact sensor circuits for faults. If the RCM detects one of the following faults on any of the impact sensor circuits, it will store diagnostic trouble code (DTC) B2296 in memory and flash, depending on the fault, either lamp fault code (LFC) 42, 43 or 44 (or higher priority code if one exists) on the airbag indicator.
Fault Conditions
The RCM monitors for the following fault conditions: low resistance. circuit open. circuit short to voltage. circuit short to ground.
Possible Causes A impact sensor status fault can be caused by: damaged wiring, terminals, or connectors. a faulty impact sensor. incorrect sensor mounting. faulted RCM.
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01/2003 2003.0 BA Falcon
501-20b-71
Occupant Restraints — Passive
501-20b-71
DIAGNOSIS AND TESTING (Continued) PINPOINT TEST J : LFC 42, 43, 44 AND DTC B2296 — RESTRAINT SYSTEM IMPACT SENSOR STATUS Test Step J1
Result / Action to Take
CHECK FOR A HARD OR INTERMITTENT DTC Enter the following diagnostic mode on the diagnostic tool: Retrieve/Flag Continuous DTCs Retrieve, flag and record any continuous DTCs for use later in this pinpoint test. Enter the following diagnostic mode on the diagnostic tool: On-Demand Self Test Enter the following diagnostic mode on the diagnostic tool: Flag DTC B2296 Retrieve and record any flagged faults for use later in this pinpoint test. Was DTC B2296 retrieved during the on-demand self test?
Yes
This is a hard fault. The fault condition is still present. This fault cannot be cleared until it is corrected and the DTC is no longer retrieved during the on-demand self test. If a flagged fault of “?” was recorded, multiple faults exist and the entire pinpoint test must be carried out before installing a new RCM. For first row driver side impact (F_D_SEN) sensor with a mounting/communications (COMM) fault, Go to J2. For first row driver side impact sensor (F_D_ SEN) with an internal (INT) fault, INSTALL a new first row driver side impact sensor. Go to J34. For first row passenger side impact sensor (F_P_ SEN) with a mounting/communications (COMM) fault, Go to J12. For first row passenger side impact sensor (F_P_ SEN) with an internal (INT) fault, INSTALL a new first row passenger side impact sensor. Go to J34. For front impact severity sensor (FNT_SEN) with a mounting/communications (COMM) fault, Go to J22. For front impact severity sensor (FNT_SEN) with an internal fault (INT) fault, INSTALL a new front impact severity sensor. Go to J34.
No
This is an intermittent fault. The fault condition is not present at this time. Go to J33.
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01/2003 2003.0 BA Falcon
501-20b-72
Occupant Restraints — Passive
501-20b-72
DIAGNOSIS AND TESTING (Continued) Test Step J2
Result / Action to Take
INSPECT THE FIRST ROW DRIVER SIDE IMPACT SENSOR MOUNTING, MOUNTING BRACKET AND MOUNTING SURFACE WARNING: If the supplemental restraint system (SRS) is
being serviced, the system must be deactivated and restraint system diagnostic tools must be installed. Refer to Airbag and Safety Belt Pretensioner Supplemental Restraint System (SRS) in this section. The airbag restraint system diagnostic tools must be removed and the airbag modules reconnected when the system is reactivated to avoid non-deployment in a collision, resulting in possible personal injury.
Yes
CLEAN, TIGHTEN the bolts or REPAIR the mounting surface as necessary. REINSTALL the first row driver side impact sensor. Go to J24.
No
Go to J3.
WARNING: Never probe the connectors on the airbag module. Doing so can result in airbag deployment, which can result in personal injury. WARNING: The safety belt buckle pretensioner is a pyrotechnic device. Never probe a pretensioner electrical connector. Doing so could result in pretensioner or airbag deployment and could result in personal injury. WARNING: Never probe the electrical connector on a side airbag module. Doing so can result in side airbag deployment. NOTE: Diagnostics or repairs are not to be performed on a seat equipped with a seat side airbag with the seat in the vehicle. Prior to attempting to diagnose or repair a seat concern when equipped with a seat side airbag, the seat must be removed from the vehicle and the restraint system diagnostic tools must be installed in the seat side airbag electrical connectors. The restraint system diagnostic tools must be removed prior to operating the vehicle over the road. NOTE: After diagnosing or repairing an SRS, the restraint system diagnostic tools must be removed before operating the vehicle over the road. NOTE: After diagnosing or repairing a seat system, the restraint system diagnostic tools must be removed before operating the vehicle over the road. NOTE: The SRS must be fully operational and free of faults before releasing the vehicle to the customer. Key in OFF position. Deactivate the system. Refer to Airbag and Safety Belt Pretensioner Supplemental Restraint System (SRS) in the Diagnosis and Testing portion of this section. Inspect the first row driver side impact sensor mounting and make sure that the retaining bolts are fully seated and tightened correctly. Remove the first row driver side impact sensor. Visually inspect the first row driver side impact sensor, mounting bracket and mounting surface for damage, corrosion or dirt. Was a significant amount of corrosion or dirt found, the first row driver side impact sensor mounting bracket attached to the mounting surface incorrectly or were the impact sensor bolts not fully seated and tightened correctly?
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01/2003 2003.0 BA Falcon
501-20b-73
Occupant Restraints — Passive
501-20b-73
DIAGNOSIS AND TESTING (Continued) Test Step J3
Result / Action to Take
INSTALL THE FIRST ROW DRIVER SIDE IMPACT SENSOR AND CARRY OUT THE ON-DEMAND SELF TEST Clean and repair the mounting surface as necessary. Clean the first row driver side impact sensor mounting bolts. Install the first row driver side impact sensor. Key in ON position.
Yes
Go to J4.
No
Fault corrected. Go to J34.
Enter the following diagnostic mode on the diagnostic tool: Flag DTC B2296 Retrieve and record any flagged faults for use later in this pinpoint test. Was DTC B2296 retrieved during the on-demand self test?
J4
CHECK THE FIRST ROW DRIVER SIDE IMPACT SENSOR GROUND CIRCUIT 1262 (W/R) FOR HIGH RESISTANCE Key in OFF position. Disconnect First Row Driver Side Impact Sensor C341. Measure the resistance between first row driver side impact sensor C341, circuit 1262 (W/R), harness side and the first row driver side impact sensor case ground.
Yes
Go to J6.
No
Go to J5.
Is the resistance less than 100 ohms?
J5
CLEAN THE FIRST ROW DRIVER SIDE IMPACT SENSOR MOUNTING SURFACE AND CARRY OUT THE ON-DEMAND SELF TEST Remove the first row driver side impact sensor. Clean and repair the mounting surface as necessary. Clean the first row driver side impact sensor mounting bolts. Install the first row driver side impact sensor.
Yes
Go to J6.
No
Fault corrected. Go to J34.
Enter the following diagnostic mode on the diagnostic tool: Flag DTC B2296 Retrieve and record any flagged faults for use later in this pinpoint test. Was DTC B2296 retrieved during the on-demand self test?
J6
CHECK CIRCUIT 1261 (W/B) AND CIRCUIT 1262 (W/R) FOR A SHORT TO GROUND BETWEEN THE FIRST ROW DRIVER SIDE IMPACT SENSOR AND THE RCM Key in OFF position. Disconnect RCM C189a. Disconnect RCM C189b. Measure the resistance between first row driver side impact sensor C341, circuit 1261 (W/R), harness side and ground; and between pin 2, circuit 1261 (W/B), harness side and ground.
Yes
Go to J7.
No
REPAIR short to ground in circuit 1261 (W/B) or circuit 1261 (W/R). Go to J34.
Are the resistances greater than 1,000,000 ohms?
G12345 en
01/2003 2003.0 BA Falcon
501-20b-74
Occupant Restraints — Passive
501-20b-74
DIAGNOSIS AND TESTING (Continued) Test Step J7
CHECK CIRCUIT 1261 (W/B) AND CIRCUIT 1261 (W/R) FOR A SHORT TO VOLTAGE BETWEEN THE FIRST ROW DRIVER SIDE IMPACT SENSOR AND THE RCM Key in ON position. Measure the voltage between first row driver side impact sensor C341, circuit 1262 (W/R), harness side and ground; and between pin 2, circuit 1261 (W/B), harness side and ground. Are the voltages less than 0.2 volt?
J8
Result / Action to Take
Yes
Go to J8.
No
REPAIR short to battery in circuit 1261 (W/B) or circuit 1262 (W/R). Go to J34.
CHECK CIRCUIT 1261 (W/B) FOR AN OPEN BETWEEN THE RCM AND THE FIRST ROW DRIVER SIDE IMPACT SENSOR Key in OFF position. Measure the resistance between RCM C189b pin 27, circuit 1261 (W/B), harness side and first row driver side impact sensor C341, circuit 1261 (W/B), harness side.
Yes
Go to J9.
No
REPAIR circuit 1261 (W/B). Go to J34.
Is the resistance less than 0.5 ohm?
J9
J10
CHECK CIRCUIT 1262 (W/R) FOR AN OPEN BETWEEN THE RCM AND THE FIRST ROW DRIVER SIDE IMPACT SENSOR Measure the resistance between RCM C189b pin 28, circuit 1262 (W/R), harness side and first row driver side impact sensor C341, circuit 1262 (W/R), harness side.
Yes
Is the resistance less than 0.5 ohm?
REPAIR circuit 1262 (W/R). Go to J34.
No
CHECK CIRCUIT 1261 (W/B) FOR A SHORT TO CIRCUIT 1262 (W/R) BETWEEN THE RCM AND THE FIRST ROW DRIVER SIDE IMPACT SENSOR Measure the resistance between first row driver side impact sensor C341, circuit 1261 (W/B), harness side and, circuit 1262 (W/R), harness side. Is the resistance greater than 1,000,000 ohms?
J11
Go to J10.
Yes
Go to J11.
No
REPAIR circuit 1261 (W/B) and circuit 1262 (W/R). Go to J34.
CHECK THE FIRST ROW DRIVER SIDE IMPACT SENSOR Connect RCM C189a. Connect RCM C189b. Install a known good first row driver side impact sensor. Enter the following diagnostic mode on the diagnostic tool: On-Demand Self Test
Yes
INSTALL the original first row driver side impact sensor. Go to J32.
No
Fault corrected. Go to J34.
Enter the following diagnostic mode on the diagnostic tool: Flag DTC B2296 Retrieve and record any flagged faults for use later in this pinpoint test. Were any faults flagged against the first row driver side impact sensor?
G12345 en
01/2003 2003.0 BA Falcon
501-20b-75
Occupant Restraints — Passive
501-20b-75
DIAGNOSIS AND TESTING (Continued) Test Step J12
Result / Action to Take
INSPECT THE FIRST ROW PASSENGER SIDE IMPACT SENSOR MOUNTING, MOUNTING BRACKET AND MOUNTING SURFACE WARNING: If the supplemental restraint system (SRS) is
being serviced, the system must be deactivated and restraint system diagnostic tools must be installed. Refer to Airbag and Safety Belt Pretensioner Supplemental Restraint System (SRS) in this section. The airbag restraint system diagnostic tools must be removed and the airbag modules reconnected when the system is reactivated to avoid non-deployment in a collision, resulting in possible personal injury.
Yes
CLEAN, TIGHTEN the bolts or REPAIR the mounting surface as necessary. REINSTALL the first row passenger side impact sensor. Go to J34.
No
Go to J13.
WARNING: Never probe the connectors on the airbag module. Doing so can result in airbag deployment, which can result in personal injury. WARNING: The safety belt buckle pretensioner is a pyrotechnic device. Never probe a pretensioner electrical connector. Doing so could result in pretensioner or airbag deployment and could result in personal injury. WARNING: Never probe the electrical connector on a side airbag module. Doing so can result in side airbag deployment. NOTE: Diagnostics or repairs are not to be performed on a seat equipped with a seat side airbag with the seat in the vehicle. Prior to attempting to diagnose or repair a seat concern when equipped with a seat side airbag, the seat must be removed from the vehicle and the restraint system diagnostic tools must be installed in the seat side airbag electrical connectors. The restraint system diagnostic tools must be removed prior to operating the vehicle over the road. NOTE: After diagnosing or repairing an SRS, the restraint system
diagnostic tools must be removed before operating the vehicle over the road.
NOTE: After diagnosing or repairing a seat system, the restraint system diagnostic tools must be removed before operating the vehicle over the road. NOTE: The SRS must be fully operational and free of faults before releasing the vehicle to the customer. Key in OFF position. Deactivate the system. Refer to Airbag and Safety Belt Pretensioner Supplemental Restraint System (SRS) in the Diagnosis and Testing portion of this section. Inspect the first row passenger side impact sensor mounting and make sure that the retaining bolts are fully seated and tightened correctly. Remove the first row passenger side impact sensor. Visually inspect the first row passenger side impact sensor, mounting bracket and mounting surface for damage, corrosion or dirt. Was a significant amount of corrosion or dirt found, the first row passenger side impact sensor mounting bracket attached to the mounting surface incorrectly or were the impact sensor bolts not fully seated and tightened correctly?
G12345 en
01/2003 2003.0 BA Falcon
501-20b-76
Occupant Restraints — Passive
501-20b-76
DIAGNOSIS AND TESTING (Continued) Test Step J13
Result / Action to Take
INSTALL THE FIRST ROW PASSENGER SIDE IMPACT SENSOR AND CARRY OUT THE ON-DEMAND SELF TEST Clean and repair the mounting surface as necessary. Clean the first row passenger side impact sensor mounting bolts. Install the first row passenger side impact sensor. Key in ON position.
Yes
Go to J14.
No
Fault corrected. Go to J34.
Enter the following diagnostic mode on the diagnostic tool: On-Demand Self Test Enter the following diagnostic mode on the diagnostic tool: Flag DTC B2296 Retrieve and record any flagged faults for use later in this pinpoint test. Was DTC B2296 retrieved during the on-demand self test?
J14
CHECK THE FIRST ROW PASSENGER SIDE IMPACT SENSOR GROUND CIRCUIT 1264 (R) FOR HIGH RESISTANCE Key in OFF position. Disconnect First Row Passenger Side Impact Sensor C345. Measure the resistance between the first row passenger side impact sensor C345, circuit 1264 (R), harness side and the first row passenger side impact sensor case ground.
Yes
Go to J16.
No
Go to J15.
Is the resistance less than 100 ohms?
J15
CLEAN THE FIRST ROW PASSENGER SIDE IMPACT SENSOR MOUNTING SURFACE AND CARRY OUT THE ON-DEMAND SELF TEST Remove the first row passenger side impact sensor. Clean and repair the mounting surface as necessary. Clean the first row passenger side impact sensor mounting bolts. Install the first row passenger side impact sensor.
Yes
Go to J16.
No
Fault corrected. Go to J34.
Enter the following diagnostic mode on the diagnostic tool: On-Demand Self Test Enter the following diagnostic mode on the diagnostic tool: Flag DTC B2296 Retrieve and record any flagged faults for use later in this pinpoint test. Was DTC B2296 retrieved during the on-demand self test?
J16
CHECK CIRCUIT 1263 (G/W) AND CIRCUIT 1264 (R) FOR A SHORT TO GROUND BETWEEN THE FIRST ROW PASSENGER SIDE IMPACT SENSOR AND THE RCM Key in OFF position. Disconnect RCM C189a. Disconnect RCM C189b. Measure the resistance between first row passenger side impact sensor C345, circuit 1263 (G/W), harness side and ground; and between, circuit 1264 (R), harness side and ground.
Yes
Go to J17.
No
REPAIR circuit 1263 (G/W) or circuit 1264 (R). Go to J34.
Are the resistances greater than 1,000,000 ohms?
G12345 en
01/2003 2003.0 BA Falcon
501-20b-77
Occupant Restraints — Passive
501-20b-77
DIAGNOSIS AND TESTING (Continued) Test Step J17
CHECK CIRCUIT 1263 (G/W) AND CIRCUIT 1264 (R) FOR A SHORT TO BATTERY BETWEEN THE FIRST ROW PASSENGER SIDE IMPACT SENSOR AND THE RCM Key in ON position. Measure the voltage between first row passenger side impact sensor C345, circuit 1263 (G/W), harness side and ground; and between, circuit 1264 (R), harness side and ground. Are the voltages less than 0.2 volt?
J18
Result / Action to Take
Yes
Go to J18.
No
REPAIR circuit 1263 (G/W) or circuit 1264 (R). Go to J34.
CHECK CIRCUIT 1263 (G/W) FOR AN OPEN BETWEEN THE RCM AND THE FIRST ROW PASSENGER SIDE IMPACT SENSOR Key in OFF position. Measure the resistance between RCM C189b pin 29, circuit 1263 (G/W), harness side and first row passenger side impact sensor C345, circuit 1263 (G/W), harness side.
Yes
Go to J19.
No
REPAIR circuit 1263 (G/W). Go to J34.
Is the resistance less than 0.5 ohm?
J19
CHECK CIRCUIT 1264 (R) FOR AN OPEN BETWEEN THE RCM AND THE FIRST ROW PASSENGER SIDE IMPACT SENSOR Measure the resistance between RCM C189b pin 30, circuit 1264 (R), Yes harness side and first row passenger side impact sensor C345, circuit Go to J20. 1264 (R), harness side. Is the resistance less than 0.5 ohm?
J20
J21
No
REPAIR circuit 1264 (R). Go to J34.
CHECK CIRCUIT 1263 (G/W) FOR A SHORT TO CIRCUIT 1264 (R) BETWEEN THE RCM AND THE FIRST ROW PASSENGER SIDE IMPACT SENSOR Measure the resistance between first row passenger side impact sensor C345, circuit 1263 (G/W), harness side and pin 1, circuit 1264 (R), harness side.
Yes
Is the resistance greater than 1,000,000 ohms?
REPAIR short between circuit 1263 (G/W) and circuit 1264 (R). Go to J24.
Go to J21.
No
CHECK THE FIRST ROW PASSENGER SIDE IMPACT SENSOR Connect RCM C189a. Connect RCM C189b. Install a known good first row passenger side impact sensor. Enter the following diagnostic mode on the diagnostic tool: On-Demand Self Test
Yes
INSTALL the original first row passenger side impact sensor. Go to J32.
No
Fault corrected. Go to J34.
Enter the following diagnostic mode on the diagnostic tool: Flag DTC B2296 Retrieve and record any flagged faults for use later in this pinpoint test. Were any faults flagged against the first row passenger side impact sensor?
G12345 en
01/2003 2003.0 BA Falcon
501-20b-78
Occupant Restraints — Passive
501-20b-78
DIAGNOSIS AND TESTING (Continued) Test Step J22
Result / Action to Take
INSPECT THE FRONT IMPACT SEVERITY SENSOR MOUNTING, MOUNTING BRACKET AND MOUNTING SURFACE WARNING: If the supplemental restraint system (SRS) is
being serviced, the system must be deactivated and restraint system diagnostic tools must be installed. Refer to Airbag and Safety Belt Pretensioner Supplemental Restraint System (SRS) in this section. The airbag restraint system diagnostic tools must be removed and the airbag modules reconnected when the system is reactivated to avoid non-deployment in a collision, resulting in possible personal injury.
Yes
CLEAN, TIGHTEN bolts or REPAIR the mounting surface as necessary. REINSTALL the front impact severity sensor. Go to J34.
No
Go to J23.
WARNING: Never probe the connectors on the airbag module. Doing so can result in airbag deployment, which can result in personal injury. WARNING: The safety belt buckle pretensioner is a pyrotechnic device. Never probe a pretensioner electrical connector. Doing so could result in pretensioner or airbag deployment and could result in personal injury. WARNING: Never probe the electrical connector on a side airbag module. Doing so can result in side airbag deployment. NOTE: Diagnostics or repairs are not to be performed on a seat equipped with a seat side airbag with the seat in the vehicle. Prior to attempting to diagnose or repair a seat concern when equipped with a seat side airbag, the seat must be removed from the vehicle and the restraint system diagnostic tools must be installed in the seat side airbag electrical connectors. The restraint system diagnostic tools must be removed prior to operating the vehicle over the road. NOTE: After diagnosing or repairing an SRS, the restraint system diagnostic tools must be removed before operating the vehicle over the road. NOTE: After diagnosing or repairing a seat system, the restraint system diagnostic tools must be removed before operating the vehicle over the road. NOTE: The SRS must be fully operational and free of faults before releasing the vehicle to the customer. Key in OFF position. Deactivate the system. Refer to Airbag and Safety Belt Pretensioner Supplemental Restraint System (SRS) in the Diagnosis and Testing portion of this section. Key in OFF position. Inspect the front impact severity sensor mounting and make sure that the retaining bolts are fully seated and tightened correctly. Remove the front impact severity sensor. Refer to Front Impact Severity Sensor. Visually inspect the front impact severity sensor, mounting bracket and mounting surface for damage, corrosion or dirt. Was a significant amount of corrosion or dirt found, the front impact severity sensor mounting bracket attached to the mounting surface incorrectly or were the front impact severity sensor bolts not fully seated and tightened correctly?
G12345 en
01/2003 2003.0 BA Falcon
501-20b-79
Occupant Restraints — Passive
501-20b-79
DIAGNOSIS AND TESTING (Continued) Test Step J23
Result / Action to Take
INSTALL THE FRONT IMPACT SEVERITY SENSOR AND CARRY OUT THE ON-DEMAND SELF TEST Clean and repair the mounting surface as necessary. Clean the front impact severity sensor mounting bolts. Install the front impact severity sensor. Refer to Front Impact Severity Sensor.
Yes
Go to J24.
No
Fault corrected. Go to J34.
Key in OFF position. Enter the following diagnostic mode on the diagnostic tool: On-Demand Self Test Enter the following diagnostic mode on the diagnostic tool: Flag DTC B2296 Retrieve and record any flagged faults for use later in this pinpoint test. Was DTC B2296 retrieved during the on-demand self test?
J24
CHECK THE FRONT IMPACT SEVERITY SENSOR GROUND CIRCUIT 618 (V) FOR HIGH RESISTANCE Key in OFF position. Disconnect Front Impact Severity Sensor C340.
Yes
Go to J26.
No Measure the resistance between front impact severity sensor C340, circuit 618 (V), harness side and the front impact severity sensor case Go to J25. ground. Is the resistance less than 100 ohms?
J25
CLEAN THE FRONT IMPACT SEVERITY SENSOR MOUNTING SURFACE AND CARRY OUT THE ON-DEMAND SELF-TEST Remove the front impact severity sensor. Refer toFront Impact Severity Sensor.
Yes
Clean and repair the mounting surface as necessary.
No
Clean the front impact severity sensor mounting bolts.
Go to J26.
Fault corrected. Go to J34.
Install the front impact severity sensor. Refer toFront Impact Severity Sensor. Key in OFF position. Enter the following diagnostic mode on the diagnostic tool: On-Demand Self Test Enter the following diagnostic mode on the diagnostic tool: Flag DTC B2296 Retrieve and record any flagged faults for use later in this pinpoint test. Was DTC B2296 retrieved during the on-demand self test?
G12345 en
01/2003 2003.0 BA Falcon
501-20b-80
Occupant Restraints — Passive
501-20b-80
DIAGNOSIS AND TESTING (Continued) Test Step J26
Result / Action to Take
CHECK CIRCUIT 617 (P) AND CIRCUIT 618 (V) FOR A SHORT TO GROUND BETWEEN THE RCM AND THE FRONT IMPACT SEVERITY SENSOR Key in OFF position. Disconnect RCM C189a. Disconnect RCM C189b. Measure the resistance between the front impact severity sensor C340, circuit 617 (P), harness side and ground; and between front impact severity sensor C340, circuit 618 (V), harness side and ground.
Yes
Go to J27.
No
REPAIR circuit 617 (P) or circuit 618 (V). Go to J34.
Are the resistances greater than 1,000,000 ohms?
J27
CHECK CIRCUIT 617 (P) AND CIRCUIT 618 (V) FOR A SHORT TO VOLTAGE BETWEEN THE RCM AND THE FRONT IMPACT SEVERITY SENSOR Key in ON position. Measure the voltage between the front impact severity sensor C340, circuit 617 (P), harness side and ground; and between the front impact severity sensor C340, circuit 618 (V), harness side and ground.
Yes
Go to J28.
No
REPAIR circuit 617 (P) or circuit 618 (V). Go to J34.
Are the voltages less than 0.2 volt?
J28
CHECK CIRCUIT 617 (P) FOR AN OPEN BETWEEN THE RCM AND THE FRONT IMPACT SEVERITY SENSOR Key in OFF position. Measure the resistance between RCM C189b pin 15, circuit 617 (P), harness side and front impact severity sensor C340, circuit 617 (P), harness side.
Yes
Go to J29.
No
REPAIR circuit 617 (P). Go to J34.
Is the resistance less than 0.5 ohm?
J29
J30
CHECK CIRCUIT 618 (V) FOR AN OPEN BETWEEN THE RCM AND THE FRONT IMPACT SEVERITY SENSOR Measure the resistance between RCM C340 pin 20, circuit 618 (V), harness side and front impact severity sensor C340, circuit 618 (V), harness side.
Yes
Is the resistance less than 0.5 ohm?
REPAIR circuit 618 (V). Go to J34.
Go to J30.
No
CHECK CIRCUIT 617 (P) FOR A SHORT TO CIRCUIT 618 (V) BETWEEN THE RCM AND THE FRONT IMPACT SEVERITY SENSOR Yes
Measure the resistance between front impact severity sensor C340, circuit 617 (P), harness side and, circuit 618 (V), harness side.
Go to J31.
Is the resistance greater than 1,000,000 ohms?
No
REPAIR circuit 617 (P) and circuit 618 (V). Go to J34.
G12345 en
01/2003 2003.0 BA Falcon
501-20b-81
Occupant Restraints — Passive
501-20b-81
DIAGNOSIS AND TESTING (Continued) Test Step J31
Result / Action to Take
CHECK THE FRONT IMPACT SEVERITY SENSOR Connect RCM C189a. Connect RCM C189b. Install a known good front impact severity sensor. Key in ON position.
Yes
INSTALL the original front impact severity sensor. Go to J32.
No
Fault corrected. Go to J34.
Enter the following diagnostic mode on the diagnostic tool: On-Demand Self Test Enter the following diagnostic mode on the diagnostic tool: Flag DTC B2296 Retrieve and record any flagged faults for use later in this pinpoint test. Were any faults flagged against the front impact severity sensor?
J32
CONFIRM THE RCM FAULT NOTE: Make sure all restraint system diagnostic tools, sensor electrical connectors, and the RCM electrical connector are connected before carrying out the on-demand self test. If not, erroneous DTCs will be recorded.
Yes
Key in OFF position.
If a “?” was flagged by the scan tool, CARRY OUT the entire pinpoint test before installing a new RCM. INSTALL a new RCM. REFER to Restraints Control Module (RCM) in this section. Go to J34.
Connect Impact Sensors.
No
Connect RCM C189a.
Fault corrected. Go to J34.
Connect RCM C189b. Key in ON position. Enter the following diagnostic mode on the diagnostic tool: On-Demand Self Test Enter the following diagnostic mode on the diagnostic tool: Flag DTC B2296 Retrieve and record any flagged faults. Was DTC B2296 retrieved during the on-demand self test?
G12345 en
01/2003 2003.0 BA Falcon
501-20b-82
Occupant Restraints — Passive
501-20b-82
DIAGNOSIS AND TESTING (Continued) Test Step J33
Result / Action to Take
CHECK FOR AN INTERMITTENT FAULT WARNING: If the supplemental restraint system (SRS) is
Yes
This is a hard fault. The fault condition is still present. The fault cannot be cleared until it is corrected and the DTC is no longer retrieved during the on-demand self test. If a flagged fault of “?” was recorded in Step V1, multiple faults exist and the entire pinpoint test must be carried out before installing a new RCM. For first row driver side impact (F_D_SEN) sensor with a mounting/communications (COMM) fault, Go to J2. WARNING: Never probe the connectors on the airbag module. Doing so can result in airbag deployment, which can result in For first row driver side impact sensor (F_S_ SEN) with an internal (INT) fault, INSTALL a personal injury. new first row driver side impact sensor. Go to J34. For first row passenger side impact sensor WARNING: The safety belt buckle pretensioner is a (F_P_ SEN) with a mounting/communications pyrotechnic device. Never probe a pretensioner electrical connector. Doing so could result in pretensioner or airbag deployment and could (COMM) fault, Go to J12. For first row passenger side impact sensor result in personal injury. (F_P_ SEN) with an internal (INT) fault, INSTALL a new first row passenger side impact WARNING: Never probe the electrical connector on a side sensor. Go to J34. airbag module. Doing so can result in side airbag deployment. For front impact severity sensor (FNT_SEN) with a mounting/communications (COMM) fault, Go NOTE: Diagnostics or repairs are not to be performed on a seat to J22. equipped with a seat side airbag with the seat in the vehicle. Prior to For front impact severity sensor (FNT_SEN) with attempting to diagnose or repair a seat concern when equipped with a seat an internal fault (INT) fault, INSTALL a new front side airbag, the seat must be removed from the vehicle and the restraint impact severity sensor. Go to J34. system diagnostic tools must be installed in the seat side airbag electrical connectors. The restraint system diagnostic tools must be removed No prior to operating the vehicle over the road. CHECK for causes of the intermittent fault. ATTEMPT to recreate the hard fault by flexing NOTE: After diagnosing or repairing an SRS, the restraint system the wire harness and cycling the ignition key diagnostic tools must be removed before operating the vehicle over frequently. REPAIR any intermittent concerns the road. found. being serviced, the system must be deactivated and restraint system diagnostic tools must be installed. Refer to Airbag and Safety Belt Pretensioner Supplemental Restraint System (SRS) in this section. The airbag restraint system diagnostic tools must be removed and the airbag modules reconnected when the system is reactivated to avoid non-deployment in a collision, resulting in possible personal injury.
NOTE: After diagnosing or repairing a seat system, the restraint system diagnostic tools must be removed before operating the vehicle over the road. NOTE: The SRS must be fully operational and free of faults before releasing the vehicle to the customer. Key in OFF position. Deactivate the system. Refer to Airbag and Safety Belt Pretensioner Supplemental Restraint System (SRS) in the Diagnosis and Testing portion of this section. Enter the following diagnostic mode on the diagnostic tool: On-Demand Self Test Enter the following diagnostic mode on the diagnostic tool: Flag DTC B2296 If DTC B2296 is retrieved during the on-demand self test, retrieve and record any flagged faults. Was DTC B2296 retrieved during the on-demand self test?
G12345 en
01/2003 2003.0 BA Falcon
501-20b-83
Occupant Restraints — Passive
501-20b-83
DIAGNOSIS AND TESTING (Continued) Test Step J34
Result / Action to Take
CHECK FOR ADDITIONAL DTCs Refer to the continuous DTCs recorded during Step J1. Were any continuous DTCs retrieved during Step J1?
Yes
Do not clear any DTCs until all DTCs have been resolved. GO to the Restraints Control Module (RCM) Diagnostic Trouble Code (DTC) Table in this section for pinpoint test direction.
No
RECONNECT the system. REACTIVATE the system. PROVE OUT the system. REFER to Airbag and Safety Belt Pretensioner Supplemental Restraint System (SRS) in this section. CLEAR all DTCs.
Pinpoint Test K: LFC 51/DTC B2691 - Driver Safety Belt Buckle Switch Circuit Fault Normal Operation
The restraints control module (RCM) checks the safety belt buckle switch circuits for faults. If the RCM detects an open circuit or short to voltage/ground fault, it will store diagnostic trouble code (DTC) B2691 in memory and flash lamp fault code (LFC) 51 (or higher priority code if one exists) on the airbag indicator.
Possible Causes
A driver safety belt buckle switch open circuit or short to voltage/ground fault can be caused by: damaged wiring, terminals, or connectors. a faulty driver safety belt buckle switch a faulted RCM. PINPOINT TEST K : LFC 51/DTC B2691 - DRIVER SAFETY BELT BUCKLE SWITCH CIRCUIT FAULT Test Step K1
Result / Action to Take
CHECK FOR A HARD OR INTERMITTENT DTC Enter the following diagnostic mode on the diagnostic tool: Yes This is a hard fault. The fault condition is still Retrieve Continuous DTCs present. This fault cannot be cleared until it is Retrieve and record any continuous DTCs for use later in this pinpoint corrected and the DTC is no longer retrieved test. during the on-demand self test. Go to K2. Enter the following diagnostic mode on the diagnostic tool: No On-Demand Self Test This is an intermittent fault. The fault condition is not present at this time. Go to K8. Was the DTC B2691 retrieved during the on-demand self test?
G12345 en
01/2003 2003.0 BA Falcon
501-20b-84
Occupant Restraints — Passive
501-20b-84
DIAGNOSIS AND TESTING (Continued) Test Step K2
Result / Action to Take
CHECK CIRCUIT 85 (B/L) FOR AN OPEN BETWEEN THE RCM AND THE DRIVER SAFETY BELT BUCKLE SWITCH WARNING: If the supplemental restraint system (SRS) is
being serviced, the system must be deactivated and restraint system diagnostic tools must be installed. Refer to Airbag and Safety Belt Pretensioner Supplemental Restraint System (SRS) in this section. The airbag restraint system diagnostic tools must be removed and the airbag modules reconnected when the system is reactivated to avoid non-deployment in a collision, resulting in possible personal injury.
Yes
Go to K3.
No
REPAIR circuit 85 (B/L). Go to K9.
WARNING: Never probe the connectors on the airbag module. Doing so can result in airbag deployment, which can result in personal injury. WARNING: The safety belt buckle pretensioner is a pyrotechnic device. Never probe a pretensioner electrical connector. Doing so could result in pretensioner or airbag deployment and could result in personal injury. WARNING: Never probe the electrical connector on a side airbag module. Doing so can result in side airbag deployment. NOTE: Diagnostics or repairs are not to be performed on a seat equipped with a seat side airbag with the seat in the vehicle. Prior to attempting to diagnose or repair a seat concern when equipped with a seat side airbag, the seat must be removed from the vehicle and the restraint system diagnostic tools must be installed in the seat side airbag electrical connectors. The restraint system diagnostic tools must be removed prior to operating the vehicle over the road. NOTE: After diagnosing or repairing a SRS the restraint system diagnostic tools must be removed before operating the vehicle over the road. NOTE: After diagnosing or repairing a seat system the restraint system diagnostic tools must be removed before operating the vehicle over the road.
NOTE: The SRS must be fully operational and free of faults before releasing the vehicle to the customer. Key in OFF position. Deactivate the system. Refer to Airbag and Safety Belt Pretensioner Supplemental Restraint System (SRS) in the Diagnosis and Testing portion of this section. Key in OFF position. Disconnect RCM C189b. Disconnect Driver Safety Belt Buckle Switch C233. Measure the resistance between RCM C189b pin 25, circuit 85 (B/L), harness side and driver safety belt buckle switch C233, circuit 85 (B/L), harness side. Is the resistance less than 0.5 ohm?
K3
CHECK CIRCUIT 1203 (BK) FOR AN OPEN Yes
Measure the resistance between driver safety belt buckle switch C233, circuit 1203 (BK), harness side and ground.
Go to K4.
Is the resistance less than 0.5 ohm?
No
REPAIR circuit 1203 (BK). Go to K9.
G12345 en
01/2003 2003.0 BA Falcon
501-20b-85
Occupant Restraints — Passive
501-20b-85
DIAGNOSIS AND TESTING (Continued) Test Step K4
CHECK CIRCUIT 85 (B/L) FOR A SHORT TO VOLTAGE Key in ON position. Measure the voltage between driver safety belt buckle switch C233, circuit 85 (B/L), harness side and ground. Is the voltage less than 0.2 volt?
K5
Result / Action to Take
Yes
Go to K5.
No
REPAIR circuit 85 (B/L). Go to K9.
CHECK CIRCUIT 1203 (BK) FOR A SHORT TO VOLTAGE Yes
Measure the voltage between driver safety belt buckle switch C233, circuit 1203 (BK), harness side and ground.
Go to K6.
Is the voltage less than 0.2 volt?
No
REPAIR circuit 1203 (BK). Go to K9.
K6
CHECK THE DRIVER SAFETY BELT BUCKLE SWITCH Yes
Connect Driver Safety Belt Buckle Switch C233 to the safety belt buckle.
Go to K7.
Connect RCM C189b.
No
Key in ON position.
INSTALL a new driver safety belt buckle and pretensioner assembly. Go to K9.
NOTE: With the safety belt buckled, the current should measure 11.0-19.4 mA. With the safety belt unbuckled, the current should measure 3.9-6.9 mA.
Measure the current flow from driver safety belt buckle switch C233, circuit 85 (B/L), harness side to component side, with the safety belt buckled and again unbuckled. Is the current between 11.0-19.4 mA with the safety belt buckled and between 3.9-6.9 mA with the safety belt unbuckled?
K7
CONFIRM THE RCM FAULT NOTE: Make sure all restraint system diagnostic tools, sensor electrical connectors, and the RCM electrical connector are connected before carrying out the on-demand self test. If not, erroneous DTCs will be recorded. Key in OFF position.
Yes
INSTALL a new RCM. REFER to Restraints Control Module (RCM) in this section. Go to K9.
No
Fault corrected. Go to K9.
Connect Driver Safety Belt Buckle Switch C233. Connect RCM C189b. Enter the following diagnostic mode on the diagnostic tool: On-Demand Self Test Was DTC B2691 retrieved during the on-demand self test?
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01/2003 2003.0 BA Falcon
501-20b-86
Occupant Restraints — Passive
501-20b-86
DIAGNOSIS AND TESTING (Continued) Test Step K8
Result / Action to Take
CHECK FOR AN INTERMITTENT FAULT WARNING: If the supplemental restraint system (SRS) is
being serviced, the system must be deactivated and restraint system diagnostic tools must be installed. Refer to Airbag and Safety Belt Pretensioner Supplemental Restraint System (SRS) in this section. The airbag restraint system diagnostic tools must be removed and the airbag modules reconnected when the system is reactivated to avoid non-deployment in a collision, resulting in possible personal injury.
Yes
Go to K2.
No
CHECK for causes of the intermittent fault. ATTEMPT to recreate the hard fault by flexing the wire harness and cycling the ignition key frequently. REPAIR any intermittent concerns found. Go to K9.
WARNING: Never probe the connectors on the airbag module. Doing so can result in airbag deployment, which can result in personal injury. WARNING: The safety belt buckle pretensioner is a pyrotechnic device. Never probe a pretensioner electrical connector. Doing so could result in pretensioner or airbag deployment and could result in personal injury. WARNING: Never probe the electrical connector on a side airbag module. Doing so can result in side airbag deployment. NOTE: Diagnostics or repairs are not to be performed on a seat equipped with a seat side airbag with the seat in the vehicle. Prior to attempting to diagnose or repair a seat concern when equipped with a seat side airbag, the seat must be removed from the vehicle and the restraint system diagnostic tools must be installed in the seat side airbag electrical connectors. The restraint system diagnostic tools must be removed prior to operating the vehicle over the road. NOTE: After diagnosing or repairing an SRS, the restraint system diagnostic tools must be removed before operating the vehicle over the road. NOTE: After diagnosing or repairing a seat system, the restraint system diagnostic tools must be removed before operating the vehicle over the road. NOTE: The SRS must be fully operational and free of faults before releasing the vehicle to the customer. Key in OFF position. Deactivate the system. Refer to Airbag and Safety Belt Pretensioner Supplemental Restraint System (SRS) in the Diagnosis and Testing portion of this section. Enter the following diagnostic mode on the diagnostic tool: On-Demand Self Test Was DTC B2691 retrieved during the on-demand self test?
K9
CHECK FOR ADDITIONAL DTCs Refer to the continuous DTCs recorded during Step K1. Were any continuous DTCs retrieved during Step K1?
Yes
Do not clear any DTCs until all DTCs have been resolved. GO to the Restraints Control Module (RCM) Diagnostic Trouble Code (DTC) Table in this section for pinpoint test direction.
No
RECONNECT the system. REACTIVATE the system. PROVE OUT the system. REFER to Airbag and Safety Belt Pretensioner Supplemental Restraint System (SRS). CLEAR all DTCs.
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01/2003 2003.0 BA Falcon
501-20b-87
Occupant Restraints — Passive
501-20b-87
DIAGNOSIS AND TESTING (Continued) Pinpoint Test L: LFC 51/DTC B2434 - Driver Safety Belt Buckle Switch Circuit Short to Ground Normal Operation The restraints control module (RCM) checks the driver safety belt buckle switch circuits for faults. If the RCM detects a short to ground fault, it will store diagnostic trouble code (DTC) B2434 in memory and flash lamp fault code (LFC) 51 (or higher priority code if one exists) on the airbag indicator.
Possible Causes A driver safety belt buckle switch circuit fault can be caused by: damaged wiring, terminals, or connectors. a faulty driver safety belt buckle switch. a faulted RCM. PINPOINT TEST L : LFC 51/DTC B2434 - DRIVER SAFETY BELT BUCKLE SWITCH CIRCUIT SHORT TO GROUND Test Step L1
Result / Action to Take
CHECK FOR A HARD OR INTERMITTENT DTC Enter the following diagnostic mode on the diagnostic tool: Retrieve Continuous DTCs
Yes
Enter the following diagnostic mode on the diagnostic tool: On-Demand Self Test
No
This is a hard fault. The fault condition is still present. This fault cannot be cleared until it is Retrieve and record any continuous DTCs for use later in this pinpoint corrected and the DTC is no longer retrieved test. during the on-demand self test. Go to L2.
Was DTC B2434 retrieved during the on-demand self test?
G12345 en
This is an intermittent fault. The fault condition is not present at this time. Go to L5.
01/2003 2003.0 BA Falcon
501-20b-88
Occupant Restraints — Passive
501-20b-88
DIAGNOSIS AND TESTING (Continued) Test Step L2
Result / Action to Take
CHECK CIRCUIT 85 (B/L) FOR A SHORT TO GROUND BETWEEN THE RCM AND THE DRIVER SAFETY BELT BUCKLE SWITCH WARNING: If the supplemental restraint system (SRS) is
being serviced, the system must be deactivated and restraint system diagnostic tools must be installed. Refer to Airbag and Safety Belt Pretensioner Supplemental Restraint System (SRS) in this section. The airbag restraint system diagnostic tools must be removed and the airbag modules reconnected when the system is reactivated to avoid non-deployment in a collision, resulting in possible personal injury.
Yes
Go to L3.
No
REPAIR circuit 85 (B/L). Go to L6.
WARNING: Never probe the connectors on the airbag module. Doing so can result in airbag deployment, which can result in personal injury. WARNING: The safety belt buckle pretensioner is a pyrotechnic device. Never probe a pretensioner electrical connector. Doing so could result in pretensioner or airbag deployment and could result in personal injury. WARNING: Never probe the electrical connector on a side airbag module. Doing so can result in side airbag deployment. NOTE: Diagnostics or repairs are not to be performed on a seat equipped with a seat side airbag with the seat in the vehicle. Prior to attempting to diagnose or repair a seat concern when equipped with a seat side airbag, the seat must be removed from the vehicle and the restraint system diagnostic tools must be installed in the seat side airbag electrical connectors. The restraint system diagnostic tools must be removed prior to operating the vehicle over the road. NOTE: After diagnosing or repairing an SRS, the restraint system diagnostic tools must be removed before operating the vehicle over the road. NOTE: After diagnosing or repairing a seat system, the restraint system diagnostic tools must be removed before operating the vehicle over the road. NOTE: The SRS must be fully operational and free of faults before releasing the vehicle to the customer. Key in OFF position. Deactivate the system. Refer to Airbag and Safety Belt Pretensioner Supplemental Restraint System (SRS) in the Diagnosis and Testing portion of this section. Disconnect Driver Safety Belt Buckle Switch C233. Disconnect RCM C189b. Measure the resistance between RCM C189b pin 25, circuit 85 (B/L), harness side and ground. Is the resistance greater than 1,000,000 ohms?
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01/2003 2003.0 BA Falcon
501-20b-89
Occupant Restraints — Passive
501-20b-89
DIAGNOSIS AND TESTING (Continued) Test Step L3
Result / Action to Take
CHECK THE DRIVER SAFETY BELT BUCKLE SWITCH Yes
Connect Driver Safety Belt Buckle Switch C233 to the safety belt buckle.
Go to L4.
Connect RCM C189b.
No
Key in ON position.
INSTALL a new driver safety belt buckle and pretensioner assembly. REFER to Section 501-20A. Go to L6.
NOTE: With the safety belt buckled, the current should measure 11.0-19.4 mA. With the safety belt unbuckled, the current should measure 3.9-6.9 mA.
Measure the current flow from driver safety belt buckle switch C233, circuit 85 (B/L), harness side to component side, with the safety belt buckled and again unbuckled. Is the current between 11.0-19.4 mA with the safety belt buckled and between 3.9-6.9 mA with the safety belt unbuckled?
L4
CONFIRM THE RCM FAULT NOTE: Make sure all restraint system diagnostic tools, sensor electrical connectors, and the RCM electrical connector are connected before carrying out the on-demand self test. If not, erroneous DTCs will be recorded. Key in OFF position.
Yes
INSTALL a new RCM. REFER to Restraints Control Module (RCM) in this section. Go to L6.
No
Fault corrected. Go to L6.
Connect Driver Safety Belt Buckle Switch C233. Connect RCM C189b. Enter the following diagnostic mode on the diagnostic tool: On-Demand Self Test Was DTC B2434 retrieved during the on-demand self test?
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01/2003 2003.0 BA Falcon
501-20b-90
Occupant Restraints — Passive
501-20b-90
DIAGNOSIS AND TESTING (Continued) Test Step L5
Result / Action to Take
CHECK FOR AN INTERMITTENT FAULT WARNING: If the supplemental restraint system (SRS) is
being serviced, the system must be deactivated and restraint system diagnostic tools must be installed. Refer to Airbag and Safety Belt Pretensioner Supplemental Restraint System (SRS) in this section. The airbag restraint system diagnostic tools must be removed and the airbag modules reconnected when the system is reactivated to avoid non-deployment in a collision, resulting in possible personal injury.
Yes
Go to L2.
No
CHECK for causes of the intermittent fault. ATTEMPT to recreate the hard fault by flexing the wire harness and cycling the ignition key frequently. REPAIR any intermittent concerns found. Go to L6.
WARNING: Never probe the connectors on the airbag module. Doing so can result in airbag deployment, which can result in personal injury. WARNING: The safety belt buckle pretensioner is a pyrotechnic device. Never probe a pretensioner electrical connector. Doing so could result in pretensioner or airbag deployment and could result in personal injury. WARNING: Never probe the electrical connector on a side airbag module. Doing so can result in side airbag deployment. NOTE: Diagnostics or repairs are not to be performed on a seat equipped with a seat side airbag with the seat in the vehicle. Prior to attempting to diagnose or repair a seat concern when equipped with a seat side airbag, the seat must be removed from the vehicle and the restraint system diagnostic tools must be installed in the seat side airbag electrical connectors. The restraint system diagnostic tools must be removed prior to operating the vehicle over the road. NOTE: After diagnosing or repairing an SRS, the restraint system diagnostic tools must be removed before operating the vehicle over the road. NOTE: After diagnosing or repairing a seat system, the restraint system diagnostic tools must be removed before operating the vehicle over the road. NOTE: The SRS must be fully operational and free of faults before releasing the vehicle to the customer. Key in OFF position. Deactivate the system. Refer to Airbag and Safety Belt Pretensioner Supplemental Restraint System (SRS) in the Diagnosis and Testing portion of this section. Enter the following diagnostic mode on the diagnostic tool: On-Demand Self Test Was DTC B2434 retrieved during the on-demand self test?
L6
CHECK FOR ADDITIONAL DTCs Refer to the continuous DTCs recorded during Step L1. Were any continuous DTCs retrieved during Step L1?
Yes
Do not clear any DTCs until all DTCs have been resolved. GO to the Restraints Control Module (RCM) Diagnostic Trouble Code (DTC) Table in this section for pinpoint test direction.
No
RECONNECT the system. REACTIVATE the system. PROVE OUT the system. REFER to Airbag and Safety Belt Pretensioner Supplemental Restraint System (SRS). CLEAR all DTCs.
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01/2003 2003.0 BA Falcon
501-20b-91
Occupant Restraints — Passive
501-20b-91
DIAGNOSIS AND TESTING (Continued) Pinpoint Test M: LFC 51/DTC B2435 Driver Safety Belt Buckle Switch Current Out of Range Normal Operation The restraints control module (RCM) checks the driver safety belt buckle switch circuits for faults. If the RCM detects a current out of range fault, it will store diagnostic trouble code (DTC) B2435 in memory and flash lamp fault code (LFC) 51 (or higher priority code if one exists) on the airbag indicator.
Possible Causes A driver safety belt buckle switch current out of range fault can be caused by: damaged wiring, terminals, or connectors. a faulty driver safety belt buckle and pretensioner assembly. a faulted RCM. PINPOINT TEST M : LFC 51/DTC B2435 - DRIVER SAFETY BELT BUCKLE SWITCH CURRENT OUT OF RANGE Test Step M1
Result / Action to Take
CHECK FOR A HARD OR INTERMITTENT DTC Enter the following diagnostic mode on the diagnostic tool: Retrieve Continuous DTCs
Yes
Enter the following diagnostic mode on the diagnostic tool: On-Demand Self Test
No
This is a hard fault. The fault condition is still present. This fault cannot be cleared until it is Retrieve and record any continuous DTCs for use later in this pinpoint corrected and the DTC is no longer retrieved test. during the on-demand self test. Go to M2.
Was DTC B2435 retrieved during the on-demand self test?
G12345 en
This is an intermittent fault. The fault condition is not present at this time. Go to M6.
01/2003 2003.0 BA Falcon
501-20b-92
Occupant Restraints — Passive
501-20b-92
DIAGNOSIS AND TESTING (Continued) Test Step M2
Result / Action to Take
CHECK CIRCUIT 85 (B/L) FOR AN OPEN BETWEEN THE RCM AND THE DRIVER SAFETY BELT BUCKLE SWITCH WARNING: If the supplemental restraint system (SRS) is
being serviced, the system must be deactivated and restraint system diagnostic tools must be installed. Refer to Airbag and Safety Belt Pretensioner Supplemental Restraint System (SRS) in this section. The airbag restraint system diagnostic tools must be removed and the airbag modules reconnected when the system is reactivated to avoid non-deployment in a collision, resulting in possible personal injury.
Yes
Go to M3.
No
REPAIR circuit 85 (B/L). Go to M7.
WARNING: Never probe the connectors on the airbag module. Doing so can result in airbag deployment, which can result in personal injury. WARNING: The safety belt buckle pretensioner is a pyrotechnic device. Never probe a pretensioner electrical connector. Doing so could result in pretensioner or airbag deployment and could result in personal injury. WARNING: Never probe the electrical connector on a side airbag module. Doing so can result in side airbag deployment. NOTE: Diagnostics or repairs are not to be performed on a seat equipped with a seat side airbag with the seat in the vehicle. Prior to attempting to diagnose or repair a seat concern when equipped with a seat side airbag, the seat must be removed from the vehicle and the restraint system diagnostic tools must be installed in the seat side airbag electrical connectors. The restraint system diagnostic tools must be removed prior to operating the vehicle over the road. NOTE: After diagnosing or repairing an SRS, the restraint system diagnostic tools must be removed before operating the vehicle over the road. NOTE: After diagnosing or repairing a seat system, the restraint system diagnostic tools must be removed before operating the vehicle over the road. NOTE: The SRS must be fully operational and free of faults before releasing the vehicle to the customer. Key in OFF position. Deactivate the system. Refer to Airbag and Safety Belt Pretensioner Supplemental Restraint System (SRS) in the Diagnosis and Testing portion of this section. Key in OFF position. Disconnect RCM C189b. Disconnect Driver Safety Belt Buckle Switch C233. Measure the resistance between RCM C189b pin 25, circuit 85 (B/L), harness side and driver safety belt buckle switch C233, circuit 85 (B/L), harness side. Is the resistance less than 0.5 ohm?
M3
CHECK CIRCUIT 1203 (BK) FOR AN OPEN Yes
Measure the resistance between driver safety belt buckle switch C233, circuit 1203 (BK), harness side and ground.
Go to M4.
Is the resistance less than 0.5 ohm?
No
REPAIR circuit 1203 (BK). Go to M7.
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01/2003 2003.0 BA Falcon
501-20b-93
Occupant Restraints — Passive
501-20b-93
DIAGNOSIS AND TESTING (Continued) Test Step M4
Result / Action to Take
CHECK THE SAFETY BELT BUCKLE SWITCH Yes
Connect Driver Safety Belt Buckle Switch C233 to the safety belt buckle.
Go to M5.
Connect RCM C189b.
No
Key in ON position.
INSTALL a new driver safety belt buckle and pretensioner assembly. Go to M7.
NOTE: With the safety belt buckled, the current should measure 11.0-19.4 mA. With the safety belt unbuckled, the current should measure 3.9-6.9 mA.
Measure the current flow from driver safety belt buckle switch C233, circuit 85 (B/L), harness side to component side, with the safety belt buckled and again unbuckled. Is the current between 11.0-19.4 mA with the safety belt buckled and between 3.9-6.9 mA with the safety belt unbuckled?
M5
CONFIRM THE RCM FAULT NOTE: Make sure all restraint system diagnostic tools, sensor electrical connectors, and the RCM electrical connector are connected before carrying out the on-demand self test. If not, erroneous DTCs will be recorded. Key in OFF position.
Yes
INSTALL a new RCM. REFER to Restraints Control Module (RCM) in this section. Go to M7.
No
Fault corrected. Go to M7.
Connect Driver Safety Belt Switch C233. Connect RCM C189b. Enter the following diagnostic mode on the diagnostic tool: On-Demand Self Test Was DTC B2435 retrieved during the on-demand self test?
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01/2003 2003.0 BA Falcon
501-20b-94
Occupant Restraints — Passive
501-20b-94
DIAGNOSIS AND TESTING (Continued) Test Step M6
Result / Action to Take
CHECK FOR AN INTERMITTENT FAULT WARNING: If the supplemental restraint system (SRS) is
being serviced, the system must be deactivated and restraint system diagnostic tools must be installed. Refer to Airbag and Safety Belt Pretensioner Supplemental Restraint System (SRS) in this section. The airbag restraint system diagnostic tools must be removed and the airbag modules reconnected when the system is reactivated to avoid non-deployment in a collision, resulting in possible personal injury.
Yes
Go to M2.
No
CHECK for causes of the intermittent fault. ATTEMPT to recreate the hard fault by flexing the wire harness and cycling the ignition key frequently. REPAIR any intermittent concerns found. Go to M7.
WARNING: Never probe the connectors on the airbag module. Doing so can result in airbag deployment, which can result in personal injury. WARNING: The safety belt buckle pretensioner is a pyrotechnic device. Never probe a pretensioner electrical connector. Doing so could result in pretensioner or airbag deployment and could result in personal injury. WARNING: Never probe the electrical connector on a side airbag module. Doing so can result in side airbag deployment. NOTE: After diagnosing or repairing an SRS, the restraint system diagnostic tools must be removed before operating the vehicle over the road. NOTE: After diagnosing or repairing a seat system, the restraint system diagnostic tools must be removed before operating the vehicle over the road. NOTE: The SRS must be fully operational and free of faults before releasing the vehicle to the customer. Key in OFF position. Deactivate the system. Refer to Airbag and Safety Belt Pretensioner Supplemental Restraint System (SRS) in the Diagnosis and Testing portion of this section. Enter the following diagnostic mode on the diagnostic tool: On-Demand Self Test Was DTC B2435 retrieved during the on-demand self test?
M7
CHECK FOR ADDITIONAL DTCs Refer to the continuous DTCs recorded during Step M1. Were any continuous DTCs retrieved during Step M1?
Yes
Do not clear any DTCs until all DTCs have been resolved. GO to the Restraints Control Module (RCM) Diagnostic Trouble Code (DTC) Table in this section for pinpoint test direction.
No
RECONNECT the system. REACTIVATE the system. PROVE OUT the system. REFER to Airbag and Safety Belt Pretensioner Supplemental Restraint System (SRS) in this section. CLEAR all DTCs.
Pinpoint Test N: LFC 52/DTC B2692 Passenger Safety Belt Buckle Switch
Circuit Fault Normal Operation The restraints control module (RCM) checks the passenger safety belt buckle switch circuits for faults. If the RCM detects an open circuit or short to voltage/ground fault, it will store diagnostic trouble
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01/2003 2003.0 BA Falcon
501-20b-95
Occupant Restraints — Passive
501-20b-95
DIAGNOSIS AND TESTING (Continued) code (DTC) B2692 in memory and flash lamp fault code (LFC) 52 (or higher priority code if one exists) on the airbag indicator.
Possible Causes A passenger safety belt buckle switch open circuit or short to voltage/ground fault can be caused by: damaged wiring, terminals, or connectors. a faulty passenger safety belt buckle switch. a faulted RCM. PINPOINT TEST N : LFC 52/DTC B2692 - PASSENGER SAFETY BELT BUCKLE SWITCH CIRCUIT FAULT Test Step N1
Result / Action to Take
CHECK FOR A HARD OR INTERMITTENT DTC Enter the following diagnostic mode on the diagnostic tool: Retrieve Continuous DTCs
Yes
Enter the following diagnostic mode on the diagnostic tool: On-Demand Self Test
No
This is a hard fault. The fault condition is still present. This fault cannot be cleared until it is Retrieve and record any continuous DTCs for use later in this pinpoint corrected and the DTC is no longer retrieved test. during the on-demand self test. Go to N2.
Was the DTC B2692 retrieved during the on-demand self test?
G12345 en
This is an intermittent fault. The fault condition is not present at this time. Go to N8.
01/2003 2003.0 BA Falcon
501-20b-96
Occupant Restraints — Passive
501-20b-96
DIAGNOSIS AND TESTING (Continued) Test Step N2
Result / Action to Take
CHECK CIRCUIT 1514 (R-B) FOR AN OPEN BETWEEN THE RCM AND THE PASSENGER SAFETY BELT BUCKLE SWITCH WARNING: If the supplemental restraint system (SRS) is
being serviced, the system must be deactivated and restraint system diagnostic tools must be installed. Refer to Airbag and Safety Belt Pretensioner Supplemental Restraint System (SRS) in this section. The airbag restraint system diagnostic tools must be removed and the airbag modules reconnected when the system is reactivated to avoid non-deployment in a collision, resulting in possible personal injury.
Yes
Go to N3.
No
REPAIR circuit 1514 (R-B). Go to N9.
WARNING: Never probe the connectors on the airbag module. Doing so can result in airbag deployment, which can result in personal injury. WARNING: The safety belt buckle pretensioner is a pyrotechnic device. Never probe a pretensioner electrical connector. Doing so could result in pretensioner or airbag deployment and could result in personal injury. WARNING: Never probe the electrical connector on a side airbag module. Doing so can result in side airbag deployment. NOTE: Diagnostics or repairs are not to be performed on a seat equipped with a seat side airbag with the seat in the vehicle. Prior to attempting to diagnose or repair a seat concern when equipped with a seat side airbag, the seat must be removed from the vehicle and the restraint system diagnostic tools must be installed in the seat side airbag electrical connectors. The restraint system diagnostic tools must be removed prior to operating the vehicle over the road. NOTE: After diagnosing or repairing an SRS, the restraint system diagnostic tools must be removed before operating the vehicle over the road. NOTE: After diagnosing or repairing a seat system, the restraint system diagnostic tools must be removed before operating the vehicle over the road. NOTE: The SRS must be fully operational and free of faults before releasing the vehicle to the customer. Key in OFF position. Deactivate the system. Refer to Airbag and Safety Belt Pretensioner Supplemental Restraint System (SRS) in the Diagnosis and Testing portion of this section. Key in OFF position. Disconnect RCM C189b. Disconnect Passenger Safety Belt Buckle Switch C234. Measure the resistance between RCM C189b pin 26, circuit 1514 (R-B), harness side and the passenger safety belt buckle switch C234, circuit 1514 (R-B), harness side. Is the resistance less than 0.5 ohm?
N3
CHECK CIRCUIT 1203 (BK) FOR AN OPEN Yes
Measure the resistance between passenger safety belt buckle switch C234, circuit 1203 (BK), harness side and ground.
Go to N4.
Is the resistance less than 0.5 ohm?
No
REPAIR circuit 1203 (BK). Go to N9.
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01/2003 2003.0 BA Falcon
501-20b-97
Occupant Restraints — Passive
501-20b-97
DIAGNOSIS AND TESTING (Continued) Test Step N4
CHECK CIRCUIT 1514 (R-B) FOR A SHORT TO VOLTAGE Key in ON position. Measure the voltage between passenger seat belt buckle switch C234, circuit 1514 (R-B), harness side and ground. Is the voltage less than 0.2 volt?
N5
Result / Action to Take
Yes
Go to N5.
No
REPAIR circuit 1514 (R-B). Go to N9.
CHECK FOR SHORT TO VOLTAGE ON CIRCUIT 1203 (BK) Yes
Measure the voltage between the passenger seat belt buckle switch C234, circuit 1203 (BK), harness side and ground.
Go to N6.
Is the voltage less than 0.2 volt?
No
REPAIR circuit 1203 (BK). Go to N9.
N6
CHECK THE SAFETY BELT BUCKLE SWITCH Yes
Connect Passenger Safety Belt Buckle Switch C234 to the safety belt buckle.
Go to N7.
Connect RCM C189b.
No
Key in ON position.
INSTALL a new passenger safety belt buckle and pretensioner assembly. Go to N9.
NOTE: With the safety belt buckled, the current should measure 11.0-19.4 mA. With the safety belt unbuckled, the current should measure 3.9-6.9 mA.
Measure the current flow from the passenger safety belt buckle switch C234, circuit 1514 (R/B), harness side to component side, with the safety belt buckled and again unbuckled. Is the current between 11.0-19.4 mA with the safety belt buckled and between 3.9-6.9 mA with the safety belt unbuckled?
N7
CONFIRM THE RCM FAULT NOTE: Make sure all restraint system diagnostic tools, sensor electrical connectors, and the RCM electrical connector are connected before carrying out the on-demand self test. If not, erroneous DTCs will be recorded. Key in OFF position.
Yes
INSTALL a new RCM. REFER to Restraints Control Module (RCM) in this section. Go to N9.
No
Fault corrected. Go to N9.
Connect Passenger Safety Belt Buckle Switch C234. Connect RCM C189b. Enter the following diagnostic mode on the diagnostic tool: On-Demand Self Test Was the DTC B2692 retrieved during the on-demand self test?
G12345 en
01/2003 2003.0 BA Falcon
501-20b-98
Occupant Restraints — Passive
501-20b-98
DIAGNOSIS AND TESTING (Continued) Test Step N8
Result / Action to Take
CHECK FOR AN INTERMITTENT FAULT WARNING: If the supplemental restraint system (SRS) is
being serviced, the system must be deactivated and restraint system diagnostic tools must be installed. Refer to Airbag and Safety Belt Pretensioner Supplemental Restraint System (SRS) in this section. The airbag restraint system diagnostic tools must be removed and the airbag modules reconnected when the system is reactivated to avoid non-deployment in a collision, resulting in possible personal injury.
Yes
Go to N2.
No
CHECK for causes of the intermittent fault. ATTEMPT to recreate the hard fault by flexing the wire harness and cycling the ignition key frequently. REPAIR any intermittent concerns found. Go to N9.
WARNING: Never probe the connectors on the airbag module. Doing so can result in airbag deployment, which can result in personal injury. WARNING: The safety belt buckle pretensioner is a pyrotechnic device. Never probe a pretensioner electrical connector. Doing so could result in pretensioner or airbag deployment and could result in personal injury. WARNING: Never probe the electrical connector on a side airbag module. Doing so can result in side airbag deployment. NOTE: Diagnostics or repairs are not to be performed on a seat equipped with a seat side airbag with the seat in the vehicle. Prior to attempting to diagnose or repair a seat concern when equipped with a seat side airbag, the seat must be removed from the vehicle and the restraint system diagnostic tools must be installed in the seat side airbag electrical connectors. The restraint system diagnostic tools must be removed prior to operating the vehicle over the road. NOTE: After diagnosing or repairing an SRS, the restraint system diagnostic tools must be removed before operating the vehicle over the road. NOTE: After diagnosing or repairing a seat system, the restraint system diagnostic tools must be removed before operating the vehicle over the road. NOTE: The SRS must be fully operational and free of faults before releasing the vehicle to the customer. Key in OFF position. Deactivate the system. Refer to Airbag and Safety Belt Pretensioner Supplemental Restraint System (SRS) in the Diagnosis and Testing portion of this section. Enter the following diagnostic mode on the diagnostic tool: On-Demand Self Test Was DTC B2692 retrieved during the on-demand self test?
N9
CHECK FOR ADDITIONAL DTCs Refer to the continuous DTCs recorded during Step N1. Were any continuous DTCs retrieved during Step N1?
Yes
Do not clear any DTCs until all DTCs have been resolved. GO to the Restraints Control Module (RCM) Diagnostic Trouble Code (DTC) Table in this section for pinpoint test direction.
No
RECONNECT the system. REACTIVATE the system. PROVE OUT the system. REFER to Airbag and Safety Belt Pretensioner Supplemental Restraint System (SRS). CLEAR all DTCs.
G12345 en
01/2003 2003.0 BA Falcon
501-20b-99
Occupant Restraints — Passive
501-20b-99
DIAGNOSIS AND TESTING (Continued) Pinpoint Test O: LFC 52/DTC B2438 - Passenger Safety Belt Buckle Switch Circuit Short to Ground Normal Operation The restraints control module (RCM) checks the passenger safety belt buckle switch circuits for faults. If the RCM detects a short to ground fault, it will store diagnostic trouble code (DTC) B2438 in memory and flash lamp fault code (LFC) 52 (or higher priority code if one exists) on the airbag indicator.
Possible Causes A passenger safety belt buckle switch circuit fault can be caused by: damaged wiring, terminals, or connectors. a faulty passenger safety belt buckle switch. a faulted RCM. PINPOINT TEST O : LFC 52/DTC B2438 - PASSENGER SAFETY BELT BUCKLE SWITCH CIRCUIT SHORT TO GROUND Test Step O1
Result / Action to Take
CHECK FOR A HARD OR INTERMITTENT DTC Enter the following diagnostic mode on the diagnostic tool: Retrieve Continuous DTCs
Yes
Enter the following diagnostic mode on the diagnostic tool: On-Demand Self Test
No
This is a hard fault. The fault condition is still present. This fault cannot be cleared until it is Retrieve and record any continuous DTCs for use later in this pinpoint corrected and the DTC is no longer retrieved test. during the on-demand self test. Go to O2.
Was DTC B2438 retrieved during the on-demand self test?
G12345 en
This is an intermittent fault. The fault condition is not present at this time. Go to O5.
01/2003 2003.0 BA Falcon
501-20b-100
Occupant Restraints — Passive
501-20b-100
DIAGNOSIS AND TESTING (Continued) Test Step O2
Result / Action to Take
CHECK CIRCUIT 1514 (R/B) FOR A SHORT TO GROUND BETWEEN THE RCM AND THE PASSENGER SAFETY BELT BUCKLE SWITCH WARNING: If the supplemental restraint system (SRS) is
being serviced, the system must be deactivated and restraint system diagnostic tools must be installed. Refer to Airbag and Safety Belt Pretensioner Supplemental Restraint System (SRS) in this section. The airbag restraint system diagnostic tools must be removed and the airbag modules reconnected when the system is reactivated to avoid non-deployment in a collision, resulting in possible personal injury.
Yes
Go to O3.
No
REPAIR circuit 1514 (R/B). Go to O6.
WARNING: Never probe the connectors on the airbag module. Doing so can result in airbag deployment, which can result in personal injury. WARNING: The safety belt buckle pretensioner is a pyrotechnic device. Never probe a pretensioner electrical connector. Doing so could result in pretensioner or airbag deployment and could result in personal injury. WARNING: Never probe the electrical connector on a side airbag module. Doing so can result in side airbag deployment. NOTE: Diagnostics or repairs are not to be performed on a seat equipped with a seat side airbag with the seat in the vehicle. Prior to attempting to diagnose or repair a seat concern when equipped with a seat side airbag, the seat must be removed from the vehicle and the restraint system diagnostic tools must be installed in the seat side airbag electrical connectors. The restraint system diagnostic tools must be removed prior to operating the vehicle over the road. NOTE: After diagnosing or repairing an SRS, the restraint system diagnostic tools must be removed before operating the vehicle over the road. NOTE: After diagnosing or repairing a seat system, the restraint system diagnostic tools must be removed before operating the vehicle over the road. NOTE: The SRS must be fully operational and free of faults before releasing the vehicle to the customer. Key in OFF position. Deactivate the system. Refer to Airbag and Safety Belt Pretensioner Supplemental Restraint System (SRS) in the Diagnosis and Testing portion of this section. Key in OFF position. Disconnect Passenger Safety Belt Buckle Switch C234. Disconnect RCM C189b. Measure the resistance between RCM C189b pin 26, circuit 1514 (R/B), harness side and ground. Is the resistance greater than 1,000,000 ohms?
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01/2003 2003.0 BA Falcon
501-20b-101
Occupant Restraints — Passive
501-20b-101
DIAGNOSIS AND TESTING (Continued) Test Step O3
Result / Action to Take
CHECK THE PASSENGER SAFETY BELT BUCKLE SWITCH Yes
Connect Passenger Safety Belt Buckle Switch C234 to the safety belt buckle.
Go to O4.
Connect RCM C189b.
No
Key in ON position.
INSTALL a new passenger safety belt buckle and pretensioner assembly. Go to O6.
NOTE: With the safety belt buckled, the current should measure 11.0-19.4 mA. With the safety belt unbuckled, the current should measure 3.9-6.9 mA.
Measure the current flow from the passenger safety belt buckle switch C234, circuit 1514 (R/B), harness side to component side, with the safety belt buckled and again unbuckled. Is the current between 11.0-19.4 mA with the safety belt buckled and between 3.9-6.9 mA with the safety belt unbuckled?
O4
CONFIRM THE RCM FAULT NOTE: Make sure all restraint system diagnostic tools, sensor electrical connectors, and the RCM electrical connector are connected before carrying out the on-demand self test. If not, erroneous DTCs will be recorded. Connect Passenger Safety Belt Buckle Switch C234.
Yes
INSTALL a new RCM. REFER to Restraints Control Module (RCM) in this section. Go to O6.
No
Fault corrected. Go to O6.
Enter the following diagnostic mode on the diagnostic tool: On-Demand Self Test Was DTC B2438 retrieved during the on-demand self test?
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01/2003 2003.0 BA Falcon
501-20b-102
Occupant Restraints — Passive
501-20b-102
DIAGNOSIS AND TESTING (Continued) Test Step O5
Result / Action to Take
CHECK FOR AN INTERMITTENT FAULT WARNING: If the supplemental restraint system (SRS) is
being serviced, the system must be deactivated and restraint system diagnostic tools must be installed. Refer to Airbag and Safety Belt Pretensioner Supplemental Restraint System (SRS) in this section. The airbag restraint system diagnostic tools must be removed and the airbag modules reconnected when the system is reactivated to avoid non-deployment in a collision, resulting in possible personal injury.
Yes
Go to O2.
No
CHECK for causes of the intermittent fault. ATTEMPT to recreate the hard fault by flexing the wire harness and cycling the ignition key frequently. REPAIR any intermittent concerns found. Go to O6.
WARNING: Never probe the connectors on the airbag module. Doing so can result in airbag deployment, which can result in personal injury. WARNING: The safety belt buckle pretensioner is a pyrotechnic device. Never probe a pretensioner electrical connector. Doing so could result in pretensioner or airbag deployment and could result in personal injury. WARNING: Never probe the electrical connector on a side airbag module. Doing so can result in side airbag deployment. NOTE: Diagnostics or repairs are not to be performed on a seat equipped with a seat side airbag with the seat in the vehicle. Prior to attempting to diagnose or repair a seat concern when equipped with a seat side airbag, the seat must be removed from the vehicle and the restraint system diagnostic tools must be installed in the seat side airbag electrical connectors. The restraint system diagnostic tools must be removed prior to operating the vehicle over the road. NOTE: After diagnosing or repairing an SRS, the restraint system diagnostic tools must be removed before operating the vehicle over the road. NOTE: After diagnosing or repairing a seat system, the restraint system diagnostic tools must be removed before operating the vehicle over the road. NOTE: The SRS must be fully operational and free of faults before releasing the vehicle to the customer. Key in OFF position. Deactivate the system. Do not remove the seat at this time. Refer to Airbag and Safety Belt Pretensioner Supplemental Restraint System (SRS) in the Diagnosis and Testing portion of this section. Enter the following diagnostic mode on the diagnostic tool: On-Demand Self Test Was DTC B2438 retrieved during the on-demand self test?
O6
CHECK FOR ADDITIONAL DTCs Refer to the continuous DTCs recorded during Step O1. Were any continuous DTCs retrieved during Step O1?
Yes
Do not clear any DTCs until all DTCs have been resolved. GO to the Restraints Control Module (RCM) Diagnostic Trouble Code (DTC) Table in this section for pinpoint test direction.
No
RECONNECT the system. REACTIVATE the system. PROVE OUT the system. REFER to Airbag and Safety Belt Pretensioner Supplemental Restraint System (SRS). CLEAR all DTCs.
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01/2003 2003.0 BA Falcon
501-20b-103
Occupant Restraints — Passive
501-20b-103
DIAGNOSIS AND TESTING (Continued) Pinpoint Test P: LFC 52/DTC B2439 Passenger Safety Belt Buckle Switch Resistance Out of Range Normal Operation The restraints control module (RCM) checks the passenger safety belt buckle switch circuits for faults. If the RCM detects a current out of range fault, it will store diagnostic trouble code (DTC) B2439 in memory and flash lamp fault code (LFC) 52 (or higher priority code if one exists) on the airbag indicator.
Possible Causes A passenger safety belt buckle switch current out of range fault can be caused by: damaged wiring, terminals, or connectors. a faulty passenger safety belt buckle switch. a faulted RCM. PINPOINT TEST P : LFC 52/DTC B2439 - PASSENGER SAFETY BELT BUCKLE SWITCH RESISTANCE OUT OF RANGE Test Step P1
Result / Action to Take
CHECK FOR A HARD OR INTERMITTENT DTC Enter the following diagnostic mode on the diagnostic tool: Retrieve Continuous DTCs
Yes
Enter the following diagnostic mode on the diagnostic tool: On-Demand Self Test
No
This is a hard fault. The fault condition is still present. This fault cannot be cleared until it is Retrieve and record any continuous DTCs for use later in this pinpoint corrected and the DTC is no longer retrieved test. during the on-demand self test. Go to P2.
Was DTC B2439 retrieved during the on-demand self test?
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This is an intermittent fault. The fault condition is not present at this time. Go to P6.
01/2003 2003.0 BA Falcon
501-20b-104
Occupant Restraints — Passive
501-20b-104
DIAGNOSIS AND TESTING (Continued) Test Step P2
Result / Action to Take
CHECK CIRCUIT 1514 (R/B) FOR AN OPEN BETWEEN THE RCM AND THE PASSENGER SAFETY BELT BUCKLE SWITCH WARNING: If the supplemental restraint system (SRS) is
being serviced, the system must be deactivated and restraint system diagnostic tools must be installed. Refer to Airbag and Safety Belt Pretensioner Supplemental Restraint System (SRS) in this section. The airbag restraint system diagnostic tools must be removed and the airbag modules reconnected when the system is reactivated to avoid non-deployment in a collision, resulting in possible personal injury.
Yes
Go to P3.
No
REPAIR circuit 1514 (R/B). Go to P7.
WARNING: Never probe the connectors on the airbag module. Doing so can result in airbag deployment, which can result in personal injury. WARNING: The safety belt buckle pretensioner is a pyrotechnic device. Never probe a pretensioner electrical connector. Doing so could result in pretensioner or airbag deployment and could result in personal injury. WARNING: Never probe the electrical connector on a side airbag module. Doing so can result in side airbag deployment. NOTE: Diagnostics or repairs are not to be performed on a seat equipped with a seat side airbag with the seat in the vehicle. Prior to attempting to diagnose or repair a seat concern when equipped with a seat side airbag, the seat must be removed from the vehicle and the restraint system diagnostic tools must be installed in the seat side airbag electrical connectors. The restraint system diagnostic tools must be removed prior to operating the vehicle over the road. NOTE: After diagnosing or repairing an SRS, the restraint system diagnostic tools must be removed before operating the vehicle over the road. NOTE: After diagnosing or repairing a seat system, the restraint system diagnostic tools must be removed before operating the vehicle over the road. NOTE: The SRS must be fully operational and free of faults before releasing the vehicle to the customer. Key in OFF position. Deactivate the system. Refer to Airbag and Safety Belt Pretensioner Supplemental Restraint System (SRS) in the Diagnosis and Testing portion of this section. Key in OFF position. Disconnect RCM C189b. Disconnect Passenger Safety Belt Buckle Switch C234. Measure the resistance between RCM C189b pin 26, circuit 1514 (R/B), harness side and passenger safety belt buckle switch C234, circuit 1514 (R/B), harness side. Is the resistance less than 0.5 ohm?
P3
CHECK CIRCUIT 1203 (BK) FOR AN OPEN Yes
Measure the resistance between passenger safety belt buckle switch C234, circuit 1203 (BK), harness side and ground.
Go to P4.
Is the resistance less than 0.5 ohm?
No
REPAIR circuit 1203 (BK). Go to P7.
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01/2003 2003.0 BA Falcon
501-20b-105
Occupant Restraints — Passive
501-20b-105
DIAGNOSIS AND TESTING (Continued) Test Step P4
Result / Action to Take
CHECK THE SAFETY BELT BUCKLE SWITCH Yes
Connect Passenger Safety Belt Buckle Switch C234 to the safety belt buckle.
Go to P5.
Connect RCM C189b.
No
Key in ON position.
INSTALL a new passenger safety belt buckle and pretensioner assembly. Go to P7.
NOTE: With the safety belt buckled, the current should measure 11.0-19.4 mA. With the safety belt unbuckled, the current should measure 3.9-6.9 mA.
Measure the current flow from the passenger safety belt buckle switch C234, circuit 1514 (R/B), harness side to component side, with the safety belt buckled and again unbuckled. Is the current between 11.0-19.4 mA with the safety belt buckled and between 3.9-6.9 mA with the safety belt unbuckled?
P5
CONFIRM THE RCM FAULT NOTE: Make sure all restraint system diagnostic tools, sensor electrical
connectors, and the RCM electrical connector are connected before carrying out the on-demand self test. If not, erroneous DTCs will be recorded. Key in OFF position.
Yes
INSTALL a new RCM. REFER to Restraints Control Module (RCM) in this section. Go to P7.
No
Fault corrected. Go to P7.
Connect Passenger Safety Belt Buckle Switch C234. Connect RCM C189b. Enter the following diagnostic mode on the diagnostic tool: On-Demand Self Test Was DTC B2439 retrieved during the on-demand self test?
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01/2003 2003.0 BA Falcon
501-20b-106
Occupant Restraints — Passive
501-20b-106
DIAGNOSIS AND TESTING (Continued) Test Step P6
Result / Action to Take
CHECK FOR AN INTERMITTENT FAULT WARNING: If the supplemental restraint system (SRS) is
being serviced, the system must be deactivated and restraint system diagnostic tools must be installed. Refer to Airbag and Safety Belt Pretensioner Supplemental Restraint System (SRS) in this section. The airbag restraint system diagnostic tools must be removed and the airbag modules reconnected when the system is reactivated to avoid non-deployment in a collision, resulting in possible personal injury.
Yes
Go to P2.
No
CHECK for causes of the intermittent fault. ATTEMPT to recreate the hard fault by flexing the wire harness and cycling the ignition key frequently. REPAIR any intermittent concerns found. Go to P7.
WARNING: Never probe the connectors on the airbag module. Doing so can result in airbag deployment, which can result in personal injury. WARNING: The safety belt buckle pretensioner is a pyrotechnic device. Never probe a pretensioner electrical connector. Doing so could result in pretensioner or airbag deployment and could result in personal injury. WARNING: Never probe the electrical connector on a side airbag module. Doing so can result in side airbag deployment. NOTE: Diagnostics or repairs are not to be performed on a seat equipped with a seat side airbag with the seat in the vehicle. Prior to attempting to diagnose or repair a seat concern when equipped with a seat side airbag, the seat must be removed from the vehicle and the restraint system diagnostic tools must be installed in the seat side airbag electrical connectors. The restraint system diagnostic tools must be removed prior to operating the vehicle over the road. NOTE: After diagnosing or repairing an SRS, the restraint system diagnostic tools must be removed before operating the vehicle over the road. NOTE: After diagnosing or repairing a seat system, the restraint system diagnostic tools must be removed before operating the vehicle over the road. NOTE: The SRS must be fully operational and free of faults before releasing the vehicle to the customer. Key in OFF position. Deactivate the system. Refer to Airbag and Safety Belt Pretensioner Supplemental Restraint System (SRS) in the Diagnosis and Testing portion of this section. Enter the following diagnostic mode on the diagnostic tool: On-Demand Self Test Was DTC B2439 retrieved during the on-demand self test?
P7
CHECK FOR ADDITIONAL DTCs Refer to the continuous DTCs recorded during Step P1. Were any continuous DTCs retrieved during Step P1?
Yes
Do not clear any DTCs until all DTCs have been resolved. GO to the Restraints Control Module (RCM) Diagnostic Trouble Code (DTC) Table in this section for pinpoint test direction.
No
RECONNECT the system. REACTIVATE the system. PROVE OUT the system. REFER to Airbag and Safety Belt Pretensioner Supplemental Restraint System (SRS) in this section. CLEAR all DTCs.
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01/2003 2003.0 BA Falcon
501-20b-107
Occupant Restraints — Passive
501-20b-107
DIAGNOSIS AND TESTING (Continued) Pinpoint Test Q: LFC 15/DTC C1414 Incorrect Vehicle ID Normal Operation The restraint control module (RCM) monitors the electrical condition at C189a pins 20 and 21 to detect the vehicle identification code. The RCM compares the pin state with a preprogrammed code. If the RCM detects an unexpected condition at either of these pins, it will store diagnostic trouble code (DTC) C1414 in memory and flash lamp fault code (LFC) 15 (or higher priority code if one exist) on the airbag indicator.
Possible Causes An incorrect vehicle identification code can be caused by: incorrect RCM for vehicle. a wiring concern at RCM C189a pins 20 or 21. a faulted RCM. PINPOINT TEST Q : LFC 15/DTC C1414 - INCORRECT VEHICLE ID Test Step Q1
Result / Action to Take
CHECK FOR A HARD OR INTERMITTENT DTC Enter the following diagnostic mode on the diagnostic tool: Retrieve Continuous DTCs
Yes
Enter the following diagnostic mode on the diagnostic tool: On-Demand Self Test
No
This is a hard fault. The fault condition is still present. This fault cannot be cleared until it is Retrieve and record any continuous DTCs for use later in this pinpoint corrected and the DTC is no longer retrieved test. during the on-demand self test. Go to Q2.
Was DTC C1414 retrieved during the on-demand self test?
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This is an intermittent fault. The fault condition is not present at this time. Go to Q6.
01/2003 2003.0 BA Falcon
501-20b-108
Occupant Restraints — Passive
501-20b-108
DIAGNOSIS AND TESTING (Continued) Test Step Q2
Result / Action to Take
CHECK THE VEHICLE IDENTIFICATION PIN NO. 21 WARNING: If the supplemental restraint system (SRS) is
being serviced, the system must be deactivated and restraint system diagnostic tools must be installed. Refer to Airbag and Safety Belt Pretensioner Supplemental Restraint System (SRS) in this section. The airbag restraint system diagnostic tools must be removed and the airbag modules reconnected when the system is reactivated to avoid non-deployment in a collision, resulting in possible personal injury.
Yes
DETERMINE the cause of incorrect harness configuration. REPAIR as necessary. Go to Q7.
No
Go to Q3.
WARNING: Never probe the connectors on the airbag module. Doing so can result in airbag deployment, which can result in personal injury. WARNING: The safety belt buckle pretensioner is a pyrotechnic device. Never probe a pretensioner electrical connector. Doing so could result in pretensioner or airbag deployment and could result in personal injury. WARNING: Never probe the electrical connector on a side airbag module. Doing so can result in side airbag deployment. NOTE: Diagnostics or repairs are not to be performed on a seat equipped with a seat side airbag with the seat in the vehicle. Prior to attempting to diagnose or repair a seat concern when equipped with a seat side airbag, the seat must be removed from the vehicle and the restraint system diagnostic tools must be installed in the seat side airbag electrical connectors. The restraint system diagnostic tools must be removed prior to operating the vehicle over the road. NOTE: After diagnosing or repairing an SRS, the restraint system diagnostic tools must be removed before operating the vehicle over the road. NOTE: After diagnosing or repairing a seat system, the restraint system diagnostic tools must be removed before operating the vehicle over the road. NOTE: The SRS must be fully operational and free of faults before releasing the vehicle to the customer. NOTE: For this application, RCM C189a pin 21 must have no connection. Key in OFF position. Deactivate the system. Refer to Airbag and Safety Belt Pretensioner Supplemental Restraint System (SRS) in the Diagnosis and Testing portion of this section. Disconnect RCM C189a. Inspect C189a harness side. Make sure there is no wire attached to pin cavity 21. Is a wire attached at C189a pin cavity 21?
Q3
CHECK FOR GROUND AT THE VEHICLE IDENTIFICATION PIN 20 CIRCUIT 1203 (B/G) NOTE: For this application, RCM C189a pin 20 must have ignition voltage.
Key in ON position. Measure the resistance between RCM C189a pin 20, circuit 1203 (B/G), harness side and ground,
Yes
Go to Q4.
No
REPAIR circuit 1203 (B/G). Go to Q7.
Is the resistance less than 0.5 ohm?
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01/2003 2003.0 BA Falcon
501-20b-109
Occupant Restraints — Passive
501-20b-109
DIAGNOSIS AND TESTING (Continued) Test Step Q4
Q5
Result / Action to Take
CHECK THE RCM PART NUMBER Check the part number on the RCM against the part number listed in the master parts catalog.
Yes
Did the part number on the RCM match the part number listed in the master parts catalog?
No
Go to Q5.
INSTALL a new RCM with the correct part number. Go to Q7.
CONFIRM THE RCM FAULT NOTE: Make sure all restraint system diagnostic tools, sensor electrical connectors, and the RCM electrical connector are connected before carrying out the on-demand self test. If not, erroneous DTCs will be recorded.
Yes
INSTALL a new RCM. Go to Q7.
No
Fault corrected. Go to Q7.
Key in OFF position. Connect RCM C189a. Enter the following diagnostic mode on the diagnostic tool: On-Demand Self Test Was DTC C1414 retrieved during the on-demand self test?
Q6
CHECK FOR INTERMITTENT FAULTS Yes
Refer to the continuous DTCs recorded during Step Q1. Was the continuous DTC retrieved during Step Q1 an intermittent fault?
Go to Q2.
No
CHECK for causes of the intermittent fault. ATTEMPT to recreate the hard fault by flexing the wire harness and cycling the ignition key frequently. REPAIR any intermittent concerns found. Go to Q7.
Q7
CHECK FOR ADDITIONAL DTCs Refer to the continuous DTCs recorded during Step Q1. Were any continuous DTCs retrieved during Step Q1?
Yes
Do not clear any DTCs until all DTCs have been resolved. GO to the Restraints Control Module (RCM) Diagnostic Trouble Code (DTC) Table in this section for pinpoint test direction.
No
RECONNECT the system. REACTIVATE the system. PROVE OUT the system. REFER to Airbag and Safety Belt Pretensioner Supplemental Restraint System (SRS) in this section. CLEAR all DTCs.
Pinpoint Test R: LFC 49/DTC C1947 - Seat Possible Causes Track Position Sensor Circuit Short to A driver seat track position sensor short to ground Ground fault can be caused by: Normal Operation The restraints control module (RCM) monitors the driver seat track position sensor circuits. If the RCM detects a short to ground, it will store diagnostic trouble code (DTC) C1947 in memory and flash lamp fault code (LFC) 49 (or higher priority code if one exists) on the airbag indicator.
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damaged wiring, terminals, or connectors. a faulty driver seat track position sensor. a faulted RCM.
01/2003 2003.0 BA Falcon
501-20b-110
Occupant Restraints — Passive
501-20b-110
DIAGNOSIS AND TESTING (Continued) PINPOINT TEST R : LFC 49/DTC C1947 - SEAT TRACK POSITION SENSOR CIRCUIT SHORT TO GROUND Test Step R1
Result / Action to Take
CHECK FOR A HARD OR INTERMITTENT DTC Enter the following diagnostic mode on the diagnostic tool: Retrieve Continuous DTCs
Yes
Enter the following diagnostic mode on the diagnostic tool: On-Demand Self Test
No
This is a hard fault. The fault condition is still present. This fault cannot be cleared until it is Retrieve and record any continuous DTCs for use later in this pinpoint corrected and the DTC is no longer retrieved test. during the on-demand self test. Go to R2.
Was DTC C1947 retrieved during the on-demand self test?
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This is an intermittent fault. The fault condition is not present at this time. Go to R5.
01/2003 2003.0 BA Falcon
501-20b-111
Occupant Restraints — Passive
501-20b-111
DIAGNOSIS AND TESTING (Continued) Test Step R2
Result / Action to Take
CHECK CIRCUIT 8107 (BR/G) AND CIRCUIT 8108 (B/O) FOR A SHORT TO GROUND BETWEEN THE RCM AND THE DRIVER SEAT WARNING: If the supplemental restraint system (SRS) is
being serviced, the system must be deactivated and restraint system diagnostic tools must be installed. Refer to Airbag and Safety Belt Pretensioner Supplemental Restraint System (SRS) in this section. The airbag restraint system diagnostic tools must be removed and the airbag modules reconnected when the system is reactivated to avoid non-deployment in a collision, resulting in possible personal injury.
Yes
Go to R3.
No
REPAIR circuit 8107 (BR/G) or circuit 8108 (B/O). Go to R6.
WARNING: Never probe the connectors on the airbag module. Doing so can result in airbag deployment, which can result in personal injury. WARNING: The safety belt buckle pretensioner is a pyrotechnic device. Never probe a pretensioner electrical connector. Doing so could result in pretensioner or airbag deployment and could result in personal injury. WARNING: Never probe the electrical connector on a side airbag module. Doing so can result in side airbag deployment. NOTE: Diagnostics or repairs are not to be performed on a seat equipped with a seat side airbag with the seat in the vehicle. Prior to attempting to diagnose or repair a seat concern when equipped with a seat side airbag, the seat must be removed from the vehicle and the restraint system diagnostic tools must be installed in the seat side airbag electrical connectors. The restraint system diagnostic tools must be removed prior to operating the vehicle over the road. NOTE: After diagnosing or repairing an SRS, the restraint system
diagnostic tools must be removed before operating the vehicle over the road.
NOTE: After diagnosing or repairing a seat system, the restraint system diagnostic tools must be removed before operating the vehicle over the road. NOTE: The SRS must be fully operational and free of faults before releasing the vehicle to the customer. Key in OFF position. Deactivate the system. Refer to Airbag and Safety Belt Pretensioner Supplemental Restraint System (SRS) in the Diagnosis and Testing portion of this section. Key in OFF position. Disconnect RCM C189b. Disconnect Seat Track Position Sensor C72. Measure the resistance between RCM C189b pin 23, circuit 8107 (BR/G), harness side and ground; and between pin 24, circuit 8108 (B/O), harness side and ground. Are the resistances greater than 1,000,000 ohms?
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01/2003 2003.0 BA Falcon
501-20b-112
Occupant Restraints — Passive
501-20b-112
DIAGNOSIS AND TESTING (Continued) Test Step R3
Result / Action to Take
CHECK THE SEAT TRACK POSITION SENSOR Connect RCM C189a. Install a known good seat track position sensor. Enter the following diagnostic mode on the diagnostic tool: On-Demand Self Test
Yes
Go to R4.
No
Fault corrected. Go to R6.
Was DTC C1947 retrieved during the on-demand self test?
R4
CONFIRM THE RCM FAULT NOTE: Make sure all restraint system diagnostic tools, sensor electrical connectors, and the RCM electrical connector are connected before carrying out the on-demand self test. If not, erroneous DTCs will be recorded. Key in OFF position.
Yes
INSTALL a new RCM. REFER to Restraints Control Module (RCM) in this section. Go to R6.
No
Fault corrected. Go to R6.
Reinstall the original seat track position sensor. Connect Seat Track Position Sensor C72. Key in ON position. Enter the following diagnostic mode on the diagnostic tool: On-Demand Self Test Was DTC C1947 retrieved during the on-demand self test?
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01/2003 2003.0 BA Falcon
501-20b-113
Occupant Restraints — Passive
501-20b-113
DIAGNOSIS AND TESTING (Continued) Test Step R5
Result / Action to Take
CHECK FOR AN INTERMITTENT FAULT WARNING: If the supplemental restraint system (SRS) is
being serviced, the system must be deactivated and restraint system diagnostic tools must be installed. Refer to Airbag and Safety Belt Pretensioner Supplemental Restraint System (SRS) in this section. The airbag restraint system diagnostic tools must be removed and the airbag modules reconnected when the system is reactivated to avoid non-deployment in a collision, resulting in possible personal injury.
Yes
Go to R2.
No
CHECK for causes of the intermittent fault. ATTEMPT to recreate the hard fault by flexing the wire harness and cycling the ignition key frequently. REPAIR any intermittent concerns found. Go to R6.
WARNING: Never probe the connectors on the airbag module. Doing so can result in airbag deployment, which can result in personal injury. WARNING: The safety belt buckle pretensioner is a pyrotechnic device. Never probe a pretensioner electrical connector. Doing so could result in pretensioner or airbag deployment and could result in personal injury. WARNING: Never probe the electrical connector on a side airbag module. Doing so can result in side airbag deployment. NOTE: Diagnostics or repairs are not to be performed on a seat equipped with a seat side airbag with the seat in the vehicle. Prior to attempting to diagnose or repair a seat concern when equipped with a seat side airbag, the seat must be removed from the vehicle and the restraint system diagnostic tools must be installed in the seat side airbag electrical connectors. The restraint system diagnostic tools must be removed prior to operating the vehicle over the road. NOTE: After diagnosing or repairing an SRS, the restraint system
diagnostic tools must be removed before operating the vehicle over the road.
NOTE: After diagnosing or repairing a seat system, the restraint system diagnostic tools must be removed before operating the vehicle over the road. NOTE: The SRS must be fully operational and free of faults before releasing the vehicle to the customer. Key in OFF position. Deactivate the system. Refer to Airbag and Safety Belt Pretensioner Supplemental Restraint System (SRS) in the Diagnosis and Testing portion of this section. Enter the following diagnostic mode on the diagnostic tool: On-Demand Self Test Was DTC C1947 retrieved during the on-demand self test?
R6
CHECK FOR ADDITIONAL DTCs Refer to the continuous DTCs recorded during Step R1. Were any continuous DTCs retrieved during Step R1?
Yes
Do not clear any DTCs until all DTCs have been resolved. GO to the Restraints Control Module (RCM) Diagnostic Trouble Code (DTC) Table in this section for pinpoint test direction.
No
RECONNECT the system. REACTIVATE the system. PROVE OUT the system. REFER to Airbag and Safety Belt Pretensioner Supplemental Restraint System (SRS) in this section. CLEAR all DTCs.
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01/2003 2003.0 BA Falcon
501-20b-114
Occupant Restraints — Passive
501-20b-114
DIAGNOSIS AND TESTING (Continued) Pinpoint Test S: LFC 49/DTC C1948 - Seat Track Position Sensor Circuit Resistance Out of Range NOTE: Due to the seat track position sensor being a Hall-effect type sensor, this pinpoint test will be diagnosing a current out of range fault instead of the current DTC definition for a resistance out of range fault.
Normal Operation The restraints control module (RCM) monitors the driver seat track position sensor circuits. If the RCM detects a current out of range condition, it will store diagnostic trouble code (DTC) C1948 in memory and flash lamp fault code (LFC) 49 (or higher priority code if one exists) on the airbag indicator.
Possible Causes A driver safety belt buckle and pretensioner switch current out of range fault can be caused by: damaged wiring, terminals, or connectors. a faulty driver seat track position sensor. a faulted RCM. PINPOINT TEST S : LFC 49/DTC C1948 - SEAT TRACK POSITION SENSOR CIRCUIT RESISTANCE OUT OF RANGE Test Step S1
Result / Action to Take
CHECK FOR A HARD OR INTERMITTENT DTC Enter the following diagnostic mode on the diagnostic tool: Retrieve Continuous DTCs
Yes
Enter the following diagnostic mode on the diagnostic tool: On-Demand Self Test
No
This is a hard fault. The fault condition is still present. This fault cannot be cleared until it is Retrieve and record any continuous DTCs for use later in this pinpoint corrected and the DTC is no longer retrieved test. during the on-demand self test. Go to S2.
Was DTC C1948 retrieved during the on-demand self test?
G12345 en
This is an intermittent fault. The fault condition is not present at this time. Go to S6.
01/2003 2003.0 BA Falcon
501-20b-115
Occupant Restraints — Passive
501-20b-115
DIAGNOSIS AND TESTING (Continued) Test Step S2
Result / Action to Take
CHECK CIRCUIT 8107 (BR/G) FOR AN OPEN WARNING: If the supplemental restraint system (SRS) is
being serviced, the system must be deactivated and restraint system diagnostic tools must be installed. Refer to Airbag and Safety Belt Pretensioner Supplemental Restraint System (SRS) in this section. The airbag restraint system diagnostic tools must be removed and the airbag modules reconnected when the system is reactivated to avoid non-deployment in a collision, resulting in possible personal injury.
Yes
Go to S3.
No
REPAIR circuit 8107 (BR/G). Go to S7.
WARNING: Never probe the connectors on the airbag module. Doing so can result in airbag deployment, which can result in personal injury. WARNING: The safety belt buckle pretensioner is a pyrotechnic device. Never probe a pretensioner electrical connector. Doing so could result in pretensioner or airbag deployment and could result in personal injury. WARNING: Never probe the electrical connector on a side airbag module. Doing so can result in side airbag deployment. NOTE: Diagnostics or repairs are not to be performed on a seat equipped with a seat side airbag with the seat in the vehicle. Prior to attempting to diagnose or repair a seat concern when equipped with a seat side airbag, the seat must be removed from the vehicle and the restraint system diagnostic tools must be installed in the seat side airbag electrical connectors. The restraint system diagnostic tools must be removed prior to operating the vehicle over the road. NOTE: After diagnosing or repairing an SRS, the restraint system
diagnostic tools must be removed before operating the vehicle over the road.
NOTE: After diagnosing or repairing a seat system, the restraint system diagnostic tools must be removed before operating the vehicle over the road. NOTE: The SRS must be fully operational and free of faults before releasing the vehicle to the customer. Key in OFF position. Deactivate the system. Refer to Airbag and Safety Belt Pretensioner Supplemental Restraint System (SRS) in the Diagnosis and Testing portion of this section. Key in OFF position. Disconnect RCM C189a. Disconnect Seat Track Position Sensor C72. Measure the resistance between RCM C189b pin 23, circuit 8107 (BR/G), harness side and driver seat track position sensor C72, circuit 8107 (BR/G), harness side. Is the resistance less than 0.5 ohm?
S3
CHECK CIRCUIT 8108 (B/O) FOR AN OPEN
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Measure the resistance between RCM C189b pin 24, circuit 8108 (B/O), harness side and driver seat track position sensor C72, circuit 8108 (B/O), harness side.
Yes
Is the resistance less than 0.5 ohm?
REPAIR circuit 8108 (B/O). Go to S7.
Go to S4.
No
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DIAGNOSIS AND TESTING (Continued) Test Step S4
Result / Action to Take
CHECK THE SEAT TRACK POSITION SENSOR Connect RCM C189a. Install a known good seat track position sensor. Connect Seat Track Position Sensor C72. Key in ON position.
Yes
Go to S5.
No
Fault corrected. Go to S7.
Enter the following diagnostic mode on the diagnostic tool: On-Demand Self Test Was DTC C1948 retrieved during the on-demand self test?
S5
CONFIRM THE RCM FAULT NOTE: Make sure all restraint system diagnostic tools, sensor electrical
connectors, and the RCM electrical connector are connected before carrying out the on-demand self test. If not, erroneous DTCs will be recorded. Key in OFF position.
Yes
INSTALL a new RCM. REFER to Restraints Control Module (RCM). Go to S7.
No
Fault corrected. Go to S7.
Reinstall the original seat track position sensor. Connect Seat Track Position Sensor C72. Key in ON position. Enter the following diagnostic mode on the diagnostic tool: On-Demand Self Test Was DTC C1948 retrieved during the on-demand self test?
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DIAGNOSIS AND TESTING (Continued) Test Step S6
Result / Action to Take
CHECK FOR AN INTERMITTENT FAULT WARNING: If the supplemental restraint system (SRS) is
being serviced, the system must be deactivated and restraint system diagnostic tools must be installed. Refer to Airbag and Safety Belt Pretensioner Supplemental Restraint System (SRS) in this section. The airbag restraint system diagnostic tools must be removed and the airbag modules reconnected when the system is reactivated to avoid non-deployment in a collision, resulting in possible personal injury.
Yes
Go to S2.
No
CHECK for causes of the intermittent fault. ATTEMPT to recreate the hard fault by flexing the wire harness and cycling the ignition key frequently. REPAIR any intermittent concerns found. Go to S7.
WARNING: Never probe the connectors on the airbag module. Doing so can result in airbag deployment, which can result in personal injury. WARNING: The safety belt buckle pretensioner is a pyrotechnic device. Never probe a pretensioner electrical connector. Doing so could result in pretensioner or airbag deployment and could result in personal injury. WARNING: Never probe the electrical connector on a side airbag module. Doing so can result in side airbag deployment. NOTE: Diagnostics or repairs are not to be performed on a seat equipped with a seat side airbag with the seat in the vehicle. Prior to attempting to diagnose or repair a seat concern when equipped with a seat side airbag, the seat must be removed from the vehicle and the restraint system diagnostic tools must be installed in the seat side airbag electrical connectors. The restraint system diagnostic tools must be removed prior to operating the vehicle over the road. NOTE: After diagnosing or repairing an SRS, the restraint system
diagnostic tools must be removed before operating the vehicle over the road.
NOTE: After diagnosing or repairing a seat system, the restraint system diagnostic tools must be removed before operating the vehicle over the road. NOTE: The SRS must be fully operational and free of faults before releasing the vehicle to the customer. Key in OFF position. Deactivate the system. Refer to Airbag and Safety Belt Pretensioner Supplemental Restraint System (SRS) in the Diagnosis and Testing portion of this section. Enter the following diagnostic mode on the diagnostic tool: On-Demand Self Test Was DTC C1948 retrieved during the on-demand self test?
S7
CHECK FOR ADDITIONAL DTCs Refer to the continuous DTCs recorded during Step S1. Were any continuous DTCs retrieved during Step S1?
Yes
Do not clear any DTCs until all DTCs have been resolved. GO to the Restraints Control Module (RCM) Diagnostic Trouble Code (DTC) Table in this section for pinpoint test direction.
No
RECONNECT the system. REACTIVATE the system. PROVE OUT the system. REFER to Airbag and Safety Belt Pretensioner Supplemental Restraint System (SRS). CLEAR all DTCs.
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DIAGNOSIS AND TESTING (Continued) Pinpoint Test T: LFC 49/DTC C1982 - Seat Track Position Sensor Circuit Fault Normal Operation The restraints control module (RCM) monitors the driver seat track position sensor circuits. If the RCM detects a open or short to battery, it will store diagnostic trouble code (DTC) C1982 in memory and flash lamp fault code (LFC) 49 (or higher priority code if one exists) on the airbag indicator.
Possible Causes A driver seat track position sensor open circuit or short to battery fault can be caused by: damaged wiring, terminals, or connectors. a faulted RCM. PINPOINT TEST T : LFC 49/DTC C1982 - SEAT TRACK POSITION SENSOR CIRCUIT FAULT Test Step T1
Result / Action to Take
CHECK FOR A HARD OR INTERMITTENT DTC Enter the following diagnostic mode on the diagnostic tool: Retrieve Continuous DTCs
Yes
Enter the following diagnostic mode on the diagnostic tool: On-Demand Self Test
No
This is a hard fault. The fault condition is still present. This fault cannot be cleared until it is Retrieve and record any continuous DTCs for use later in this pinpoint corrected and the DTC is no longer retrieved test. during the on-demand self test. Go to T2.
Was DTC C1982 retrieved during the on-demand self test?
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This is an intermittent fault. The fault condition is not present at this time. Go to T6.
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DIAGNOSIS AND TESTING (Continued) Test Step T2
Result / Action to Take
CHECK CIRCUIT 8107 (BR/G) FOR AN OPEN WARNING: If the supplemental restraint system (SRS) is
being serviced, the system must be deactivated and restraint system diagnostic tools must be installed. Refer to Airbag and Safety Belt Pretensioner Supplemental Restraint System (SRS) in this section. The airbag restraint system diagnostic tools must be removed and the airbag modules reconnected when the system is reactivated to avoid non-deployment in a collision, resulting in possible personal injury.
Yes
Go to T3.
No
REPAIR circuit 8107 (BR/G). Go to T7.
WARNING: Never probe the connectors on the airbag module. Doing so can result in airbag deployment, which can result in personal injury. WARNING: The safety belt buckle pretensioner is a pyrotechnic device. Never probe a pretensioner electrical connector. Doing so could result in pretensioner or airbag deployment and could result in personal injury. WARNING: Never probe the electrical connector on a side airbag module. Doing so can result in side airbag deployment. NOTE: Diagnostics or repairs are not to be performed on a seat equipped with a seat side airbag with the seat in the vehicle. Prior to attempting to diagnose or repair a seat concern when equipped with a seat side airbag, the seat must be removed from the vehicle and the restraint system diagnostic tools must be installed in the seat side airbag electrical connectors. The restraint system diagnostic tools must be removed prior to operating the vehicle over the road. NOTE: After diagnosing or repairing an SRS, the restraint system
diagnostic tools must be removed before operating the vehicle over the road.
NOTE: After diagnosing or repairing a seat system, the restraint system diagnostic tools must be removed before operating the vehicle over the road. NOTE: The SRS must be fully operational and free of faults before releasing the vehicle to the customer. Key in OFF position. Deactivate the system. Refer to Airbag and Safety Belt Pretensioner Supplemental Restraint System (SRS) in the Diagnosis and Testing portion of this section. Key in OFF position. Disconnect RCM C189a. Disconnect Seat Track Position Sensor C72. Measure the resistance between RCM C189b pin 23, circuit 8107 (BR/G), harness side and driver seat track position sensor C72, circuit 8107 (BR/G), harness side. Is the resistance less than 0.5 ohm?
T3
CHECK CIRCUIT 8108 (B/O) FOR AN OPEN
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Measure the resistance between RCM C189b pin 24, circuit 8108 (B/O), harness side and driver seat track position sensor C72, circuit 8108 (B/O), harness side.
Yes
Is the resistance less than 0.5 ohm?
REPAIR circuit 8108 (B/O). Go to T7.
Go to T4.
No
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DIAGNOSIS AND TESTING (Continued) Test Step T4
CHECK CIRCUITS 8107 (BR/G) AND 8108 (B/O) FOR A SHORT TO VOLTAGE Key in ON position. Measure the voltage between RCM C189b pin 23, circuit 8107 (BR/G), harness side and ground; and between pin 24, circuit 8108 (B/O), harness side and ground. Are the voltages less than 0.2 volt?
T5
Result / Action to Take
Yes
Go to T5.
No
REPAIR circuit 8107 (BR/G) or circuit 8108 (B/O). Go to T7.
CONFIRM THE RCM FAULT NOTE: Make sure all restraint system diagnostic tools, sensor electrical connectors, and the RCM electrical connector are connected before carrying out the on-demand self test. If not, erroneous DTCs will be recorded. Key in OFF position.
Yes
INSTALL a new RCM. REFER to Restraints Control Module (RCM) in this section. Go to T7.
No
Fault corrected. Go to T7.
Connect RCM C189a. Connect Seat Track Position Sensor C72. Key in ON position. Enter the following diagnostic mode on the diagnostic tool: On-Demand Self Test Was DTC C1982 retrieved during the on-demand self test?
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DIAGNOSIS AND TESTING (Continued) Test Step T6
Result / Action to Take
CHECK FOR AN INTERMITTENT FAULT WARNING: If the supplemental restraint system (SRS) is
being serviced, the system must be deactivated and restraint system diagnostic tools must be installed. Refer to Airbag and Safety Belt Pretensioner Supplemental Restraint System (SRS) in this section. The airbag restraint system diagnostic tools must be removed and the airbag modules reconnected when the system is reactivated to avoid non-deployment in a collision, resulting in possible personal injury.
Yes
Go to T2.
No
CHECK for causes of the intermittent fault. ATTEMPT to recreate the hard fault by flexing the wire harness and cycling the ignition key frequently. REPAIR any intermittent concerns found. Go to T7.
WARNING: Never probe the connectors on the airbag module. Doing so can result in airbag deployment, which can result in personal injury. WARNING: The safety belt buckle pretensioner is a pyrotechnic device. Never probe a pretensioner electrical connector. Doing so could result in pretensioner or airbag deployment and could result in personal injury. WARNING: Never probe the electrical connector on a side airbag module. Doing so can result in side airbag deployment. NOTE: Diagnostics or repairs are not to be performed on a seat equipped with a seat side airbag with the seat in the vehicle. Prior to attempting to diagnose or repair a seat concern when equipped with a seat side airbag, the seat must be removed from the vehicle and the restraint system diagnostic tools must be installed in the seat side airbag electrical connectors. The restraint system diagnostic tools must be removed prior to operating the vehicle over the road. NOTE: After diagnosing or repairing an SRS, the restraint system
diagnostic tools must be removed before operating the vehicle over the road.
NOTE: After diagnosing or repairing a seat system, the restraint system diagnostic tools must be removed before operating the vehicle over the road. NOTE: The SRS must be fully operational and free of faults before releasing the vehicle to the customer. Key in OFF position. Deactivate the system. Refer to Airbag and Safety Belt Pretensioner Supplemental Restraint System (SRS) in the Diagnosis and Testing portion of this section. Enter the following diagnostic mode on the diagnostic tool: On-Demand Self Test Was DTC C1982 retrieved during the on-demand self test?
T7
CHECK FOR ADDITIONAL DTCs Refer to the continuous DTCs recorded during Step T1. Were any continuous DTCs retrieved during Step T1?
Yes
Do not clear any DTCs until all DTCs have been resolved. GO to the Restraints Control Module (RCM) Diagnostic Trouble Code (DTC) Table in this section for pinpoint test direction.
No
RECONNECT the system. REACTIVATE the system. PROVE OUT the system. REFER to Airbag and Safety Belt Pretensioner Supplemental Restraint System (SRS) in this section. CLEAR all DTCs.
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DIAGNOSIS AND TESTING (Continued) Pinpoint Test U: No Communication With The Restraints Control Module (RCM) Normal Operation The scan tool communicates with the restraints control module (RCM) through the diagnostics connector pin, circuit 70 (SB/W).
Possible Causes A no communication fault with the RCM can be caused by: damaged wiring, terminals, or connectors. a faulty diagnostics connector. a faulted RCM.
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DIAGNOSIS AND TESTING (Continued) PINPOINT TEST U : NO COMMUNICATION WITH THE RESTRAINTS CONTROL MODULE (RCM) Test Step U1
Result / Action to Take
CHECK THE RCM C189a PIN 11 FOR DAMAGE WARNING: If the supplemental restraint system (SRS) is
being serviced, the system must be deactivated and restraint system diagnostic tools must be installed. Refer to Airbag and Safety Belt Pretensioner Supplemental Restraint System (SRS) in this section. The airbag restraint system diagnostic tools must be removed and the airbag modules reconnected when the system is reactivated to avoid non-deployment in a collision, resulting in possible personal injury.
Yes
Go to U2.
No
REPAIR RCM C189a or RCM C189a pin 11 as necessary. RETEST the communication to the RCM. REACTIVATE the system. REFER to Airbag and Safety Belt Pretensioner Supplemental Restraint System (SRS) in this section.
WARNING: Never probe the connectors on the airbag module. Doing so can result in airbag deployment, which can result in personal injury. WARNING: The safety belt buckle pretensioner is a pyrotechnic device. Never probe a pretensioner electrical connector. Doing so could result in pretensioner or airbag deployment and could result in personal injury. WARNING: Never probe the electrical connector on a side airbag module. Doing so can result in side airbag deployment. NOTE: Diagnostics or repairs are not to be performed on a seat equipped with a seat side airbag with the seat in the vehicle. Prior to attempting to diagnose or repair a seat concern when equipped with a seat side airbag, the seat must be removed from the vehicle and the restraint system diagnostic tools must be installed in the seat side airbag electrical connectors. The restraint system diagnostic tools must be removed prior to operating the vehicle over the road. NOTE: After diagnosing or repairing an SRS, the restraint system
diagnostic tools must be removed before operating the vehicle over the road.
NOTE: After diagnosing or repairing a seat system, the restraint system diagnostic tools must be removed before operating the vehicle over the road. NOTE: The SRS must be fully operational and free of faults before releasing the vehicle to the customer. Key in OFF position. Deactivate the system. Refer to Airbag and Safety Belt Pretensioner Supplemental Restraint System (SRS) in the Diagnosis and Testing portion of this section. Disconnect RCM C189a. Inspect RCM C189a, harness side and RCM C189a, component side, pin 11 for damage. Are RCM C189a and RCM C189a pin 11 OK?
U2
CHECK DLC PIN FOR DAMAGE Inspect DLC diagnostics connector and pin for damage. Are DLC diagnostics connector and pin OK?
Yes
Go to U3.
No
REPAIR DLC or pin as necessary. RETEST the communication to the RCM. REACTIVATE the system. REFER to Airbag and Safety Belt Pretensioner Supplemental Restraint System (SRS) in this section.
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DIAGNOSIS AND TESTING (Continued) Test Step U3
CHECK THE IGNITION CIRCUIT 16 (R/G) FOR AN OPEN Key in ON position. Measure the voltage between RCM C189a pin 12, circuit 16 (R/G), harness side and ground. Is the voltage greater than 10 volts?
U4
Yes
Go to U4.
No
REPAIR circuit 16 (R/G). RETEST the communication to the RCM. REACTIVATE the system. REFER to Airbag and Safety Belt Pretensioner Supplemental Restraint System (SRS) in this section.
CHECK GROUND CIRCUIT 1203 (B/G) FOR AN OPEN Key in OFF position. Measure the resistance between RCM C189a pin 16, circuit 1203 (B/G), harness side and a sheet metal ground near the RCM. Is the resistance less than 1 ohm?
U5
Result / Action to Take
Yes
Go to U5.
No
REPAIR circuit 1203 (B/G). RETEST the communication to the RCM. REACTIVATE the system. REFER to Airbag and Safety Belt Pretensioner Supplemental Restraint System (SRS) in this section.
CHECK CIRCUIT 70 (SB/W) FOR AN OPEN Yes
Measure the resistance between RCM C189a pin 11, circuit 70 (SB/W), harness side and DLC pin, circuit 70 (SB/W), harness side.
Go to U6.
Is the resistance less than 5 ohms?
No
REPAIR circuit 70 (SB/W). RETEST the communication to the RCM. REACTIVATE the system. REFER to Airbag and Safety Belt Pretensioner Supplemental Restraint System (SRS) in this section.
U6
CONFIRM THE RCM FAULT NOTE: Make sure the safety belt pretensioner restraint system diagnostic tools, sensor electrical connectors, and the RCM electrical connector are connected before carrying out the on-demand self test. If not, erroneous DTCs will be recorded. Connect RCM C189a. Enter the following diagnostic mode on the diagnostic tool: On-Demand Self Test Did the scan tool communicate with the RCM?
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Yes
Fault corrected. REACTIVATE the system. REFER to Airbag and Safety Belt Pretensioner Supplemental Restraint System (SRS) in this section.
No
INSTALL a new RCM. RETEST the communication to the RCM. REACTIVATE the system. REFER to Airbag and Safety Belt Pretensioner Supplemental Restraint System (SRS) in this section.
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GENERAL PROCEDURES 3. Inspect the entire vehicle for damage, including the following components: steering column and clockspring. instrument panel knee bolsters and mounting points. WARNING: If the supplemental restraint instrument panel braces and brackets. system (SRS) is being serviced, the system must instrument panel and mounting points. be deactivated and restraint system diagnostic tools must be installed. For additional information, seats and seat mounting points. refer to Airbag and Safety Belt Pretensioner safety belts, safety belt buckles, and safety Supplemental Restraint System (SRS) in this belt retractors. For additional information, section. refer to Section 501-20A. The airbag restraint system diagnostic tools must supplemental restraint system (SRS) wiring, be removed and the airbag modules reconnected wiring harnesses, and connectors. when the system is reactivated to avoid non-deployment in a collision, resulting in 4. After carrying out the review and inspection of the possible personal injury. entire vehicle for damage, repair or install new components as needed. NOTE: Diagnostics or repairs are not to be carried out on a seat equipped with a seat side airbag with the seat in the vehicle. Prior to attempting to diagnose or Airbag Disposal — Deployed Airbag repair a seat concern when equipped with a seat side WARNING: Always wear safety glasses when airbag, the seat must be removed from the vehicle repairing an airbag supplemental restraint system and the restraint system diagnostic tools must be installed in the seat side airbag electrical connectors. (SRS) vehicle and when handling an airbag module. This will reduce the risk of injury in the The restraint system diagnostic tools must be event of an accidental deployment. removed prior to operating the vehicle over the road. 1. Dispose of the deployed airbag modules and safety belt pretensioners in the same manner as NOTE: After diagnosing or repairing an SRS, the any other part to be scrapped. restraint system diagnostic tools must be
Inspection and Repair After a Supplemental Restraint System (SRS) Deployment
removed before operating the vehicle over the road.
NOTE: After diagnosing or repairing a seat system, the restraint system diagnostic tools must be removed before operating the vehicle over the road. NOTE: The SRS must be fully operational and free of faults before releasing the vehicle to the customer. 1. When any deployable device (driver airbag, passenger airbag, seat side airbag, safety belt pretensioner, etc.) or combination of devices are deployed and/or the RCM has the DTC B1231 (Crash Data Memory Full) in memory, the repair of the vehicle’s supplemental restraint system (SRS) is to include the removal of all deployed devices and the installation of new deployable devices, the removal and installation of new impact sensors, and the removal and installation of a new RCM. 2. When any damage to the impact sensor mounting points or mounting hardware has occurred, repair or install new mounting points and mounting hardware as needed.
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Airbag Disposal — Undeployed, Inoperative WARNING: Carry a live airbag module with the airbag and trim cover or deployment door pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. NOTE: All inoperative airbag modules and safety belt pretensioners have been placed on the Mandatory Return List. All discolored or damaged airbag modules must be treated the same as any inoperative live airbag being returned. 1. Remove the inoperative component from the vehicle. For additional information, refer to the appropriate airbag procedure in this section or to Section 501-20A for the safety belt/pretensioner assembly. NOTE: When installing a new airbag module, a prepaid return postcard is provided with the replacement airbag module. The serial number for the new part and the vehicle registration number (VRN) must be recorded and sent to Ford Motor Company.
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GENERAL PROCEDURES (Continued) 2. If installing a new airbag module: 2. Cut the clockspring wire harness. Remove the sheathing over the wires. 1. For a new driver airbag module, record the necessary information and return the inoperative driver airbag module to Ford Motor Company. 2. For a new passenger airbag module, record the necessary information and return the inoperative passenger airbag module to Ford Motor Company. 3. For a new seat mounted airbag module module, record the necessary information and return the inoperative side airbag module to Ford Motor Company.
Airbag Disposal — Driver, Undeployed, Scrapped Vehicle
3. Strip the insulation from all four wires. Perform an ohms check from the stripped end of each wire to the connector end. If any of the four wires reads WARNING: Always wear safety glasses when more than 0.5 ohm use another connector. repairing an airbag supplemental restraint system (SRS) vehicle and when handling an airbag CAUTION: The clockspring electrical module. This will reduce the risk of injury in the connectors are unique and cannot be reversed event of an accidental deployment. when connected to the driver airbag module. Match the electrical connector key to the keyway WARNING: Never probe the connectors on in the driver airbag module. Do not force the the airbag module. Doing so can result in airbag electrical connectors into the driver airbag deployment, which can result in personal injury. module. 4. Match the driver airbag module electrical WARNING: Carry a live airbag module with connector key to the keyway in the driver airbag the airbag and trim cover pointed away from your module. Connect the two driver airbag module body. This will reduce the risk of injury in the electrical connectors to the driver airbag module. event of an accidental deployment. Remote Deployment
WARNING: Do not set a live airbag module down with the trim cover face down. This will reduce the risk of injury in the event of an accidental deployment. WARNING: Remote deployment is to be performed outdoors with all personnel at least 6 meters (20 feet) away to ensure personal safety. Due to the loud report which occurs when the airbag is deployed, hearing protection is required. WARNING: To reduce the risk of serious personal injury, read and follow all warnings, cautions, notes and instructions in the driver airbag module removal and installation procedure. 1. Remove the driver airbag module from the vehicle. For additional information, refer to Driver airbag Module in this section.
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GENERAL PROCEDURES (Continued) 5. Twist together one wire from each pair.
6. Obtain two wires (20 gauge minimum) at least 6 meters (20 feet) long and attach one end of each wire to each twisted splice.
9. Deploy the airbag module by touching the other ends of the two wires to the terminals of a 12-volt battery.
10. To allow for cooling, wait at least ten minutes before approaching the deployed airbag. 11. Dispose of the deployed airbag module in the same manner as any other part to be scrapped.
Airbag Disposal — Passenger, Undeployed, Scrapped Vehicle Remote Deployment
7. Place the airbag module on a flat surface in an open outdoor area with the trim cover and airbag facing up. 8. Remain at least 6 meters (20 feet) away from the airbag module.
WARNING: Always wear safety glasses when repairing an airbag supplemental restraint system (SRS) vehicle and when handling an airbag module or safety belt retractor/pretensioner assembly. This will reduce the risk of injury in the event of an accidental deployment. WARNING: Never probe the connectors on the airbag module. Doing so can result in airbag deployment, which can result in personal injury. WARNING: Carry a live airbag module with the airbag and trim cover or deployment door pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. WARNING: Do not place the driver or passenger airbag module with the trim cover or deployment door facing down, as the forces of the deploying airbag could cause it to ricochet and cause personal injury. WARNING: Remote deployment is to be performed outdoors with all personnel at least 6 meters (20 feet) away to ensure personal safety. Due to the loud report which occurs when the airbag is deployed, hearing protection is required. 1. Remove the passenger airbag from the vehicle. For additional information, refer to Passenger airbag Module in this section.
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GENERAL PROCEDURES (Continued) 2. Cut and strip all four wires at the airbag electrical connector.
3. Twist together one wire from each pair.
7. Deploy the airbag module by touching the other ends of the two wires to the terminals of a 12-volt battery.
8. To allow for cooling, wait at least ten minutes before approaching the deployed airbag. 9. Dispose of the deployed airbag module in the same manner as any other part to be scrapped.
Airbag Disposal — Side Airbag, Undeployed, Scrapped Vehicle Deactivation
4. Obtain two wires (20 gauge minimum) at least 6 meters (20 feet) long and attach one end of each wire to each twisted splice.
5. Place the airbag module on a flat surface in an open outdoor area with the trim cover facing upward. 6. Remain at least 6 meters (20 feet) away from the airbag module.
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WARNING: Always wear safety glasses when repairing an airbag supplemental restraint system (SRS) vehicle and when handling an airbag module. This will reduce the risk of injury in the event of an accidental deployment. WARNING: Remote deployment is to be performed outdoors with all personnel at least 6 meters (20 feet) away to ensure personal safety. Due to the loud report which occurs when the airbag is deployed, hearing protection is required. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side airbag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side airbag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. Please refer to the appropriate vehicle shop manual to determine location of the front airbag sensors. The side impact sensors (if equipped) are located at or near the base of the B-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). NOTE: A typical safety canopy disposal is shown that is similar for all vehicles. 01/2003 2003.0 BA Falcon
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GENERAL PROCEDURES (Continued) NOTE: The safety canopy module deployment for a scrapped vehicle will occur in its installed position in the vehicle. NOTE: The left hand side is shown, the right hand side is similar. 1. Disconnect the battery ground cable and wait at least one minute. For additional information, refer to Section 414-01. 2. Deploy the side curtain module by touching the other ends of the two wires to the terminals of a 12-volt battery.
WARNING: The safety belt buckle pretensioner is pyrotechnic device. Never probe a pretensioner electrical connector. Doing so could result in pretensioner or airbag deployment and could result in personal injury. WARNING: Carry a live safety belt buckle pretensioner so as to keep fingers and clothing away from moveable parts. This will reduce the risk of injury in the event of an accidental deployment. 1. Remove the inoperative safety belt buckle pretensioner from the vehicle. For additional information, refer to Section 501-20A. 2. Package and return the inoperative safety belt buckle pretensioner or safety belt retractor pretensioner to Ford Motor Company.
Safety Belt Pretensioner Disposal — Undeployed, Scrapped Vehicle Remote Deployment
3. To allow for cooling, wait at least ten minutes before approaching the deployed side curtain module. 4. Dispose of the deployed side curtain module in the same manner as any other part to be scrapped.
Safety Belt Pretensioner Disposal — Deployed WARNING: The safety belt buckle pretensioner is pyrotechnic device. Always wear safety glasses when repairing an airbag equipped vehicle and when handling a safety belt buckle pretensioner. 1. Dispose of the deployed safety belt pretensioner in the same manner as any other part to be scrapped.
Safety Belt Pretensioner Disposal — Undeployed, Inoperative WARNING: The safety belt buckle pretensioner is pyrotechnic device. Always wear safety glasses when repairing an airbag equipped vehicle and when handling a safety belt buckle pretensioner.
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WARNING: Always wear safety glasses when repairing an airbag supplemental restraint system (SRS) vehicle and when handling an airbag module, or safety belt buckle pretensioner. This will reduce the risk of injury in the event of an accidental deployment. WARNING: The safety belt buckle pretensioner is pyrotechnic device. Never probe a pretensioner electrical connector. Doing so could result in pretensioner or airbag deployment and could result in personal injury. WARNING: Remote deployment is to be performed outdoors with all personnel at least 6.1 meters (20 feet) away to ensure personal safety. Due to the loud report which occurs when the safety belt pretensioner is deployed, hearing protection is required. WARNING: Do not position the safety belt buckle pretensioner so that moveable parts contact the support surface, as the forces of the deploying pretensioner can cause it to ricochet and cause personal injury. 1. Remove the safety belt buckle pretensioner assembly from the vehicle. For additional information, refer to Section 501-20A. 2. Connect the adaptor lead to the pretensioner connector. 3. Connect the deployment lead to the adaptor lead.
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501-20b-130
Occupant Restraints — Passive
501-20b-130
GENERAL PROCEDURES (Continued) 4. Position the safety belt buckle pretensioner assembly on a flat surface in an open outdoor area so that moveable parts do not contact the support surface. WARNING: Before proceeding, ensure that all personnel working in the vicinity are aware of the fact that a loud noise(bang) is about to ocur. Do not allow anybody to approach closer than six metres. 5. Move as far away as possible from the vehicle and connect the clips to the battery.
Special Tool(s) Diagnostic Tool, Restraint System (2 req’d) 418-F088 (105-R0012)
Deactivation WARNING: Always wear safety glasses when repairing an airbag supplemental restraint system (SRS) vehicle and when handling an airbag module. This will reduce the risk of injury in the event of an accidental deployment. WARNING: Carry a live airbag module with the airbag and trim cover pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. WARNING: Do not set a live airbag module down with the trim cover face down. This will reduce the risk of injury in the event of an accidental deployment.
WARNING: The pretensioner should not be handled immediately following a deployment as the unit will be hot. 6. Deploy the module. Depress both switches. 7. Dispose of the deployed safety belt buckle pretensioner in the same manner as any other part to be scrapped.
Supplemental Restraint System (SRS) Deactivation and Reactivation Special Tool(s) Diagnostic Tool, Restraint System (2 req’d) 418-F395 (014-R1079)
Diagnostic Tool, Restraint System (4 req’d) 418-F403
WARNING: Never probe the connectors on the airbag module. Doing so can result in airbag deployment, which can result in personal injury. WARNING: The safety belt buckle pretensioner is a pyrotechnic device. Never probe a pretensioner electrical connector. Doing so could result in pretensioner or airbag deployment and could result in personal injury. WARNING: Never probe the connectors on the side airbag module. Doing so can result in side airbag deployment. WARNING: Vehicle sensor orientation is critical for proper system operation. If a vehicle equipped with an airbag supplemental restraint system (SRS) is involved in a collision, inspect the sensor mounting bracket and wiring pigtail for deformation. Replace and properly position the sensor or any other damaged supplemental restraint system (SRS) components whether or not the airbag is deployed. WARNING: The restraint system diagnostic tool is for restraint system service only. Remove from vehicle prior to road use. Failure to remove could result in injury and possible violation of vehicle safety standards. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or
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01/2003 2003.0 BA Falcon
501-20b-131
Occupant Restraints — Passive
501-20b-131
GENERAL PROCEDURES (Continued) 1. From under the front LH seat, remove the replacing any front or side airbag supplemental restraint system diagnostic tool from the safety restraint system (SRS) components and before belt buckle pretensioner electrical connector. servicing, replacing, adjusting or striking components near the front or side airbag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The side impact sensors (if equipped) are located at or near the base of the B-pillars. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). NOTE: If a seat equipped with a seat mounted side airbag and/or a safety belt pretensioner (if equipped) system is being serviced, the airbag system must be deactivated. NOTE: Restraint system diagnostic tools MUST be installed under the seats in the seat side airbag (if equipped) and safety belt pretensioner.
2. From under the front LH seat, connect the safety belt buckle pretensioner electrical connector.
NOTE: Diagnostics or repairs are not to be performed on a seat equipped with a seat side airbag with the seat in the vehicle. Prior to attempting to diagnose or repair a seat concern when equipped with a seat side airbag, the seat must be removed from the vehicle and the restraint system diagnostic tools must be installed in the seat side airbag electrical connectors. The restraint system diagnostic tools must be removed prior to operating the vehicle over the road. NOTE: After diagnosing or repairing an SRS, the restraint system diagnostic tools must be removed before operating the vehicle over the road. NOTE: The SRS must be fully operational and free of faults before releasing the vehicle to the customer. 1. Remove drivers airbag module as described later in this section. Reactivation
Item 1 2
Description Seat belt pretensioners Pretensioner electrical connector
WARNING: To reduce the risk of serious personal injury, read and follow all warnings, cautions, and notes at the beginning of the deactivation procedure. NOTE: Make sure the negative battery cable is still disconnected before continuing with the reactivation portion of this procedure.
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01/2003 2003.0 BA Falcon
501-20b-132
Occupant Restraints — Passive
501-20b-132
GENERAL PROCEDURES (Continued) 3. From under the front RH seat, remove the restraint system diagnostic tool from the safety belt buckle pretensioner electrical connector.
4. From under the front RH seat, connect the safety belt buckle pretensioner electrical connector.
Item 1 2
Description Seat belt pretensioners Pretensioner electrical connector
servicing, replacing, adjusting or striking components near the front or side airbag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The side impact sensors (if equipped) are located at or near the base of the B-pillars. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). 1. Disconnect the battery ground cable and wait at least one minute. For additional information, refer to Section 414-01. All vehicles NOTE: Make sure the negative battery cable is still disconnected before continuing with the reactivation portion of this procedure. 1. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger airbag module electrical connector.
2. Connect the passenger airbag module electrical connector.
Vehicles with power seats 1. Connect the battery ground cable. For additional information, refer to Section 414-01. All vehicles 1. Position the front seats rearward. Vehicles with power seats WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side airbag supplemental restraint system (SRS) components and before
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501-20b-133
Occupant Restraints — Passive
501-20b-133
GENERAL PROCEDURES (Continued) 3. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger airbag electrical connector.
7. Position the driver airbag module to the steering wheel. 1. Connect the horn switch electrical connector. CAUTION: The clockspring electrical connectors are unique and cannot be reversed when connected to the driver airbag module. Match the electrical connector key to the keyway in the driver airbag module. Do not force the electrical connectors into the driver airbag module. 2. Connect the driver airbag module electrical connectors as noted during removal. 3. Position the driver airbag module to the steering wheel.
4. Connect the passenger airbag module electrical connector.
Item 1 2 3
Description Clokspring LH connector Clokspring RH connector Steering wheel audio controls connector
5. Close the glove compartment. 6. Remove the restraint system diagnostic tools from NOTE: Make sure the negative battery cable is still the clockspring electrical connector at the top of disconnected before continuing with the installation the steering column. portion of this procedure. 8. Remove the restraint system diagnostic tool from the clockspring electrical connector at the top of the steering column.
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01/2003 2003.0 BA Falcon
501-20b-134
Occupant Restraints — Passive
501-20b-134
GENERAL PROCEDURES (Continued) 9. Position the driver airbag module to the steering wheel. 1. Connect the driver airbag module electrical connector. 2. Slide and engage the driver airbag module electrical connector locking clip. 3. Connect the horn switch electrical connector. 4. Position the driver airbag module to the steering wheel. 5. Push driver airbag module assembly until seats into the steering wheel.
Item 1 2 3
Description Clokspring LH connector Clokspring RH connector Steering wheel audio controls connector
10. Install the two driver airbag module bolts (one shown). Rotate wheel 90° to access airbag attachment rotate again in oppsite direction to make second attachment.
11. Connect the battery ground cable. For additional information, refer to Section 414-01.
12. With all the restraint system diagnostic tools removed, prove out the supplemental restraint system (SRS). For additional information, refer to the Airbag and Safety Belt Pretensioner Supplemental Restraint System (SRS) in the Diagnosis and Testing portion of Section 501-20b.
Weld Nut Repair — Missing Weld Nut WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side airbag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side airbag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The side impact sensors (if equipped) are located at or near the base of the B-pillars. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). CAUTION: Installing a J-nut in place of a weld nut is not a recommended repair. NOTE: C-pillar repair shown, others similar. 1. Remove the component from where the weld nut is to be repaired. 2. Drill three equally spaced in 1.75mm (5/64) holes in close proximity to where the weld nut face will be plug welded back to the sheet metal.
3. Obtain the appropriate 6 mm (0.24in) or 8mm (0.32in) weld nut. 4. Obtain the appropriate 6 mm (0.24in) by 1.0 or 8mm (0.32in) by 1.25 grounding screw (self-tapping).
WARNING: The restraint system diagnostic tool is for restraint system service only. Remove from the vehicle prior to road use. Failure to remove could result in injury and possible violation of vehicle safety standards. G12355 en
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501-20b-135
Occupant Restraints — Passive
501-20b-135
GENERAL PROCEDURES (Continued) 5. Set up for the positioning of the weld nut. 10. Tighten the attaching screws to specification. For additional information, refer to Specifications in 1. Route a sufficient length of wire through the this section. weld nut clearance hole and back out an adjacent access hole. Weld Nut Repair — Stripped Weld Nut 2. Position a weld nut, shoulder end up, onto the wire. WARNING: To avoid accidental deployment 3. Position a flat washer onto the wire and and possible personal injury, the backup power secure it so it cannot be pulled off. supply must be depleted before repairing or replacing any front or side airbag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side airbag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The side impact sensors (if equipped) are located at or near the base of the B-pillars. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). 1. Inspect the weld nut and surrounding area for repair. If there is not enough clearance for a larger bolt stud to go through or a larger bolt head to Item Description turn, then a Heli-Coil® will have to be made. 1 Cord Follow the instructions with the Heli-Coil® 2 Weld nut repair kit. 3 Flat Washer 2. If a 6 mm weld nut is stripped, drill out the hole using a letter “H” or 6.5mm (0.26in) drill bit. Then 6. Plug weld the weld nut into position. tap, using an 8mm by 1.25 bit. 1. Pull the welding wire back through the Do not oversize a 6 mm weld nut by more clearance hole, allowing the weld nut and flat than 8mm. washer to follow the welding wire through and stop against the sheet metal. 3. If an 8 mm weld nut is stripped, drill the hole using a letter “R” or in 9.75mm (0.3990) drill bit. 2. Make sure the weld nut shoulder is aligned Then tap, using a 10mm by 1.50 bit. through the clearance hole in the sheet metal. Do not oversize an 8 mm weld nut by more 3. With the weld nut firmly held in position, plug than 10 mm. weld the weld nut at the three holes drilled previously. 4. Obtain the appropriate oversized screw. 5. Install the attaching screw(s) to the component. 6. Tighten the attaching screws to specification. For additional information, refer to Specifications in this section.
7. Metal finish as required. 8. Verify the nut is securely in place. 9. Install the component with the previously obtained screw. G12357 en
01/2003 2003.0 BA Falcon
501-20b-136
Occupant Restraints — Passive
501-20b-136
REMOVAL AND INSTALLATION
Front Impact Severity Sensor Special Tool(s) Diagnostic Tool, Restraint System (2 req’d) 418-F395 (014-R1079)
Diagnostic Tool, Restraint System (4 req’d) 418-F403
1. Disconnect the battery ground cable (14301) and wait at least one minute. For additional information, refer to Section 414-01. WARNING: To reduce the risk of serious personal injury, read and follow all warnings, cautions, notes, and instructions in the supplemental restraint system (SRS) deactivation/reactivation procedure. 2. Deactivate the supplemental restraint system (SRS). For additional information, refer to Supplemental Restraint System (SRS) Deactivation and Reactivation in the General Procedures portion of this section. Remove scrivets and remove the modesty panel. 3. Remove the pin-type retainers and pull the lower grill opening shroud back, creating an opening to access the front impact severity sensor.
Diagnostic Tool, Restraint System (2 req’d) 418-F088 (105-R0012)
Removal WARNING: Vehicle sensor orientation is critical for proper system operation. If a vehicle equipped with an airbag supplemental restraint system (SRS) is involved in a collision, inspect the sensor mounting bracket and wiring pigtail for NOTE: The front impact severity sensor is mounted deformation. Replace and properly position the under the lower radiator support. sensor or any other damaged supplemental 4. Remove the front impact severity sensor and restraint system (SRS) components whether or bracket. not the airbag is deployed. 1. Remove the bolts. WARNING: To avoid accidental deployment 2. Disconnect and remove the front impact and possible personal injury, the backup power severity sensor and bracket. supply must be depleted before repairing or replacing any front or side airbag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side airbag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The side airbag sensors are located at or near the base of the B-pillars. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). NOTE: Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure Item Description again. 1 Bolt 2 Front impact severity sensor G12360 en
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501-20b-137
Occupant Restraints — Passive
501-20b-137
REMOVAL AND INSTALLATION (Continued) Item 3
Description Electrical connector
Installation WARNING: To reduce the risk of serious personal injury, read and follow all warnings, cautions and notes at the beginning of the removal procedure. NOTE: Make sure the negative battery cable is still disconnected before continuing with the installation portion of this procedure.
4. Disconnect the battery ground cable and wait at least one minute. For additional information, refer to Section 414-01. 5. Position the lower grill opening shroud and install the pin-type retainers Position the modesty panel trim over the latch and secure with scrivets.
NOTE: Make sure the lower radiator support and front impact severity sensor bracket mating surfaces are clean and debris free. 1. Install the front impact severity sensor. 1. Connect the front impact severity sensor. 2. Position the front impact severity sensor and bracket so the locator tab goes into the lower radiator support opening and the sensor bracket sits flat up against the support. 3. Install the bolts.
Item 1 2 3
Description Bolt Front impact severity sensor Electrical connector
2. Connect the battery ground cable. For additional information, refer to Section 414-01. 3. With the restraint system diagnostic tools installed at all deployable devices, prove out the supplemental restraint system (SRS). For additional information, refer to Airbag and Safety Belt Pretensioner Supplemental Restraint System (SRS), in the Diagnosis and Testing portion of this section.
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WARNING: To reduce the risk of serious personal injury, read and follow all warnings, cautions, notes, and instructions in the supplemental restraint system (SRS) deactivation/reactivation procedure. 6. Reactivate the supplemental restraint system (SRS). For additional information, refer to Supplemental Restraint System (SRS) Deactivation and Reactivation in the General Procedures portion of this section. WARNING: The restraint system diagnostic tool is for restraint system service only. Remove from the vehicle prior to road use. Failure to remove could result in injury and possible violation of vehicle safety standards. 7. With all the restraint system diagnostic tools removed, prove out the supplemental restraint system (SRS). For additional information, refer to Airbag and Safety Belt Pretensioner Supplemental Restraint System (SRS), in the Diagnosis and Testing portion of this section.
01/2003 2003.0 BA Falcon
501-20b-138
Occupant Restraints — Passive
501-20b-138
REMOVAL AND INSTALLATION (Continued)
Side Impact Sensor — First Row, B — Pillar Special Tool(s) Diagnostic Tool, Restraint System (2 req’d) 418-F395 (014-R1079)
Diagnostic Tool, Restraint System (4 req’d) 418-F403
NOTE: The right-hand drive passenger side is shown, all others are similar. 1. Disconnect the battery ground cable (14301) and wait at least one minute. For additional information, refer to Section 414-01. WARNING: To reduce the risk of serious personal injury, read and follow all warnings, notes, and instructions in the supplemental restraint system (SRS) deactivation/reactivation procedure. 2. Deactivate the supplemental restraint system (SRS). For additional information, refer to Supplemental Restraint System (SRS) Deactivation and Reactivation in the General Procedures portion of this section. 3. Remove the B-pillar trim panel. For additional information, refer to Section 501-05.
Diagnostic Tool, Restraint System (2 req’d) 418-F088 (105-R0012)
Removal WARNING: Vehicle sensor orientation is critical for correct system operation. If a vehicle equipped with an airbag supplemental restraint system (SRS) is involved in a collision, inspect the sensor mounting bracket and wiring pigtail for deformation. Replace and correctly position the sensor or any other damaged supplemental restraint system (SRS) components whether or not the airbag is deployed.
Item 1 2
Description B-Pillar side impact sensor Screw
WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side airbag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side airbag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The side impact sensors (if equipped) are located at or near the base of the B-pillars. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). NOTE: Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again.
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01/2003 2003.0 BA Falcon
501-20b-139
Occupant Restraints — Passive
501-20b-139
REMOVAL AND INSTALLATION (Continued) 4. Remove the side impact sensor. 1. Remove the bolt. 2. Disconnect the electrical connector. 3. Remove the side impact sensor.
Item 1 2 3
Description Electrical connector Bolt B-Pillar side impact sensor
Installation WARNING: To reduce the risk of serious personal injury, read and follow all warnings, cautions and notes at the beginning of the removal procedure. NOTE: Make sure the negative battery cable is still disconnected before continuing with the installation portion of this procedure.
2. Install the side impact sensor. 1. Position the side impact sensor to the B-pillar. 2. Install the bolt. 3. Connect the electrical connector.
Item 1 2 3
Description Electrical connector Bolt B-Pillar side impact sensor
3. Connect the battery ground cable. For additional information, refer to Section 414-01. 4. With the restraint system diagnostic tools installed at all deployable devices, prove out the supplemental restraint system (SRS). For additional information, refer to Airbag and Safety Belt Pretensioner Supplemental Restraint System (SRS), in the Diagnosis and Testing portion of this section.
1. Align the locator tabs to the openings in the B-pillar.
WARNING: The tightening torque of the airbag side impact sensor retaining bolt is critical for correct system operation.
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Item 1 2
Description B-Pillar side impact sensor Screw
5. Disconnect the battery ground cable and wait at least one minute. For additional information, refer to Section 414-01. NOTE: Make sure the safety belt webbing is not twisted prior to installation. I 01/2003 2003.0 BA Falcon
501-20b-140
Occupant Restraints — Passive
501-20b-140
REMOVAL AND INSTALLATION (Continued) 6. nstall the B-pillar trim panel. For additional information, refer to Section 501-05. WARNING: To reduce the risk of serious personal injury, read and follow all warnings, cautions, notes, and instructions in the supplemental restraint system (SRS) deactivation/reactivation procedure. 7. Reactivate the supplemental restraint system (SRS). For additional information, refer to Supplemental Restraint System (SRS) Deactivation and Reactivation in the General Procedures portion of this section. 8. Connect the battery ground cable. For additional information, refer to Section 414-01. WARNING: The restraint system diagnostic tool is for restraint system service only. Remove from the vehicle prior to road use. Failure to remove could result in injury and possible violation of vehicle safety standards. 9. With all the restraint system diagnostic tools removed, prove out the supplemental restraint system (SRS). For additional information, refer to Airbag and Safety Belt Pretensioner Supplemental Restraint System (SRS) in the Diagnosis and Testing portion of this section. 10. Check the active restraint system for correct operation. For additional information, refer to section Section 501-20A.
Removal WARNING: The restraints control module (RCM) orientation is critical for proper airbag supplemental restraint system (SRS) operation. If a vehicle equipped with an SRS system has been involved in a collision in which the center tunnel area has been damaged, inspect the mounting and bracket for deformation. If damaged, the RCM must be replaced whether or not the airbags have deployed. In addition, make sure the area of the RCM mounting is restored to its original condition. WARNING: Vehicle sensor orientation is critical for proper system operation. If a vehicle equipped with an airbag supplemental restraint system (SRS) is involved in a collision, inspect the sensor mounting bracket and wiring pigtail for deformation. Replace and properly position the sensor or any other damaged supplemental restraint system (SRS) components whether or not the airbag is deployed.
Diagnostic Tool, Restraint System (2 req’d) 418-F395 (014-R1079)
WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side airbag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side airbag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The side impact sensors (if equipped) are located at or near the base of the B-pillars and C-pillars. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped).
Diagnostic Tool, Restraint System (4 req’d) 418-F403
CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage can result. NOTE: Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again.
Restraints Control Module (RCM) Special Tool(s)
1. Disconnect the battery ground cable (14301) and wait at least one minute. For additional information, refer to Section 414-01. Diagnostic Tool, Restraint System (2 req’d) 418-F088 (105-R0012)
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WARNING: To reduce the risk of serious personal injury, read and follow all warnings, cautions, notes, and instructions in the supplemental restraint system (SRS) deactivation/reactivation procedure.
01/2003 2003.0 BA Falcon
501-20b-141
Occupant Restraints — Passive
501-20b-141
REMOVAL AND INSTALLATION (Continued) 2. Deactivate the supplemental restraint system 6. Remove the RCM. (SRS). For additional information, refer to 1. Position the wire harness retainer out of the Supplemental Restraint System (SRS) way. Deactivation and Reactivation in the General 2. Remove the bolts. Procedures portion of this section. 3. Remove the RCM. 3. Remove the floor console. For additional information, refer to Section 501-12. Position the carpet back. 4. Disconnect the large restraints control module (RCM) electrical connector. 1. Pinch the thumb tab and pivot the connector position assurance lever all the way back until it stops. 2. Pull out and disconnect the RCM electrical connector.
Installation WARNING: To reduce the risk of serious personal injury, read and follow all warnings, cautions and notes at the beginning of the removal procedure.
Item 1 2 3 4
Description Small RCM connector cover Small RCM connector RCM Large RCM connector
5. Disconnect the small RCM electrical connector. 1. Pull out and remove the electrical connector locking wedge. 2. Push down to release the retaining tab. 3. While releasing the retaining tab, pull out and disconnect the small RCM electrical connector.
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WARNING: The tightening torque of the airbag restraints control module (RCM) retaining nuts is critical for correct system operation. NOTE: Make sure the battery negative cable is still disconnected before continuing with the installation portion of this procedure. 1. Install the RCM. 1. Position the RCM. 2. Install the bolts. 3. Reposition the wire harness retainer.
01/2003 2003.0 BA Falcon
501-20b-142
Occupant Restraints — Passive
501-20b-142
REMOVAL AND INSTALLATION (Continued) 2. Connect the small RCM electrical connector. 1. Align the small RCM electrical connector. Push in until the connector is fully seated into the RCM. 2. Install the electrical connector locking wedge. 3. Make sure the connector position assurance lever is in the full release position before attempting to connect the connector.
CAUTION: Putting the large RCM electrical connector into the RCM on an angle can cause bad electrical connections and damage components. NOTE: The RCM has been removed for clarity.
6. Connect the battery ground cable. For additional information, refer to Section 414-01. 7. With the restraint system diagnostic tools installed at all deployable devices, prove out the supplemental restraint system (SRS). For additional information, refer to Airbag and Safety Belt Pretensioner Supplemental Restraint System (SRS) in the Diagnosis and Testing portion of this section. 8. Disconnect the battery ground cable and wait at least one minute. For additional information, refer to Section 414-01.
WARNING: To reduce the risk of serious personal injury, read and follow all warnings, cautions, notes, and instructions in the 4. Position the large RCM electrical connector into supplemental restraint system (SRS) the RCM. deactivation/reactivation procedure. With the large RCM electrical connector 9. Reactivate the supplemental restraint system uniformly aligned to the RCM, lightly push in (SRS). For additional information, refer to until a subtle audible click is heard and a Supplemental Restraint System (SRS) slight resistance is felt. Deactivation and Reactivation in the General Procedures portion of this section. CAUTION: Do not push the connector on to where the lever pivots and seats WARNING: The restraint system itself. Light pressure is needed to get the diagnostic tool is for restraint system service connector into position on the RCM before only. Remove from the vehicle prior to road using the lever to fully seat the connector. use. Failure to remove could result in injury 5. Connect the large RCM electrical connector. and possible violation of vehicle safety standards. NOTE: The RCM has been removed for clarity. 10. With all the restraint system diagnostic tools Using the connector position assurance lever, removed, prove out the supplemental restraint pivot it toward the RCM, drawing the system (SRS). For additional information, refer to connector into the RCM. Diagnostic Instructions - Airbag and Safety Belt Make sure the thumb tab is engaged to Pretensioner Supplemental Restraint System the retainer on the RCM and locked in (SRS) in the Diagnosis and Testing portion of this place. section.
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501-20b-143
Occupant Restraints — Passive
501-20b-143
REMOVAL AND INSTALLATION (Continued)
Driver Airbag Module Special Tool(s) Diagnostic Tool, Restraint System (2 req’d) 418-F395 (014-R1079)
Diagnostic Tool, Restraint System (4 req’d) 418-F403
Diagnostic Tool, Restraint System (2 req’d) 418-F088 (105-R0012)
WARNING: Never probe the connectors on the side airbag module. Doing so can result in side airbag deployment. WARNING: Vehicle sensor orientation is critical for proper system operation. If a vehicle equipped with an airbag supplemental restraint system (SRS) is involved in a collision, inspect the sensor mounting bracket and wiring pigtail for deformation. Replace and properly position the sensor or any other damaged supplemental restraint system (SRS) components whether or not the airbag is deployed. WARNING: The restraint system diagnostic tool is for restraint system service only. Remove from vehicle prior to road use. Failure to remove could result in injury and possible violation of vehicle safety standards.
WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side airbag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side airbag sensors, Removal such as doors, instrument panel, console, door WARNING: Always wear safety glasses when latches, strikers, seats and hood latches. repairing an airbag supplemental restraint system The side impact sensors (if equipped) are located at or near the base of the B-pillars and C-pillars. (SRS) vehicle and when handling an airbag To deplete the backup power supply energy, module. This will reduce the risk of injury in the disconnect the battery ground cable and wait at event of an accidental deployment. least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). WARNING: Carry a live airbag module with the airbag and trim cover pointed away from your NOTE: If a seat equipped with a seat mounted side airbag and/or a safety belt pretensioner (if equipped) body. This will reduce the risk of injury in the system is being serviced, the airbag system must event of an accidental deployment. be deactivated. WARNING: Do not set a live airbag module NOTE: Restraint system diagnostic tools MUST be down with the trim cover face down. This will installed under the seats in the seat side airbag (if reduce the risk of injury in the event of an equipped) and safety belt pretensioner. accidental deployment. NOTE: Diagnostics or repairs are not to be performed on a seat equipped with a seat side airbag with the WARNING: After deployment, the airbag seat in the vehicle. Prior to attempting to diagnose or surface can contain deposits of sodium repair a seat concern when equipped with a seat side hydroxide, a product of the gas generant airbag, the seat must be removed from the vehicle combustion that is irritating to the skin. Wash and the restraint system diagnostic tools must be your hands with soap and water afterwards. installed in the seat side airbag electrical connectors. The restraint system diagnostic tools must be WARNING: Never probe the connectors on removed prior to operating the vehicle over the the airbag module. Doing so can result in airbag road. deployment, which can result in personal injury. WARNING: The safety belt buckle pretensioner is a pyrotechnic device. Never probe a pretensioner electrical connector. Doing so could result in pretensioner or airbag deployment and could result in personal injury. G12363 en
NOTE: After diagnosing or repairing an SRS, the restraint system diagnostic tools must be removed before operating the vehicle over the road. NOTE: After diagnosing or repairing a seat system, the restraint system diagnostic tools must be 01/2003 2003.0 BA Falcon
501-20b-144
Occupant Restraints — Passive
501-20b-144
REMOVAL AND INSTALLATION (Continued) removed before operating the vehicle over the road. NOTE: The SRS must be fully operational and free of faults before releasing the vehicle to the customer. 1. Disconnect the battery ground cable and wait at least one minute. For additional information, refer to Section 414-01. 2. Remove the two steering wheel back cover plugs. 3. Remove the two driver airbag module bolts (one shown).
Item 3
Description Steering wheel audio controls connector
5. Attach the restraint system diagnostic tools to the clockspring electrical connectors at the top of the steering column.
6. Push in on the glove compartment sides, releasing the stops and lowering it out of the way.
4. Remove the driver airbag module. 1. Release the two retaining tabs. Disconnect the driver airbag module electrical connector. Label the driver airbag module squib number on the driver airbag module electrical connector before disconnecting. 2. Release the two retaining tabs. Disconnect the driver airbag module electrical connector. Label the driver airbag module squib number on the driver airbag module electrical connector before disconnecting. 7. Through the glove compartment opening, release 3. Disconnect the horn switch electrical the tab and disconnect the passenger airbag connector. module electrical connector. 4. Remove the driver airbag module.
Item 1 2
Description Clokspring LH connector Clokspring RH connector
G12363 en
01/2003 2003.0 BA Falcon
501-20b-145
Occupant Restraints — Passive
501-20b-145
REMOVAL AND INSTALLATION (Continued) 8. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger airbag module electrical connector.
3. Attach the restraint system diagnostic tool to the front RH seat safety belt buckle pretensioner floor electrical connector.
Vehicles with power seats
4. Attach the restraint system diagnostic tool to the vehicle harness side of the LH side air curtain electrical connector. 5. From under the front LH seat, push in to release the tab and disconnect the safety belt buckle pretensioner electrical connector.
WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side airbag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side airbag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The side impact sensors (if equipped) are located at or near the base of the B-pillars. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). 1. Vehicles with power seats, disconnect the battery ground cable and wait at least one minute. For additional information, refer to Section 414-01. 2. From under the front RH seat, push in to release 6. Attach the restraint system diagnostic tool to the the tab and disconnect the safety belt buckle front LH seat safety belt buckle pretensioner floor pretensioner electrical connector. electrical connector.
7. Connect the battery ground cable. For additional information, refer to Section 414-01.
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01/2003 2003.0 BA Falcon
501-20b-146
Occupant Restraints — Passive
501-20b-146
REMOVAL AND INSTALLATION (Continued) 8. With the restraint system diagnostic tools installed at all deployable devices, prove out the supplemental restraint system (SRS). For additional information, refer to Airbag and Safety Belt Pretensioner Supplemental Restraint System (SRS) in this section. 9. Disconnect the battery ground cable and wait at least one minute. For additional information, refer to Section 414-01. Installation WARNING: To reduce the risk of serious personal injury, read and follow all warnings, cautions, and notes at the beginning of the deactivation procedure. Vehicles with power seats 1. 2. 3. 4.
Item Description Clokspring LH connector For vehicles with power seats, connect the battery 1 2 Clokspring RH connector ground cable. For additional information, refer to Section 414-01. 3 Steering wheel audio controls connector Position the front seats rearward. 6. Install the two driver airbag module bolts (one Disconnect the battery ground cable and wait at shown). least one minute. For additional information, refer to Section 414-01. Remove the restraint system diagnostic tools from the clockspring electrical connector at the top of the steering column.
7. Install the two steering wheel back cover plugs. 8. Connect the battery ground cable. For additional information, refer to Section 414-01. 5. Position the driver airbag module to the steering wheel. 1. Connect the horn switch electrical connector. CAUTION: The clockspring electrical connectors are unique and cannot be reversed when connected to the driver airbag module. Match the electrical connector key to the keyway in the driver airbag module. Do not force the electrical connectors into the driver airbag module. 2. Connect the driver airbag module electrical connectors as noted during removal. 3. Position the driver airbag module to the steering wheel.
G12363 en
WARNING: The restraint system diagnostic tool is for restraint system service only. Remove from vehicle prior to road use. Failure to remove could result in injury and possible violation of vehicle safety standards. 9. With the restraint system diagnostic tools still installed at the remaining deployable devices, prove out the supplemental restraint system (SRS). For additional information, refer to Airbag and Safety Belt Pretensioner Supplemental Restraint System (SRS) in the Diagnosis and Testing portion of this section. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side airbag supplemental restraint system (SRS) components and before servicing, replacing, 01/2003 2003.0 BA Falcon
501-20b-147
Occupant Restraints — Passive
501-20b-147
REMOVAL AND INSTALLATION (Continued) 15. Move and tilt the front seats to their highest and adjusting or striking components near the most forward position. front or side airbag sensors, such as doors, instrument panel, console, door latches, WARNING: To avoid accidental strikers, seats and hood latches. deployment and possible personal injury, the The side impact sensors (if equipped) are backup power supply must be depleted before located at or near the base of the B-pillars and repairing or replacing any front or side airbag C-pillars. supplemental restraint system (SRS) To deplete the backup power supply energy, components and before servicing, replacing, disconnect the battery ground cable and wait adjusting or striking components near the at least one minute. Be sure to disconnect front or side airbag sensors, such as doors, auxiliary batteries and power supplies (if instrument panel, console, door latches, equipped). strikers, seats and hood latches. 10. Disconnect the battery ground cable and wait at The side impact sensors (if equipped) are least one minute. For additional information, refer located at or near the base of the B-pillars and to Section 414-01. C-pillars. 11. Remove the restraint system diagnostic tool from To deplete the backup power supply energy, the vehicle harness side of the passenger airbag disconnect the battery ground cable and wait module electrical connector. at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). 16. Vehicles with power seats, disconnect the battery ground cable and wait at least one minute. For additional information, refer to Section 414-01. 17. From under the front RH seat, remove the restraint system diagnostic tool from the safety belt buckle pretensioner floor electrical connector.
12. Connect the passenger airbag module electrical connector.
13. Close the glove compartment. 14. Connect the battery ground cable. For additional information, refer to Section 414-01.
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01/2003 2003.0 BA Falcon
501-20b-148
Occupant Restraints — Passive
501-20b-148
REMOVAL AND INSTALLATION (Continued) 18. From under the front RH seat, connect the safety belt buckle pretensioner electrical connector.
Passenger Airbag Module Special Tool(s) Diagnostic Tool, Restraint System (2 req’d) 418-F395 (014-R1079)
Diagnostic Tool, Restraint System (4 req’d) 418-F403
Item 1 2
Description Seat belt pretensioners Pretensioner electrical connector
Diagnostic Tool, Restraint System (2 req’d) 418-F088 (105-R0012)
19. From under the front LH seat, remove the restraint system diagnostic tool from the safety belt buckle pretensioner floor electrical connector. 20. From under the front LH seat, connect the safety belt buckle pretensioner electrical connector. 21. Connect the battery ground cable. For additional Removal information, refer to Section 414-01. WARNING: Always wear safety glasses when WARNING: The restraint system repairing an airbag supplemental restraint system diagnostic tool is for restraint system service (SRS) vehicle and when handling an airbag only. Remove from the vehicle prior to road module. This will reduce the risk of injury in the use. Failure to remove could result in injury event of an accidental deployment. and possible violation of vehicle safety standards. WARNING: Carry a live airbag module with the airbag and deployment door pointed away 22. With all the restraint system diagnostic tools from your body. This will reduce the risk of injury removed, prove out the supplemental restraint system (SRS). For additional information, refer to in the event of an accidental deployment. Airbag and Safety Belt Pretensioner Supplemental Restraint System (SRS), in the Diagnosis and WARNING: Do not set a live airbag module Testing portion of this section. down with the deployment door face down. This will reduce the risk of injury in the event of an accidental deployment. WARNING: Carry a live airbag module pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. WARNING: After deployment, the airbag surface can contain deposits of sodium hydroxide, a product of the gas generant combustion that is irritating to the skin. Wash your hands with soap and water afterwards. WARNING: Never probe the connectors on the airbag module. Doing so can result in airbag deployment, which can result in personal injury.
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01/2003 2003.0 BA Falcon
501-20b-149
Occupant Restraints — Passive
501-20b-149
REMOVAL AND INSTALLATION (Continued) WARNING: Airbag modules with discolored or damaged trim covers must be replaced, not repainted.
4. Remove instrument panel lower trim.
WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side airbag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side airbag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The side impact sensors (if equipped) are located at or near the base of the B-pillars and C-pillars. To deplete the backup power supply energy, 5. Remove 3 retaining screws from air register as disconnect the battery ground cable and wait at shown. least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). NOTE: Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. NOTE: The left-hand drive is shown, the right-hand drive is similar. 1. Disconnect the battery ground cable (14301) and wait at least one minute. For additional information, refer to Section 414-01. WARNING: To reduce the risk of serious personal injury, read and follow all warnings, notes, and instructions in the supplemental restraint system (SRS) deactivation/reactivation procedure. 2. Deactivate the supplemental restraint system (SRS). For additional information, refer to Supplemental Restraint System (SRS) Deactivation and Reactivation in the General Procedures portion of this section. 3. Remove passenger side door seal and remove instrument panel end cover.
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6. Remove air register. 7. Disconnect airbag electrical connector by depressing safety lock.
01/2003 2003.0 BA Falcon
501-20b-150
Occupant Restraints — Passive
501-20b-150
REMOVAL AND INSTALLATION (Continued) 10. Remove airbag module from instrument panel.
CAUTION: Do not handle the passenger airbag module by grabbing the edges of the deployment door. Installation WARNING: To reduce the risk of serious personal injury, read and follow all warnings, cautions and notes at the beginning of the removal procedure. NOTE: Make sure the negative battery cable is still disconnected before continuing with the installation portion of this procedure. 8. Remove glovebox. 9. Remove the 4 bolts retaining the Airbag module.
1. Installation is the reverse of removal.
Clockspring Special Tool(s) Diagnostic Tool, Restraint System (2 req’d) 418-F395 (014-R1079)
Diagnostic Tool, Restraint System (4 req’d) 418-F403
Diagnostic Tool, Restraint System (2 req’d) 418-F088 (105-R0012)
G12363 en
01/2003 2003.0 BA Falcon
501-20b-151
Occupant Restraints — Passive
501-20b-151
REMOVAL AND INSTALLATION (Continued) 2. Deactivate the supplemental restraint system (SRS). For additional information, refer to WARNING: Always wear safety glasses when Supplemental Restraint System (SRS) repairing an airbag supplemental restraint system Deactivation and Reactivation in the General (SRS) vehicle and when handling an airbag Procedures portion of this section. module. This will reduce the risk of injury in the 3. Make sure the road wheels are in the event of an accidental deployment. straight-ahead position. Removal
WARNING: Carry a live airbag module with the airbag and trim cover pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. WARNING: Do not set a live airbag module down with the trim cover face down. This will reduce the risk of injury in the event of an accidental deployment. WARNING: After deployment, the airbag surface can contain deposits of sodium hydroxide, a product of the gas generant combustion that is irritating to the skin. Wash your hands with soap and water afterwards.
WARNING: To reduce the risk of serious personal injury, read and follow all warnings, cautions, notes, and instructions in the steering wheel removal and installation procedure. 4. Remove the steering wheel. For additional information, refer to Section 211-04. 5. Remove the screws and the instrument panel lower steering column cover. For additional information, refer to Section 211-04.
WARNING: Never probe the connectors on the airbag module. Doing so can result in airbag deployment, which can result in personal injury. WARNING: Airbag modules with discolored or damaged trim covers must be replaced, not repainted. WARNING: To avoid accidental deployment and possible personal injury, the backup power Item Description supply must be depleted before repairing or replacing any front or side airbag supplemental 1 Screw restraint system (SRS) components and before 2 Steering lever column adjustment servicing, replacing, adjusting or striking Screw components near the front or side airbag sensors, 3 such as doors, instrument panel, console, door 6. Apply two strips of masking tape across the latches, strikers, seats and hood latches. clockspring to prevent accidental rotation when The side impact sensors (if equipped) are located the clockspring is removed. at or near the base of the B-pillars and C-pillars. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). NOTE: Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. 1. Disconnect the battery ground cable (14301) and wait at least one minute. For additional information, refer to Section 414-01. WARNING: To reduce the risk of serious personal injury, read and follow all warnings, cautions, notes, and instructions in the supplemental restraint system (SRS) deactivation/reactivation procedure. G12366 en
CAUTION: Do not use a prying device to detach the shift lever boot or damage to the steering column shrouds may result. 01/2003 2003.0 BA Falcon
501-20b-152
Occupant Restraints — Passive
501-20b-152
REMOVAL AND INSTALLATION (Continued) 7. Detach the gear selector boot from the shrouds (column shift vehicles only).
9. Disconnect the 2 wire harness from the clocjkspring.
8. Remove the upper steering column shroud. 10. Unclip and slide the clockspring off the steering column shaft. 1. Lift where shown, releasing the retaining clips and romove the upper steering column trim panel out of the instrument cluster finish panel.
2. Remove the upper steering column shroud hard shell.
11. Attach the restraint system diagnostic tool to the vehicle harness electrical connector. 12. Connect the battery ground cable. For additional information, refer to Section 414-01. 13. With the restraint system diagnostic tools installed at all deployable devices, prove out the supplemental restraint system (SRS). For additional information, refer to Airbag and Safety Belt Pretensioner Supplemental Restraint System (SRS), in the Diagnosis and Testing portion of this section. 14. Disconnect the battery ground cable and wait at least one minute. For additional information, refer to Section 414-01. Installation 1. Before fitting the clockspring it must be centralized.
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01/2003 2003.0 BA Falcon
501-20b-153
Occupant Restraints — Passive
501-20b-153
REMOVAL AND INSTALLATION (Continued) 6. Slide the clockspring over the upper steering 2. New Clockspring shaft, and clip it to the multifunction switch. Remove the grenade pin. NOTE: This clockspring is used in another vehicle Rotate the centre hub clockwise 1/4 of a turn, application. When installed in a Falcon it is rotated relative to the body of the clockspring. 180 degrees, and the "TOP" mark should be located at the bottom. 7. Route the wiring and attach the two connectors to the wire harness bracket. 8. Refit the shrouds and gearshift selector boot (columnshift vehicles only). See Section 211-04-5 & Section 211-04-6 Vehicle repairs reusing the same clockspring 1. Remove the tape applied during clockspring removal prior to refiting the shrouds.
Item 1
Description Remove grenade pin before installing onto column
3. Existing Clockspring Rotate the centre hub fully anticlockwise relative to the body of the clockspring. The green and yellow wire harnesses should be almost aligned to the "TOP" marking on the body. Rotate the centre hub clockwise 3 1/2 turns clockwise.
WARNING: To reduce the risk of serious personal injury, read and follow all warnings, cautions, notes, and instructions in the steering wheel removal and installation procedure. 2. Install the steering wheel. Do not install the driver airbag module at this time. For additional information, refer to Section 211-04. 3. Attach the restraint system diagnostic tools to the clockspring electrical connectors at the top of the steering column.
All vehicles
4. The clockspring is now suitable for installation on a column that is installed into a vehicle with the road wheels in a straight ahead position. 5. Ensure that the two flats on the lower alloy steering shaft are vertical, with the pip at the bottom.
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1. Connect the battery ground cable. For additional information, refer to Section 414-01. 2. With the restraint system diagnostic tools installed at all deployable devices, prove out the supplemental restraint system (SRS). For additional information, refer to Airbag and Safety Belt Pretensioner Supplemental Restraint System (SRS), in the Diagnosis and Testing portion of this section. 3. Disconnect the battery ground cable and wait at least one minute. For additional information, refer to Section 414-01.
01/2003 2003.0 BA Falcon
501-20b-154
Occupant Restraints — Passive
501-20b-154
REMOVAL AND INSTALLATION (Continued) 4. Remove the restraint system diagnostic tool from the clockspring electrical connector at the top of the steering column.
7. Position the driver airbag module to the steering wheel. 1. Connect the horn switch electrical connector. CAUTION: The clockspring electrical connectors are unique and cannot be reversed when connected to the driver airbag module. Match the electrical connector key to the keyway in the driver airbag module. Do not force the electrical connectors into the driver airbag module. 2. Connect the driver airbag module electrical connectors as noted during removal. 3. Position the driver airbag module to the steering wheel. 8. Install the two driver airbag module bolts (one shown).
5. Position the driver airbag module to the steering wheel. 1. Connect the driver airbag module electrical connector. 2. Slide and engage the driver airbag module electrical connector locking clip. 3. Connect the horn switch electrical connector. 4. Position the driver airbag module to the steering wheel.
9. Install the two steering wheel back cover plugs.
Item 1 2 3
Description Clokspring LH connector Clokspring RH connector Steering wheel audio controls connector
WARNING: To reduce the risk of serious personal injury, read and follow all warnings, cautions, notes, and instructions in the supplemental restraint system (SRS) deactivation/reactivation procedure. 10. Reactivate the supplemental restraint system (SRS). For additional information, refer to Supplemental Restraint System (SRS) Deactivation and Reactivation in the General Procedures portion of this section.
WARNING: The restraint system diagnostic tool is for restraint system service only. Remove from the vehicle prior to road use. Failure to remove could result in injury 6. Remove the restraint system diagnostic tools from and possible violation of vehicle safety the clockspring electrical connectors at the top of standards. the steering column. 11. With all the restraint system diagnostic tools removed, prove out the supplemental restraint system (SRS). For additional information, refer to Airbag and Safety Belt Pretensioner Supplemental Restraint System (SRS), in the Diagnosis and Testing portion of this section.
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01/2003 2003.0 BA Falcon
501-20b-155
Occupant Restraints — Passive
501-20b-155
REMOVAL AND INSTALLATION (Continued)
Side Airbag Bridge Resistor Special Tool(s) Diagnostic Tool, Restraint System (2 req’d) 418-F395 (014-R1079)
Diagnostic Tool, Restraint System (4 req’d) 418-F403
Diagnostic Tool, Restraint System (2 req’d) 418-F088 (105-R0012)
NOTE: Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and carry out the diagnostic procedure again. 1. Disconnect the battery ground cable (14301) and wait at least one minute. For additional information, refer to Section 414-01. WARNING: To reduce the risk of serious personal injury, read and follow all warnings, notes, and instructions in the supplemental restraint system (SRS) deactivation / reactivation procedure. 2. Deactivate the supplemental restraint system (SRS). For additional information, refer to Supplemental Restraint System (SRS) Deactivation and Reactivation in the General Procedures portion of this section. Installation
WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side airbag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side airbag sensors, Removal such as doors, instrument panel, console, door latches, strikers, seats and hood latches. WARNING: Always wear safety glasses when The side impact sensors (if equipped) are located repairing an airbag supplemental restraint system at or near the base of the B-pillars and C-pillars. (SRS) vehicle and when handling an airbag To deplete the backup power supply energy, module. This will reduce the risk of injury in the disconnect the battery ground cable and wait at event of an accidental deployment. least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). WARNING: Never probe the connectors on 1. Disconnect the battery ground cable (14301) and the airbag module. Doing so can result in airbag wait at least one minute. For additional deployment, which can result in personal injury. information, refer to Section 414-01. WARNING: To avoid accidental deployment WARNING: The restraint system and possible personal injury, the backup power diagnostic tool is for restraint system service supply must be depleted before repairing or only. Remove from the vehicle prior to road replacing any front or side airbag supplemental use. Failure to remove could result in injury restraint system (SRS) components and before and possible violation of vehicle safety servicing, replacing, adjusting or striking standards. components near the front or side airbag sensors, 2. With all the restraint system diagnostic tools such as doors, instrument panel, console, door removed, prove out the supplemental restraint latches, strikers, seats and hood latches. system (SRS). For additional information, refer to The side impact sensors (if equipped) are located Airbag and Safety Belt Pretensioner Supplemental at or near the base of the B-pillars and C-pillars. Restraint System (SRS) in the Diagnosis and To deplete the backup power supply energy, Testing portion of this section. disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped).
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01/2003 2003.0 BA Falcon
501-20b-156
Occupant Restraints — Passive
501-20b-156
REMOVAL AND INSTALLATION (Continued)
Seat Position Sensor Special Tool(s) Diagnostic Tool, Restraint System (2 Req’d) 418-F403
1. Deactivate the supplemental restraint system (SRS). For additional information, refer to Supplemental Restraint System (SRS) Deactivation and Reactivation in the General Procedures portion of this section. All vehicles WARNING: To reduce the risk of serious personal injury, read and follow all warnings, cautions, notes, and instructions in the seat removal and installation procedure.
Diagnostic Tool, Restraint System (2 req’d) 418-F088 (105-R0012)
Removal All vehicles WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side airbag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side airbag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The side impact sensors (if equipped) are located at or near the base of the B-pillars. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). 1. Disconnect the battery ground cable (14301) and wait at least one minute. For additional information, refer to Section 414-01. Vehicles with side airbags WARNING: To reduce the risk of serious personal injury, read and follow all warnings, notes, and instructions in the supplemental restraint system (SRS) deactivation/reactivation procedure.
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CAUTION: Use care when handling the seat and track assembly. Dropping the assembly or sitting on a seat not secured in the vehicle can result in damaged components. 1. Remove the driver seat. For additional information, refer to Section 501-10. Vehicles with power seats 1. Remove the seat position sensor.
Item 1 2 3
Description Seat position sensor Bolt hole Sensor Electrical connector
1. Disconnect the electrical connector. 2. Remove the bolt. 3. Press the sensor tab inward to release and remove the sensor.
01/2003 2003.0 BA Falcon
501-20b-157
Occupant Restraints — Passive
501-20b-157
REMOVAL AND INSTALLATION (Continued) 4. Remove the magnet assembly bolt. could result in injury and possible violation of 5. Slide back and remove the magnet assembly. vehicle safety standards. 1. With all the restraint system diagnostic tools Vehicles with manual seat removed, prove out the supplemental restraint 1. Remove the seat position sensor. system (SRS). For additional information, refer to Airbag and Safety Belt Pretensioner Supplemental 1. Disconnect the electrical connector. Restraint System (SRS), in the Diagnosis and 2. Remove the bolt. Testing portion of this section. 3. Remove the seat position sensor. 2. Check the active restraint system for correct Installation operation. For additional information, refer to Vehicles with manual seat Section 501-20A. 1. Install the seat position sensor. 1. Position the seat position sensor. Align the sensor locator clips to the seat alignment bracket. 2. Install the bolt. 3. Connect the electrical connector. Vehicles with power seats 1. Install the seat position sensor. 1. Install the magnet assembly onto the pivot and slide forward. 2. Install the bolt. 3. Position the sensor and engage the retaining tab. 4. Install the bolt. 5. Connect the electrical connector. All vehicles WARNING: To reduce the risk of serious personal injury, read and follow all warnings, cautions, notes, and instructions in the seat removal and installation procedure. NOTE: Make sure the battery ground cable is still disconnected before proceeding with the installation portion of this procedure. 1. Install the driver seat into the vehicle. For additional information, refer to Section 501-10. Vehicles with side airbags WARNING: To reduce the risk of serious personal injury, read and follow all warnings, notes, and instructions in the supplemental restraint system (SRS) deactivation/reactivation procedure. 1. Reactivate the supplemental restraint system (SRS). For additional information, refer to Supplemental Restraint System (SRS) Deactivation and Reactivation in the General Procedures portion of this section. All vehicles WARNING: The restraint system diagnostic tool is for restraint system service only. Remove from vehicle prior to road use. Failure to remove G12369 en
Side Airbag Module Special Tool(s) Diagnostic Tool, Restraint System (2 Req’d) 418-F088 (105-R0012)
Removal WARNING: Always wear safety glasses when repairing an airbag supplemental restraint system (SRS) vehicle and when handling an airbag module. This will reduce the risk of injury in the event of an accidental deployment. WARNING: Carry a live side airbag module with the airbag and tear seam pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. WARNING: Do not set a live side airbag module down on the cover tear seam. This will reduce the risk of injury in the event of an accidental deployment. WARNING: After deployment, the airbag surface can contain deposits of sodium hydroxide, a product of the gas generant combustion that is irritating to the skin. Wash your hands with soap and water afterwards. WARNING: Never probe the connectors on the airbag module. Doing so can result in airbag deployment, which can result in personal injury. WARNING: Vehicle sensor orientation is critical for proper system operation. If a vehicle equipped with an airbag supplemental restraint system (SRS) is involved in a collision, inspect the sensor mounting bracket and wiring pigtail for deformation. Replace and properly position the sensor or any other damaged supplemental restraint system (SRS) components whether or not the airbag is deployed. 01/2003 2003.0 BA Falcon
501-20b-158
Occupant Restraints — Passive
501-20b-158
REMOVAL AND INSTALLATION (Continued) WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side airbag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side airbag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. Please refer to the appropriate vehicle shop manual to determine location of the front airbag sensors. The side airbag sensors are located at or near the base of the B-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). WARNING: The restraint system diagnostic tool is for restraint system service only. Remove from vehicle prior to road use. Failure to remove could result in injury and possible violation of vehicle safety standards. WARNING: Never power up a seat inside or out of the vehicle except using the in-car connector dedicated to power supply.
NOTE: Diagnostics may be performed on seat systems other than the side airbag or the safety belt pretensioner (if equipped) system (lumbar, climate controlled, heated, power seat track) with the seat installed in the vehicle as long as the restraint system diagnostic tools are installed under the seats in the side airbag and safety belt pretensioner to floor connectors. NOTE: After diagnosing/repairing a seat system the restraint system diagnostic tools must be removed before operating the vehicle over the road. NOTE: When replacing the side airbag after deployment, refer to Section 501-10 for additional information concerning the installation of a new side airbag. NOTE: Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. NOTE: The left-hand drive driver seat side airbag removal is shown, all others are similar. 1. Remove the affected seat from the vehicle. For additional information, refer to Section 501-10. NOTE: Use care not to damage the center hole plug.
2. Pry out and remove the seat cushion adjuster WARNING: Wait at least one minute after handle center plug. disconnecting the battery ground cable before disconnecting any supplemantal restraint system 3. Remove the seat cushion adjuster handle. electrical connector. Failure to follow this warning 1. Release the retaining tabs. could cause premature deployment and may 2. Pull and remove the seat cushion adjuster result in personal injury. handle. 4. Remove the plastic outboard side cover. CAUTION: Use care when handling the seat and track assembly. Dropping the assembly or 1. Remove reclining knob. sitting on a seat not secured in the vehicle may 2. Remove the 2 screw. result in damaged components. 3. Pull out to release the retaining clips and NOTE: If a seat equipped with a seat mounted side remove the seat cushion side shield. airbag and/or a safety belt pretensioner (if equipped) If equipped, disconnect the power seat system is being serviced the airbag system must be switch electrical connector. deactivated. Refer to Airbag and Safety Belt Pretensioner Supplemental Restraint System (SRS), in the Diagnosis and Testing portion of this section. NOTE: Restraint system diagnostic tools MUST be installed under the seats in the side airbag and safety belt pretensioner. NOTE: Diagnostics or repairs are not to be performed on a side airbag system and/or a safety belt pretensioner (if equipped) system with the seats in the vehicle. Prior to attempting to diagnose/repair the side airbag system and/or a safety belt pretensioner (if equipped) system the seats must be removed from the vehicle and the restraint system diagnostic tools must be installed in the side airbag and the safety belt pretensioner (if equipped) connectors. The restraint system diagnostic tools must be removed prior to operating the vehicle over the road. G12369 en
4. Where applicable, disconnect plugs from switch and/or memory buttons. 01/2003 2003.0 BA Falcon
501-20b-159
Occupant Restraints — Passive
501-20b-159
REMOVAL AND INSTALLATION (Continued) 5. Remove the inboard seat cushion side shield. Pull out to release the retaining clips.
NOTE: Note the wire harness routing for installation. 6. Remove three fir tree clips.
7. Remove the M10 bolts.
CAUTION: When positioning the seat or separating the seat bottom from the back, be careful not to damage the seat back pivot or the recliner mechanism. This can cause damage to the seat components. 8. Remove the M10 seat backrest. 1. Remove the seat backrest bolts. 2. Slide the seat backrest pivot stud out of the seat cushion frame and remove the seat backrest.
9. Turn the manual lumbar handle clockwise until it stops, releasing all tension on the manual lumbar support cable. 10. Remove the manual lumbar support adjustment handle. Refer to Section 501-10 Lumbar Knob. 11. Remove the seat backrest trim cover. WARNING: Front seat back trim covers installed on seats equipped with side airbags cannot be repaired; they are to be replaced (cleaning is permissible). CAUTION: Use care when separating the seat cushion trim cover from the hook and loop strip. The hook and loop strip can be torn from the seat cushion foam. 1. Undo the 4 rear J clip retainer.
G12369 en
01/2003 2003.0 BA Falcon
501-20b-160
Occupant Restraints — Passive
501-20b-160
REMOVAL AND INSTALLATION (Continued) 12. Separate the side airbag wiring harness pin-type retainers from the seat back frame.
2. Unzip side airbag cover (where fitted) and remove it with the foam assembly. NOTE: If installing a new side airbag module, use WARNING: Never probe the new retaining nuts. If the same side airbag module is connectors on the air bag module. Doing to be reused, then reuse the side airbag module so can result in air bag deployment, which retaining nuts. can result in personal injury. 13. Remove the side airbag module. WARNING: After deployment, the air 1. Remove the nuts. bag surface can contain deposits of 2. Remove the side airbag module. sodium hydroxide, a product of the gas generant combustion that is irritating to the skin. Wash your hands with soap and water afterward.
Item 1 2
G12369 en
Description Nut Side Airbag Module
01/2003 2003.0 BA Falcon
501-20b-161
Occupant Restraints — Passive
501-20b-161
REMOVAL AND INSTALLATION (Continued) objects are found, remove them. Failure to do so may result in personal injury, in the event of an WARNING: Always wear safety glasses when airbag deployment. repairing an airbag supplemental restraint system (SRS) vehicle and when handling an airbag WARNING: Inspect the side airbag cavity in module. This will reduce the risk of injury in the the seat back pad for any foreign objects. If any event of an accidental deployment. foreign objects are found, remove them. Failure to do so may result in personal injury in the event of an airbag deployment. WARNING: Carry a live side airbag module with the airbag and tear seam pointed away from your body. This will reduce the risk of injury in the WARNING: Before installing the side airbag event of an accidental deployment. module, check it for damage and foreign objects. If the airbag module is damaged, replace it. If any foreign objects are found, remove them. Failure to WARNING: Do not set a live side airbag do so may result in personal injury, in the event of module down on the cover tear seam. This will an airbag deployment. reduce the risk of injury in the event of an accidental deployment. WARNING: If the airbag cover has separated or the airbag material has been exposed, install a WARNING: Never probe the connectors on new side airbag module. Do not attempt to repair the airbag module. Doing so can result in airbag the airbag module. Failure to do so may result in deployment, which can result in personal injury. personal injury in the event of an airbag deployment. WARNING: Vehicle sensor orientation is critical for proper system operation. If a vehicle CAUTION: Make sure the side airbag wiring equipped with an airbag supplemental restraint harness is not pinched between the side airbag system (SRS) is involved in a collision, inspect the sensor mounting bracket and wiring pigtail for module and the mounting bracket. deformation. Replace and properly position the NOTE: If a seat equipped with a seat mounted side sensor or any other damaged supplemental airbag and/or a safety belt pretensioner (if equipped) restraint system (SRS) components whether or system is being serviced the airbag system must be not the airbag is deployed. deactivated. Refer to Airbag and Safety Belt Pretensioner Supplemental Restraint System (SRS), WARNING: To avoid accidental deployment in the Diagnosis and Testing portion of this section. and possible personal injury, the backup power NOTE: Restraint system diagnostic tools MUST be supply must be depleted before repairing or installed under the seats in the side airbag and safety replacing any front or side airbag supplemental belt pretensioner (if equipped) to floor connectors. restraint system (SRS) components and before servicing, replacing, adjusting or striking NOTE: Diagnostics or repairs are not to be performed components near the front or side airbag sensors, on a side airbag system and/or a safety belt such as doors, instrument panel, console, door pretensioner (if equipped) system with the seats in the latches, strikers, seats and hood latches. vehicle. Prior to attempting to diagnose/repair the side Please refer to the appropriate vehicle shop airbag system and/or a safety belt pretensioner (if manual to determine location of the front airbag equipped) system the seats must be removed from sensors. the vehicle and the restraint system diagnostic tools The side airbag sensors are located at or near the must be installed in the side airbag and the safety belt base of the B-pillar. To deplete the backup power pretensioner (if equipped) connectors at the floor supply energy, disconnect the battery ground connectors. The restraint system diagnostic tools cable and wait at least one minute. Be sure to must be removed prior to operating the vehicle over disconnect auxiliary batteries and power supplies the road. (if equipped). NOTE: Diagnostics may be performed on seat systems other than the side airbag or the safety belt WARNING: The restraint system diagnostic pretensioner (if equipped) system (lumbar, climate tool is for restraint system service only. Remove controlled, heated, power seat track) with the seat from vehicle prior to road use. Failure to remove installed in the vehicle as long as the restraint system could result in injury and possible violation of diagnostic tools are installed under the seats in the vehicle safety standards. side airbag and safety belt pretensioner to floor WARNING: Inspect the mounting surfaces of connectors. the side airbag module and the seat back frame mounting bracket for any foreign objects before installing the side airbag module. If any foreign
Installation
G12369 en
01/2003 2003.0 BA Falcon
501-20b-162
Occupant Restraints — Passive
501-20b-162
REMOVAL AND INSTALLATION (Continued) NOTE: After diagnosing/repairing a seat system the restraint system diagnostic tools must be removed before operating the vehicle over the road.
11. Connect the battery ground cable (14301). For additional information, refer to Section 414-01.
WARNING: The restraint system diagnostic tool is for restraint system service only. Remove from vehicle prior to road use. Failure to remove could result in injury and possible violation of vehicle safety standards. NOTE: Repair is made by installing a new part only. If 12. With all the restraint system diagnostic tools removed, prove out the airbag system. For the new part does not correct the condition, install the additional information, refer to Airbag and Safety original part and perform the diagnostic procedure Belt Pretensioner Supplemental Restraint System again. (SRS), in the Diagnosis and Testing portion of this NOTE: The left-hand drive driver seat side airbag section. installation is shown, all others are similar. 13. Check the restraint system for correct operation. 1. Assemble Airbag module to seat frame ensuring front plastic retaining features are located over metal bracket tabs. 2. Install the two M5 nyloc nuts. 3. Check and fit dummy module to inboard side of seat. 4. Fit foam and trim to frame. 5. Pull SIAB covering material ("chute") through and around SIAB module. 6. Close zip around seat frame.
NOTE: When replacing the side airbag after deployment, refer to Section 501-10 for additional information concerning the installation of a new side airbag.
CAUTION: Ensure that the zip is closed properly. CAUTION: Trim cover hook and loop must be securely engaged and the trim cover must be aligned in its proper orientation. 7. Insert trim cover and foam pad into seat back assembly. Refer to Front Seat Back in Section 501-10. 8. Insert seat back into seat. Refer to Front Seat Back in Section 501-10. 9. Insert plastic outboard side cover. Refer to Outer Side Cover in Section 501-10. NOTE: A repair is made by installing new components only. If a new part is installed and new part does not correct the condition, install the original part and carry out the diagnostic procedure again. NOTE: If a side airbag deployment took place, new seatback pad, trim cover, and side airbag module must be installed. A new seatback frame should be installed if necessary. CAUTION: Use care when handling the seat and track assembly. Dropping the assembly or sitting on a seat not secured in the vehicle may result in damaged components. NOTE: Make sure to follow all steps and instructions in the installation procedure of the affected seat. 10. Install the affected seat into the vehicle. For additional information, refer to Section 501-10. G12369 en
01/2003 2003.0 BA Falcon
501-25A-1
Body Repairs — General Information
501-25A-1
SECTION : 501-25A Body Repairs — General Information VEHICLE APPLICATION : 2003.0 BA Falcon CONTENTS
PAGE
DESCRIPTION AND OPERATION Body Repairs — General Information .................................................................................501-25A-2 Jigs and Measuring Equipment .........................................................................................501-25A-2 Panel Repairs ....................................................................................................................501-25A-2 Replacement Body Panels ...............................................................................................501-25A-2 Sealants and Corrosion Protection ....................................................................................501-25A-2 Dust and Water Leaks .......................................................................................................501-25A-3 Wind Noise ........................................................................................................................501-25A-3
01/2003 2003.0 BA Falcon
501-25A-2
Body Repairs — General Information
501-25A-2
DESCRIPTION AND OPERATION
Body Repairs — General Information
Generally it there is a sharp crease across a mounting point, it is better not to attempt straightening. It is recommended that any major deformation of the High Strength Low Alloy Steel (H.S.L.A.) should be vehicle be repaired on controlled measuring equipment, such as a dedicated jig, variable mounting treated as a special case, H.S.L.A. steel is heat sensitive, therefore excessive deformation and jig or a universal measuring system, jig brackets or straightening could be detrimental to the material guide charts specifically prepared to suit the vehicle. Due to the structure of the vehicle, impact forces can strength, where any doubt exists the relevant panel must be replaced. be transmitted through the whole body causing The side door strainers must not be repaired under deformation in an area well away from the point of any circumstances. impact.
Jigs and Measuring Equipment
The principle of repair using reversal of impact forces, carried out an suitable equipment, will not only return the underframe to the original specifications, it should, if applied correctly square-up the complete body shell. High strength low alloy steel (H.S.L.A.) panels will often be returned to usefulness using this principal, but care must be exercised in repairing this material.
Panel Repairs When performing repairs it is essential that the straightening or correcting of stress will not create regions, in the panel, which are stiff, brittle or weak when the metal has been returned back to its original position. Particular attention must be given to mounting points for steering or suspension systems, when making the decision to straighten panel damage. G33920 en
Replacement Body Panels The use of genuine Ford panels in all repair situations is desirable.Certain replacement panels are covered by a Lifelong Panel Warranty against perforation corrosion. Refer to an Authorised Ford Dealer for details. Genuine Ford Original Equipment Manufacturer (O.E.M.) parts are stamped from original sheet metal dies which ensure quality of size, fit, finish, strength and durability. A five year perforation warranty also applies.
Sealants and Corrosion Protection Various sealants and anti-corrosion treatments are used throughout the vehicle. Ensure the correct treatments are applied when caning out body repairs. Refer to the Corrosion Protection section of this 01/2003 2003.0 BA Falcon
501-25A-3
Body Repairs — General Information
501-25A-3
DESCRIPTION AND OPERATION (Continued) manual for sealant description and application.
Dust and Water Leaks Sealer locations should be considered when checking for dust or water leaks. The forward motion of the vehicle causes any unsealed, small opening in the lower section of the body to permit air and dust to be drawn into the body. Opening the ventilator air ducts will equalize these pressures. To eliminate dust leakage, determine the exact point at which the dust enters. Under certain conditions, water can enter the body at any point where dust can enter. To determine the exact location of a dust leak, it may be necessary to remove interior or luggage compartment trims. After removing the trim, the location of most leaks will be evident. The entrance of dust is usually indicated by a pointed shaft of dust or silt. Seal these leaks, then road test the vehicle on a dusty road to ensure all leaks are sealed. After the road test, check for indications of a dust pattern around the door openings, cowl side trim panel, lower part of the quarter trim panel and in the luggage compartment. Sometimes leaks can be located by putting bright lights under the vehicle with the above components removed, and checking the interior of the body joints and weld lines. A light will show through where leaks exist. A vacuum/air/water leak detector can be useful to locate dust leaks, wind and water leaks.
Wind Noise Air entering or exiting the vehicle through small openings in the body can result in wind noise. Sources of wind noise are detected by driving the vehicle at highway speeds in four different directions. Listen for sources of wind noise with all windows closed, radio off, A/C blower motor turned off and ventilation ducts open. A stethoscope can be used to pinpoint the source of the noise. Most wind noise-producing leaks will occur at the door and window seals or at sheet metal joints in the door or the door opening in the body. Seal all leaks with sealant or by repositioning or replacing the seals. Road test the vehicle to make sure all leaks have been adequately sealed. An alternate method of verifying corrective actions involves the use of Ultrasonic Leak Detector. After identifying the leak point through a road test, obtain a meter reading by using the leak detector. A check with the leak detector after repairing the leak will verify the effectiveness of the corrective action. A final road test may still be advisable to make sure that other objectionable leaks, not noticed because of a major leak, do not exist.
G33920 en
01/2003 2003.0 BA Falcon
501-25B-1
Body Repairs — Corrosion Protection
501-25B-1
SECTION : 501-25B Body Repairs — Corrosion Protection VEHICLE APPLICATION : 2003.0 BA Falcon CONTENTS
PAGE
DESCRIPTION AND OPERATION Electro — Coat ...................................................................................................................501-25B-2 Corrosion Prevention ..........................................................................................................501-25B-2 Corrosion Protection ...........................................................................................................501-25B-2 Safety Precautions .............................................................................................................501-25B-2 GENERAL PROCEDURES Soft Seal Locations .............................................................................................................501-25B-3 Anti — Flutter Adhesive Location .......................................................................................501-25B-5 Button Plug Locations .........................................................................................................501-25B-6 Sound Absorber Locations .................................................................................................501-25B-8 REMOVAL AND INSTALLATION Sound Absorber ..................................................................................................................501-25B-9
01/2003 2003.0 BA Falcon
501-25B-2
Body Repairs — Corrosion Protection
501-25B-2
DESCRIPTION AND OPERATION
Electro — Coat All panels supplied are E-coated in the plant. This is an anti-corrosion paint, not a surface primer. All panels must be lightly scuffed and painted with a two pack primer or primer filler (to improve appearance and to prevent top coat peeling) and then receive normal treatment up to finish coat. Fitting new panels require the removal of E-coat where welding is required and the use of a weld-through zinc rich primer.
Readily flammable overalls or gloves must not be worn during welding operations. In addition, fuel lines, tank and any other flammable materials including wiring looms must be removed if welding is to be carried out in the vicinity. When carrying out welding and similar operations, overalls etc., made of Nylon, Perion, Dralon, etc., must not be worn.
Corrosion Prevention Vehicles requiring body repair must have the anti-corrosion protection reinstated during the repair. The level of protection required and the recommended materials are contained in the following pages. Care should be taken when substituting other type materials, that they will not cause a long term problem, e.g,. Acid curing silicons will promote corrosion when used in contact with painted or bare metal panels.
Corrosion Protection Safety Precautions Anti-corrosion treatments, waxing agents and plastics used in vehicles produce vapours when heated which may cause serious injury if inhaled. In addition to the normal requirements for a safe work place, ensure the following precautions are observed: Keep a fire extinguisher within reach. This safety precaution must be taken although the anti-corrosion treatments generally do not constitute a direct fire risk. Remove anti-corrosion treatments as far as possible from the vicinity of the area to be welded. Polyurethane hard foam can be removed with cutting tools, wax and underseal are preferably removed using sanding discs or , wire brushes. Wax and underseal can also be removed usinf a hot-air-blower of the kind employed by decorators when laying plastic floors. If anti-corrosion treatments cannot be removed due to lack of space or inaccessibility, fumes and gases produced during welding operations must be extracted directly. This is best accomplished with special extractors with suction heads on flexible hoses that can be conveniently positioned in the working area. Welding operations should always be carried out in seperate, well ventilated areas. Breathing masks must always be used. A hole should be drilled in cavities filled with hard foam on the side away from the operator so that vapours can escape. G33920 en
01/2003 2003.0 BA Falcon
501-25B-3
Body Repairs — Corrosion Protection
501-25B-3
GENERAL PROCEDURES
Soft Seal Locations
Item 1 2
Description Seal Sealer Bead
G33923 en
01/2003 2003.0 BA Falcon
501-25B-4
Body Repairs — Corrosion Protection
501-25B-4
GENERAL PROCEDURES (Continued)
G33923 en
01/2003 2003.0 BA Falcon
501-25B-5
Body Repairs — Corrosion Protection
501-25B-5
GENERAL PROCEDURES (Continued)
Anti — Flutter Adhesive Location
Item 1 2 3
G33924 en
Description Anti Flutter Adhesive – 6.0 to 8.0 mm Dia. Bead Metal to Metal Adhesive 1.5 to 2.5 mm Bead Panel Hood
01/2003 2003.0 BA Falcon
501-25B-6
Body Repairs — Corrosion Protection
501-25B-6
GENERAL PROCEDURES (Continued)
Item 1 2
Description Anti Flutter Adhesive Structural Adhesive
Button Plug Locations
G33924 en
01/2003 2003.0 BA Falcon
501-25B-7
Body Repairs — Corrosion Protection
501-25B-7
GENERAL PROCEDURES (Continued)
G33926 en
01/2003 2003.0 BA Falcon
501-25B-8
Body Repairs — Corrosion Protection
501-25B-8
GENERAL PROCEDURES (Continued)
Sound Absorber Locations
G33926 en
01/2003 2003.0 BA Falcon
501-25B-9
Body Repairs — Corrosion Protection
501-25B-9
REMOVAL AND INSTALLATION
Sound Absorber Removal 1. Remove sound absorber pads.
Installation 1. Reverse the installation procedure.
G33927 en
01/2003 2003.0 BA Falcon
501-25C-1
Body Repairs — Plastic Repairs
501-25C-1
SECTION : 501-25C Body Repairs — Plastic Repairs VEHICLE APPLICATION : 2003.0 BA Falcon CONTENTS
PAGE
DESCRIPTION AND OPERATION Plastic Repairs ...................................................................................................................501-25C-2 Plastic Idendification ..........................................................................................................501-25C-2 Plastic Bumper Repair .......................................................................................................501-25C-2
01/2003 2003.0 BA Falcon
501-25C-2
Body Repairs — Plastic Repairs
501-25C-2
DESCRIPTION AND OPERATION
Plastic Repairs Plastic Idendification
Item 1 2 3 4 5 6
Description Cowl Grille PP Door Handle PA66 Mirror ABS/PC Splash shield PP Bumper cover PP Headlight lens PC (coated)
NOTE: All plastic parts have material idendification codes (Recycling Codes) acoording to SAE J1344.
PC (Polycarbonate) A stiff hard metarial that is not readily cut, sinks in water,difficult to ignite but burns with an orange spluttering flame and yellowish sooty smoke, and sweetish smell when extinguished. In the automative trade, Polycarbonate is blended with other thermoplastics to produce alloys.
PP (Polypropylene) Stiff, hard, easy to cut, has waxy almost greasy feel, floots in water,burns with a yellow flame with a trace of blue at the base of the flame, molten droplets, little smoke and smells of burning oil when extinguished. G33920 en
Automative uses include heater assemblies, batteries, fan shrouds, headlight bodies and kick panels.
ABS (Acrylonitrile Butadiene Styrene) This material is stiff, hard, easily cut with a sharp knife, sinks in water and burns readily with an orange/yellow flame (similar to an acetylene flame) with black smoke and soot flakes. Widely used in the motor car for radiator grilles, tail light bodies, interior and exterior trim panels.
Plastic Bumper Repair Polypropylene Bumpers 1. Cut the rough edges around the flaw with a knife to make it smooth. Sand the area with a sander to make an angle of about 45 degrees. CAUTION: Disconnect the battery ground cable before using any electric welding equipment. 2. Weld damaged area. For service to a cracked area, melt the crack together using an Airless Plastic Welder. For repair of a hole, degrease the area and the reverse side of the damaged area. Install aluminium tape on reverse side of, damaged area. 01/2003 2003.0 BA Falcon
501-25C-3
Body Repairs — Plastic Repairs
501-25C-3
DESCRIPTION AND OPERATION (Continued) 3. Melt the polypropylene welding rod with the welder and deposit it in the cracked area. Take care not to excessively melt the welding rod. If the part is welded with the welding rod melted like jelly, the welding strength will be lowered. Operate a heat gun 12-51 mm away from the part that will be welded. Do not move the welded rod until the welded part cools. NOTE: Do not sand part continuously.
a urethane bumper and polypropylene primer for a polypropylene bumper.
4. Sand the surface of the polypropylene little by little, since it is easily melted even by the abrasion heat. If melted, remove the melted area. Sand the areas to which service agent will be applied. 5. Apply polyproplene primer uniformly to an area larger than the serviced area with a brush. It will take about 10 minutes to dry at 20 °C. NOTE: When mixing the main and stiffering agents,be careful not to allow bubbles to form. 6. Mix the main agent and the stiffering agent in a ratio of one to one. Apply the mixed service agent to the demaged area.Since the servicing agent hardens fast (about five minutes), proceed with the work immediately after mixing the agents. It will take about 30 minutes to dry at 20°C before it can be sanded. NOTE: If excessive force is applied to the area when sanding, the surface will not become smooth. 7. Sand the area with # 180- # 240 sandpaper. If there is fuzz around the repaired area, melt it by heating it slightly with a heat gun. 8. Degrease the painted surface. NOTE: Polyproplene primer will dissolve, even after drying, if it is wiped with solvent. Use only water to clean. 9. Dry the part. 10. Add the softener to the urethane primer surfacer and spray it on the service area. 11. Air dry at 20°C for 8 hours. Force dry at 60°C for 1 hour. 12. Lightly sand the area on which the primer surfacer is sprayed and the complete surface of the bumper with #400-#600 sandpaper.Do not expose the surface of the polyproplene. (Wet sanding or dry sanding is acceptable). 13. Wipe the complete surface of the bumper with degreasing agent. Quickly wipe the surface with a clean rag to degrease it. 14. Apply a matching coat of paint to the polyproplene bumper as described in Section 501-32. Refer to Section 501-32 for refinishing techniques for other plastic components. NOTE: The paint for servicing a polypropylene bumper adheres poorly to a urethane bumper. Therefore, be sure to use only urethane primer for
G33920 en
Item 1 2 3 4 5 6
Description Front bumper absorber Front bumper retainer Front bumper cover Front grille Front lower valance panel Lower air deflector
01/2003 2003.0 BA Falcon
501-25C-4
Body Repairs — Plastic Repairs
501-25C-4
DESCRIPTION AND OPERATION (Continued)
Item 1 2 3 4 5 6
Description Rear bumper arm Rear bumper cover Bumper opening panel Rear lower valance panel Rear bumper absorber Rear bumper side retainer
Item 1 2 3 4
Description Rear bumper retainer Rear bumper absorber Rear bumper arm Rear bumper cover
G33920 en
Item 5 6
Description Rear bumper side retainer Bumper opening panel
Item 1 2 3 4 5
Description Front bumper cover Front bumper absorber Front bumper retainer Front grille Front lower valance panel
01/2003 2003.0 BA Falcon
501-25C-5
Body Repairs — Plastic Repairs
501-25C-5
DESCRIPTION AND OPERATION (Continued)
Item 1 2 3 4 5
Description Rear bumper side retainer Rear bumper absorber Rear bumper cover Lower bumper retainer - Rear Rear lower valance panel
Item 1 2 3
Description Rear bumper cover mounting bracket Rear bumper mounting bracket Rear bumper cover
G33920 en
01/2003 2003.0 BA Falcon
501-25D-1
Body Repairs — Water Leaks
501-25D-1
SECTION : 501-25D Body Repairs — Water Leaks VEHICLE APPLICATION : 2003.0 BA Falcon CONTENTS
PAGE
DESCRIPTION AND OPERATION Water Leaks .......................................................................................................................501-25D-2 General ..............................................................................................................................501-25D-2 Practical execution of tests and checks ............................................................................501-25D-2 Rectifying the leak using recommended tools, auxiliary equipment and materials ...........501-25D-3 Water leaks according to mileage or running time ............................................................501-25D-3 Water leaks after body repairs ..........................................................................................501-25D-3 Water drainage system .....................................................................................................501-25D-3 Water leaks, diagnosis and corrective action: Front passenger compartment .................501-25D-4
01/2003 2003.0 BA Falcon
501-25D-2
Body Repairs — Water Leaks
501-25D-2
DESCRIPTION AND OPERATION
Water Leaks General If water leaks occur after bodywork repairs, the cause can be established using the checks described below. A systematic and logical procedure is required to locate water leaks. Before beginning extensive checks, a thorough visual inspection must be carried out. Visual Inspection The following characteristics may indicate existing leaks: Check the clearance and accurate fit of ancillary components such as the hood, tailgate, doors, and so on. Check for correct fit and possible damage to sealing elements such as blanking plugs, rubber door seals, and so on. Check water drain holes for unhindered flow. Various tests can be used to provide further information on possible leaks: Water test Washer test Road test Test with UV lamp Special mirror test Chalk (powder) test Flow tube (smoke) test
Practical execution of tests and checks Water test NOTE: Never aim a jet of water directly at a rubber seal. Carry out the water test with a second person present (passenger compartment). Use variable washer nozzles (concentrated water jet to fine spray mist). Start in the lower section and spray the whole area, working upwards in stages. The following are suitable for the water test: softened water (liquid soap additive)
Automatic car wash
At various speeds. On various road surfaces. With loaded or unloaded vehicle. Driving through puddles (splash water).
Test with UV lamp Wet the test area with clear water from the outside. Prepare test liquid (see Owner’s Handbook) and apply it from the outside using a suitable water sprayer. Illuminate the relevant area from the inside using the UV lamp. The test liquid will make the leak visible. UV lamp
Benefits of the UV lamp: No need to dry out wet areas before the test. The ingress of water and its subsequent path can be identified precisely. No need to remove most ancillary components from the vehicle.
Mirror test A mirror can be used to see into hard-to-reach areas. Mirror Benefits A switchable light built into the mirror area. The angle of inclination of the mirror can be set manually using the handle. The connector between the handle and the mirror is flexible.
Further tests can be carried out in the washer system. Chalk test (Powder test) Some leaks originate here, or only occur here. The relevant passenger compartment should be In this test, the clamping load and the bearing checked using a torch during the wash procedure. surface of the seal are checked. Performing the test: Road test Dust the sealing surface with chalk powder. If no leaks are located during the tests above, Slowly close the liftgate/door and open it road tests should be carried out on wet roads. again. Road tests under various conditions: G33920 en
01/2003 2003.0 BA Falcon
501-25D-3
Body Repairs — Water Leaks
501-25D-3
DESCRIPTION AND OPERATION (Continued) Check the width and continuity of the chalk imprint to ensure the seal is operating effectively.
Smoke test Test for locating leaks. Set the interior ventilation to the maximum setting. Use a smoke generator machine to create smoke in the test area (interior). A second assistant locates points at which the smoke escapes on the outside.
Age-related factors: Environmental factors UV radiation Extreme climatic conditions Corrosion can have a serious impact on bodywork, in particular as a result of: Lightly or heavily rusted seal carriers Rusted body seal welds Perforation corrosion
Water leaks after body repairs
If a vehicle develops a leak after body repairs, the following points must be taken into consideration in Other equipment such as stethoscopes or particular: ultrasound measuring instruments can be used to The correct seating of ancillary components and locate leaks. their seals (e.g. rear lamps, etc.) must be checked. Rectifying the leak using recommended The correct alignment of doors and luggage tools, auxiliary equipment and materials compartment lids/tailgates must be checked. The Tools and auxiliary equipment: associated seals must not be damaged and must be installed correctly. Dry, absorbent cloths Check that welded seams are correctly sealed. Variable washer nozzle The correct seating of rubber grommets must be Torch, fluorescent tube checked. Mirror The windows must be installed precisely and the Compressed air sealer must take contact with the body all the way Seal lip installer round. Wet/dry vacuum cleaner Seals are fitted correctly as per PCP. Sealing compound compressor Water drainage system Remover for interior trim If a vehicle develops water leaks, then areas into Cutter blade or pocket knife which water is routed or drained should be checked Wedge (wood or plastic) first. (eg. sunroof) Hot air blower Water drainage, front UV lamp Stethoscope Air flow checker Ultrasonic measuring instrument
Other test equipment
Water leaks according to mileage or running time Increasing mileage has an effect on the problem of leaks in a vehicle. Possible influencing factors are: Servicing and maintenance of seals: No maintenance, lack of maintenance or incorrect maintenance Using an incorrect agent (ie. cleaner etc.) Damaged seals: As a result of aging, wear or incorrect handling/assembly. (eg. door sag/demage) Heavy soiling of the vehicle: Heavy soiling of a vehicle can seriously impair the function of water drainage channels in particular, and also of rubber seals. G33920 en
01/2003 2003.0 BA Falcon
501-25D-4
Body Repairs — Water Leaks
501-25D-4
DESCRIPTION AND OPERATION (Continued) Water drainage, side and rear
Diagnosis: Ingress of water into A-pillar area or instrument cluster area Cause: Breaks in adhesive beads Corrective action: Breaks in adhesive beads can be located from inside by using compressed air. The leak can be identified from outside by the escaping air. A second test method is by means of a water test. Diagnosis of a water leak
Sliding roof drainage
Drainage water tank
Water leaks, diagnosis and corrective action: Front passenger compartment Windscreens NOTE: The repair must be carried out in line with approved methods.
Item 1 2
Description Compressed air test Water test
Side windows In the case of fixed side windows (directly glazed), the same problems can arise as for a windscreen. The same corrective actions must therefore be used.
NOTE: In both air/water tests the roof rail weather/strip must be removed first.
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01/2003 2003.0 BA Falcon
501-25D-5
Body Repairs — Water Leaks
501-25D-5
DESCRIPTION AND OPERATION (Continued) Side windows
Item 3
Description Interior door trim
Door seals NOTE: When adjusting the clamping load, the edge alignment of the relevant components must always be taken into consideration. NOTE: Do not realign the flange too far in the direction of the door, as this can reduce the bearing surface of the seal to the door.
Door seal NOTE: If a foam watershield becomes damaged in any way, then it must always be renewed. Diagnosis: Water ingress in the lower part of the interior door trim or in the rocker panel area. Cause: The foam watershield fitted behind the interior door trim exists to drain off water that has entered the door via the drainage holes, either downwards or outwards. If the water shield or foam watershield is damaged or has been fitted incorrectly, then water can get into the passenger compartment. In addition to this, the drainage holes can become clogged with leaves, dirt or excess cavity protection agents. Water gathers in the door and ingresses into the passenger compartment. Check foam watershield for damage or correct fitting. Door seal
Item 1 2
Diagnosis: Ingress of water into the rocker panel area Cause: Insufficient clamping load between seal footprint and sealing surface. Corrective action: Check clamping load: Refer to Chalk Test. Adjust the clamping load: The clamping load is normally adjusted using the striker. When doing so, the edge alignment from the door to the side panel, or from the front door to the rear door must be taken into account. Another setting method is to realign the panel flange for the seal mounting. The clamping load is increased by moving the flange towards the door. Check the bearing surface: Apply chalk evenly to the surface of the seal. Evenly coat the bearing surface of the door with vaseline. Close the door fully, the lock must engage. Open the door. The imprint of the chalk (bearing surface) can be identified in the film of grease. The bearing surface should be at least 5mm across at all points.
Description Door sheetmetal Foam watershield
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01/2003 2003.0 BA Falcon
501-25D-6
Body Repairs — Water Leaks
501-25D-6
DESCRIPTION AND OPERATION (Continued) Checking the seal
Item 1 2 3
Description Panel flange bent too far inwards: small bearing surface Panel flange adjusted correctly: correct bearing surface Check clamping load with a strip of paper
Correct installation of the door seal NOTE: If the seal has a connecting joint, this must always be at the bottom of the door surround.
Other cause: The door seal is attached to the welded flange all the way round. If this welded flange is uneven or damaged at any point (usually in areas with narrow radii) then this point could be subject to leaks. A stretched seal carrier can also cause a leak. In both cases, water gets into the vehicle interior under the seal carrier. Corrective action: Align the deformed welded flange using a hammer and anvil block, prevent and if necessary repair any paint damage. A stretched seal carrier must be realigned by hand. If this is no longer possible, the seal must be renewed.
Sliding roof/tilting roof
NOTE: In the case of a sliding or tilting roof, the Other causes: external rubber seal and the lock actuator or latch The door seal must completely seal the door mechanism must be checked first of all. where it meets the bodywork. Diagnosis: Water can ingress directly or indirectly into the interior of the vehicle if the seal is damaged at Ingress of water at sliding roof aperture any point. Cause: Corrective action: The sliding roof/tilting roof is installed in a A damaged or worn door seal must always be water trap. The water drains off via the water renewed in full. trap, water drain holes and drain hoses. The drain hoses lead downwards on both sides via When renewing the seal, the following must the A-pillar and C-pillar. be taken into account: The drain holes or drain hoses can become Always fit the seal first in the area of the clogged with leaves, dirt, underbody narrow radii (corner points). protection and so on. Next, secure the seal to the flange evenly by Corrective action: tapping lightly with a rubber hammer. The installed seal must not be kinked at any point. Check the water trap for leaks. NOTE: The prescribed length of a seal must not be Check the drain hoses for leaks and for shortened. correct connection to the water trap.
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01/2003 2003.0 BA Falcon
501-25D-7
Body Repairs — Water Leaks
501-25D-7
DESCRIPTION AND OPERATION (Continued) Check the drainage system for unhindered flow, and blow out with compressed air if necessary. Check the external seal and the correct adjustment of the sliding roof.
Item 1 2
Description Roof sheetmetal Headliner
Corrective action: Seal the broken seal welds. If a leak is found in the heater or ventilation housing, the drain holes must be checked first. The housing may have to be removed to check the foam watershield and its bearing surface for damage. Checking foam watershields and water drain holes
Apron panel and heating/ventilation Diagnosis: Ingress of water into the front footwell area Cause: The apron panel is sealed in several places to adjacent components, such as at the joints to the A-pillar or to the floor pan. These seals can be broken. The heater and ventilation housing is attached to the apron panel. The through area is sealed with a foam watershield that is fixed to the housing. The housing has drain holes to allow the water to drain off. If the foam watershield is defective or the drain hole is clogged, water can ingress into the front footwell area. Heater and ventilation housing seal NOTE: Damaged foam watershield must always be renewed.
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Other causes: Fastening bolts and routing holes for cables and hoses must be checked for leaks in the area of the apron panel and instrument cluster (rubber grommets in particular). If the footwell area is wet, then the door hinge seal, the door light switch and cable routing holes must also be checked.
01/2003 2003.0 BA Falcon
501-25D-8
Body Repairs — Water Leaks
501-25D-8
DESCRIPTION AND OPERATION (Continued) Door light switch seal
Rear drip rail seal Diagnosis: Ingress of water into side headlining area Cause: The roof outer panel is sealed with a seal weld at the connection point to the side panel. This seal weld can be concealed with a bezel or trim strip. In the case of estate and hatchback vehicles, there is an additional seal to the rear roof crossmember. Water can enter here if there is a break in the seal weld. Corrective action: Remove trim strip or bezel. Check and re-seal the seal weld. Drip rail seal
If there is a water leak, the seal must be checked for damage and the seal carrier must be checked for correct seating. The clamping load and the bearing surface of the lid must also be checked for leaks. Corrective action: The adjustment of the lid is made using the lock striker or the lock. Rubber bump stops are attached to both sides of the luggage compartment opening. These are normally adjustable, and the clamping load can be modified. The narrow radii of the luggage compartment lid seal are also problem areas. Check the seal for correct installation position
Other cause: The seal is not attached evenly around the lid because of a deformed or uneven welded flange. Corrective action: Check the seal and bearing surface. Re-align a deformed or uneven welded flange. Uneven welded flange. NOTE: The seal carrier covers a defective weld.
Luggage compartment seal Diagnosis: Ingress of water into the luggage compartment Cause: The luggage compartment lid seal corresponds to the door seal. G33920 en
Other cause: 01/2003 2003.0 BA Falcon
501-25D-9
Body Repairs — Water Leaks
501-25D-9
DESCRIPTION AND OPERATION (Continued) Leaking weld on welded flange (melted through). Water can ingress into the luggage compartment under the seal carrier. Corrective action: Pull the seal from the seal carrier. Seal the leaking weld using sealing compound.
Check the routing holes for rubber grommets, cables and hoses
Welds melted through
Forced air extraction
Tailgate
Diagnosis: Ingress of water into side luggage compartment area Cause: The forced air extraction for the vehicle interior is located in the lower side panel area of the luggage compartment. The ventilation housing is sealed with a rubber watershield on the bodywork side. The rubber flap of the forced air extraction must be able to move freely and not be warped. Corrective action: Remove the forced air extraction. Detach the bumper if required. Check the seal area between the bodywork and housing, as well as the rubber flap. If rubber flaps are warped,reposition by lifting fixing. Replace demaged air extractor as necessary.
Diagnosis: Ingress of water into rear headlining area Cause: The leak problems of the tailgate correspond to those of the doors. In addition to this, the area to be sealed is much bigger. The routing holes for cables and hoses must also be sealed. The rubber grommets for the routing holes must be checked for damage and correct seating (fully unhooked). The mounting points of the tailgate hinges may leak. Corrective action: Check the seal for the forced air extraction. Check the rubber grommets and renew if necessary. Check the hinge mounting points, and re-seal with sealing compound if necessary.
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01/2003 2003.0 BA Falcon
501-25D-10
Body Repairs — Water Leaks
501-25D-10
DESCRIPTION AND OPERATION (Continued) Rear window Diagnosis: Ingress of water into the luggage compartment area Cause: Rear window leaking. Check for leak in the same way as for leaking windscreen.
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01/2003 2003.0 BA Falcon
501-25E-1
Body Repairs - Wind Noise
501-25E-1
SECTION : 501-25E Body Repairs - Wind Noise VEHICLE APPLICATION : 2003.0 BA Falcon CONTENTS
PAGE
DESCRIPTION AND OPERATION Wind Noise ........................................................................................................................ 501-25E-2 General ..............................................................................................................................501-25E-2 Normal air flow noises .......................................................................................................501-25E-2 Noises caused partly by changes in the direction of air flow and by air flow around separate components .......................................................................................................................501-25E-2 Noise caused by vibrating seals .......................................................................................501-25E-2 Escaping noises ...............................................................................................................501-25E-3 Cavity noises ....................................................................................................................501-25E-3 Wind noise with the sun roof open ....................................................................................501-25E-3 Wind noises from the door seals .......................................................................................501-25E-3 Wind noises ......................................................................................................................501-25E-4 Summary ..........................................................................................................................501-25E-4 Problem sources in practice ..............................................................................................501-25E-4 Sequence for performing a wind noise diagnosis (diagram) .............................................501-25E-6 Workshop diagnosis ..........................................................................................................501-25E-6
01/2003 2003.0 BA Falcon
501-25E-2
Body Repairs - Wind Noise
501-25E-2
DESCRIPTION AND OPERATION
Wind Noise General
The build-up and decay of turbulence and the associated pressure changes lead to creation of sound waves. A similar effect can be observed at the A-pillar on a vehicle. Here the area where eddies are usually formed is directly above the side window. This makes it easy for the noise (roaring) to be passed to the vehicle interior.
Wind noise can not be completely eliminated, however the aim of vehicle development is to significantly reduce wind noise levels and increase customer comfort is to reduce wind noise. The quieter that noise producing components such as the engine, Eddy current zone drive train, tyres etc. become, the more the wind noise at high speeds will be heard. Apart from general wind rush, some noises may arise which are typically heard as an irritating hissing or whistling. The causes of these noises may be partly caused by production or repair factors. They are mostly caused by incorrectly mounted components, which must be correctly installed in the correct position.
Normal air flow noises At high speed, as air flows past uniform flat surfaces such as the roof, side windows, etc., turbulent air layers form, in which air pressure variations occur. Part of this pressure variation spreads in the form of sound waves and is transferred to the vehicle interior by the side windows and seals. Here the noise is particularly loud because of the closeness of the side window to the driver or passenger. The noise experienced is mostly a low roaring, which becomes louder as speed increases.
Noises caused partly by changes in the direction of air flow and by air flow around separate components If air flows over an edge on a vehicle, the air flow cannot fully the contour of the surface, and it breaks up at the edge. Eddies are formed, which collapse again after a certain time or distance. Change in the direction of air flow
Item 1 2 3
Item Description 1 Air flow 2 Build up of eddies Eddy currents are also formed underneath the vehicle, and so associated noise is also produced. When air flows past smaller components or through smaller gaps (such as the radiator grill), the roaring noise can become a whistling, which may increase in pitch and becomes louder as speed increases.
Noise caused by vibrating seals Seals which are not making firm contact in the window and door areas can also lead to vibrations caused by pressure variations on the outside of the vehicle which then means transfer of noise into the vehicle interior. The vibrating part of the seal operates here in the same way as loudspeaker membrane. This type of noise could be described as a "buzz" and sometimes can originate around windscreen perimeters.
Description Eddy Sound Wave Flow
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01/2003 2003.0 BA Falcon
501-25E-3
Body Repairs - Wind Noise
501-25E-3
DESCRIPTION AND OPERATION (Continued) Origin of vibrations (diagram)
resonate. The note produced depends on the volume of the cavity and the size of the opening. (For example, making a note by blowing across the top of a bottle).
Wind noise with the sun roof open Problem: When the sliding roof is open at about 60 km/h a low frequency noise is produced (drumming).
Cause: When the sliding roof is fully open, perceptible air pressure variations occur inside the vehicle because of the air current over the opening. Item 1 2
Description Vibrating Seal Radiation into the Vehicle Interior
Escaping noises Small leaks in the vehicle interior sealing system allow small currents of air to enter. This leads to the creation of "free stream noise" (a stream of air mixes with still air and in doing so causes turbulence). The loudness of free stream noise increases strongly with increasing escape speed and can be heard as a hissing noise (for example, letting the air out of a tyre).
Cavity noises If a bodywork cavity is open to the outside of the vehicle, this can cause the air volume in the cavity to
Corrective action: At speeds above about 60km/h, close the sliding roof slightly until the drumming noise is no longer heard.
Wind noises from the door seals Because of the air currents passing by the sides of the bodywork and over the roof, the pressure outside is slightly lower. Because of the heating and ventilation system the pressure inside the vehicle is slightly higher. This pressure difference causes, for example, the doors to lift away from the seals by several millimetres at high speeds. If there is also a side wind affecting the moving vehicle, this effect is increased. The resulting differences in gap are compensated for by the use of flexible door seals (when the door seals are intact).
Routes by which external sound is transferred to the inside of a vehicle
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01/2003 2003.0 BA Falcon
501-25E-4
Body Repairs - Wind Noise
501-25E-4
DESCRIPTION AND OPERATION (Continued) Item 1 2 3
Item 4 5 6 7
Description Interior ventilation Windscreen sealing Glass run w/strip
Description Sun roof seal Primary and Secondary Door Seals Boot lid seal Interior ventilation
Wind noises Normal
Concern
Type of wind noise Normal air flow noises Noises caused partly by changes in the direction of air flow and by air flow around separate components Noises caused by vibrations seals (ie. "buzz" Air escape and air passage noises Cavity noises
Summary The creation and intensity of wind noise on a vehicle depends on the fundamental shape and structure of the different components. There are two subjective evaluation and service diagnosis methods in which sound levels can be reduced and sound nature improved in a vehicle interior: Reduction in the intensity of the noise sources Reduction of the noise transmission routes In order to achieve a general improvement in the wind noise situation in the vehicle, both factors must be taken into account. The sealing systems of the doors, windows and tailgate have a major influence on the acoustic comfort in a vehicle.
Problem sources in practice Seal on driver and passenger door Diagnosis: Wind noise from the door seal at the top of the door Cause: The alignment of the door frame to the roof/bodyside is incorrect Corrective action: Re-align the door with the side window open Check the door seal to sealing surface contact area. The width of the sealing area or "footprint" should be at least 5mm.
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Where do they arise? Roof, side windows A-pillars, side mirrors, windscreen wipers
Door gaps too wide, door/window seals not seated firmly Leaks in the bodywork sealing system Unsealed bodywork cavities
The correct gap between the door and A-pillar or door and roof
Adjustment of the tailgate Diagnosis: Wind noise coming from where the roof meets the top edge of the tailgate Cause: Tailgate is set too high Corrective action: Loosen the tailgate where it is attached at the hinges and move the tailgate further down. When doing so, pay attention to the gaps with adjacent components.
01/2003 2003.0 BA Falcon
501-25E-5
Body Repairs - Wind Noise
501-25E-5
DESCRIPTION AND OPERATION (Continued) Reset the lock if necessary. Tailgate too high
The seal around the sun roof must touch it evenly all round. Correct installation of the sun roof
Sun roof adjustment Adjustment of the right-hand windscreen
Diagnosis: wiper arm Wind noise from the sun roof Diagnosis: Cause: Wind noise from the area of the right-hand Sun roof incorrectly adjusted windscreen wiper Corrective action: Cause: Adjust the sun roof according to the following Windscreen wiper arm is set too high requirements: Corrective action: There must be an equal gap all round the sun Remove the wiper arm from its shaft and roof. reposition it so that it lies within the black The sun roof must be adjusted to suit the roof ceramic band on the w/screen. contour. The front edge of the sun roof should close flush with the top face of the roof itself, or slightly lower.
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01/2003 2003.0 BA Falcon
501-25E-6
Body Repairs - Wind Noise
501-25E-6
DESCRIPTION AND OPERATION (Continued) Adjustment of the wiper arm
as when the wind noise was produced earlier. If this road test does not show that the work has been successful, additional techniques such as powder testing, stethoscope testing or ultrasonic detection must be employed.
Workshop diagnosis Before repair work is carried out, a visual check of the vehicle must be performed, paying special attention to the fit of the doors. When the doors are adjusted to fit exactly, development of wind noise can often be eliminated at high speeds (lifting of doors off the seals). Item 1 2
Description Too high (above black ceramic bend) Correct (within black ceramic bend)
Sequence for performing a wind noise diagnosis
Stethoscope testing The stethoscope is a simple and appropriate tool for finding bodywork air leaks. If the blower is turned on at the highest speed and all the doors, windows and other openings are closed, the air pressure inside the vehicle can be made higher than that outside. The outside of the vehicle is then checked for streams of escaping air.
1. Customer concern What is the customer concern and what Powder test details can they supply about the wind noise? By coating the contact surface of the door seal 2. Under which conditions does the wind noise with white powder (eg. chalk), door seals that do appear? not make close contact can be found. To do this, 1. Sequence A: A diagnosis is possible based the door is carefully closed and re-opened. In this on the details supplied by the customer. way, the sealing surfaces which do not touch will Carry out corrective measures to remedy be visible. the wind noise. Ultrasonic detector Road test the vehicle to check that the concern is resolved. The vehicle must be It is also possible to detect leaks using an driven in the exactly same way as when ultrasonic detector and a tone generator. To do the wind noise was produced with the this, the ultrasonic tone generator is put inside the customer. vehicle and the outside of the vehicle is tested If the corrective measures based on the using the detector tuned to the generator. The information supplied by the customer detector will quite easily show any leaks present. were not successful, further testing must Road tests be carried out in the workshop (see sequence B). The causes and origins of wind noises can often 2. Sequence B: A diagnosis based on details be located by a road test. Attention should be supplied by the customer is not possible paid to the following points: Test for faults in the workshop, referring Choose a dry, flat and straight road with as to any TSB (Technical Service Bulletin) little traffic as possible. which may be relevant. Make sure that the tyres are at the correct Visually check external seals, check gaps. pressure, to avoid tyre noise. Visual check: Have any components been Vehicle speed should be the max legal/safe fitted to the vehicle after manufacture or speed (eg. 100km/h) has the vehicle been repaired after an accident? Road surface should be smooth Perform a diagnosis based on the road Wind speed should be minimal test. Testing should be carried out in N,E,S,W Carry out corrective measures based on directions if possible the diagnosis. Perform another road test. The vehicle A separate rear seat auditor is required for must be driven in the exactly same way wind noise in the rear of the vehicle
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01/2003 2003.0 BA Falcon
501-25E-7
Body Repairs - Wind Noise
501-25E-7
DESCRIPTION AND OPERATION (Continued) All windows should be checked to ensure fitment and condition is correct The A/C blower fan should be OFF A standard medical stethoscope with the amplifier and removed is a usefull aspiration leak diagnosis tool (source from medical suppliers or chemist) Powered chalk can be used to idendify air leak paths If a suspect leak/source of wind noise has been idendified the vehicle should be stopped on the side of the road and cloth tape or similiar used to cover the suspected leak.Continue test and confirm leak ha sbeen eliminated/reduced.
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01/2003 2003.0 BA Falcon
501-25G-1
Body Repairs - Noise, Vibration and Harshness
501-25G-1
SECTION : 501-25G Body Repairs - Noise, Vibration and Harshness VEHICLE APPLICATION : 2002.50 BA Falcon CONTENTS
PAGE
DESCRIPTION AND OPERATION Noise, Vibration and Harshness ..........................................................................................501-25G-2 Introduction ........................................................................................................................501-25G-2 What is understood by NVH in vehicle technology ...........................................................501-25G-2 Types of noise in NVH technology ....................................................................................501-25G-2 Noise transmission through air ..........................................................................................501-25G-2 Sound transmission through a body .................................................................................501-25G-2 Combination of transmission through air and bodies ........................................................501-25G-3 Vibration technology ..........................................................................................................501-25G-3 Noise and oscillation behaviour in a vehicle .....................................................................501-25G-6 Noise and oscillation behaviour of intake and exhaust systems .......................................501-25G-6 Bodywork ...........................................................................................................................501-25G-8
01/2003 2002.50 BA Falcon
501-25G-2
Body Repairs - Noise, Vibration and Harshness
501-25G-2
DESCRIPTION AND OPERATION
Noise, Vibration and Harshness Introduction This chapter gives an overview of how noise, vibration and harshness (NVH) can be produced in a vehicle, and which corrective measures are possible.
What is understood by NVH in vehicle technology N = Noise - Sound, can be heard V = Vibration - Oscillation, can be felt H = Harshness - Roughness, can be heard and felt
Types of noise in NVH technology Noises in a vehicle are classified by their notes: Low notes - growling, droning Mid-pitch notes - buzzing, whirring High notes - howling, whistling, squeaking Loud howling and whistling is painful to the ears.
Item 1 2 3
Description Sound source e.g. Engine Sound wave Amplitude
Where the different notes come from in a vehicle: Low notes are mostly produced by the engine. Low notes are also caused by the road surface, especially if the surface is rough. This is a form of droning which can be felt by the vehicle occupants as vibration or roughness. High notes however, which are experienced as howling or whistling noises are often air currents (wind noise) or come from attached components such as the generator, power steering pump or drivebelt. There are also clattering noises which can occur when driving over an uneven road. These jerking noises are produced by, for example, the shock absorbers, chassis components or loose articles inside the vehicle.
Noise transmission through air Spreading of sound waves in the air
Sound transmission through a body Sound is passed through liquids or solids e.g. through the car bodywork.
The sound is spread by longitudinal waves in the form of pressure changes in the air.
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01/2003 2002.50 BA Falcon
501-25G-3
Body Repairs - Noise, Vibration and Harshness
501-25G-3
DESCRIPTION AND OPERATION (Continued) Noise transmission in a vehicle
Low frequency oscillations can usually be Item Description seen (large amplitudes). 1 Sound through air High frequency vibrations can be heard, but 2 Sound vibrations will also be felt as vibrations in the floor, - Example steering wheel or seat. The source of the noise is the engine Resonance Engine noises are: Every body has a natural frequency of vibration. radiated directly through the air If a system able to vibrate (a vehicle) is excited at transmitted as vibrations from the engine to the its natural frequency of vibration, it will start to bodywork and radiated into the passenger resonate. compartment as air borne sound, for instance by Uneven engine running appears for instance the bulkhead. when the resonant frequency is reached (critical The speed of transmission (speed of sound) in liquids engine speed). or solids depends on the material, but is generally Once the engine speed increases above this faster than that in air (about 5 times faster). speed, the engine will very soon run smoothly Combination of transmission through air again.
and bodies
NOTE: Sound transmission through both air and bodies is of prime importance in vehicle technology.
Vibration Technology Frequencies below 20 Hz (low frequencies) and those above 20,000 Hz (20 kHz; high frequencies) are not heard by the human ear. The engine is made to oscillate vertically in its flexible mountings by unevenness in the road. Engine mountings which are not tuned will transmit oscillations to the bodywork and hence to the occupants. - The following basic rules apply: In vehicle technology, not only audible frequencies but also inaudible (low) frequencies must be considered.
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Damping If a damper is installed parallel to a spring, the damping characteristic acts to reduce the movement of a body. This is also the way in which a shock absorber on a vehicle works. Damping affects the resonance of an object or system. The mass being moved is damped by a correctly operating shock absorber, so that shaking of the bodywork stops immediately. The shock absorber in a vehicle is an oscillation damper, which allows the bodywork to oscillate in a damped manner.
01/2003 2002.50 BA Falcon
501-25G-4
Body Repairs - Noise, Vibration and Harshness
501-25G-4
DESCRIPTION AND OPERATION (Continued) Oscillation
Isolation In oscillation technology, the term isolation means decoupling (separation) of components and systems. Example: An engine is mounted in sprung elements, so that as little oscillation as possible is passed to the vehicle. In automotive technology, the isolation technique used is nearly always rubber mounting. The elasticity of the rubber acts like a spring. The effectiveness of this type of decoupling depends on the construction of the component.
Item 1 2
Description Undamped oscillation Damped oscillation
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01/2003 2002.50 BA Falcon
501-25G-5
Body Repairs - Noise, Vibration and Harshness
501-25G-5
DESCRIPTION AND OPERATION (Continued) Directional loading of a rubber mounting in order to achieve optimum isolation
Item 1 2
Description Engine Engine mounting
Absorption Sound waves are reflected from hard surfaces If they meet soft surfaces, they are absorbed. Here both the material and the material thickness play important roles.
Item 1 2
Description Reflection of sound waves Absorption of sound waves
All sound deadening components such as door trim, carpets, headlining, parcel shelves and the seats are removed from a vehicle.
Example:
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01/2003 2002.50 BA Falcon
501-25G-6
Body Repairs - Noise, Vibration and Harshness
501-25G-6
DESCRIPTION AND OPERATION (Continued) The result of this is that the sound is directly reflected (the sound level rises), and a concert hall effect is produced.
Noise and oscillation behaviour in a vehicle The occupants of a vehicle experience different levels of sound or noise depending on where they are sitting.
Sound/noise wave (standing wave) in a vehicle
Item 1 2
necessary for these type of oscillating components to be connected to the body using stiff connection points. The exhaust system especially is an oscillating component and requires optimal isolation through its connection to the floor and also good routing and positioning of the fixing points in order to reduce the solid body sound transmission.
Description Driver sits in a "wave calm" Rear passenger sits in a "wave swell"
Noise and oscillation behaviour of intake and exhaust systems The vehicle exhaust system as an air borne sound and solid body sound source
Intake system Intake system
Ways in which sound is transmitted The top illustration shows the ways in which sound can be transmitted from intake and exhaust systems. Apart from air borne sound, solid body sound is predominant in both systems. In order to keep this proportion as small as possible, it is G00001 en
Item 1 2 3
Description Intake manifold Connection hose Fixing component (rubber mounted) 01/2003 2002.50 BA Falcon
501-25G-7
Body Repairs - Noise, Vibration and Harshness
501-25G-7
DESCRIPTION AND OPERATION (Continued) Item 4 5
Description Air cleaner Resonator
The volume and length of intake systems are matched exactly. No changes may be carried out during service or repair work. When attaching components (hoses and tubes), pay attention that all connections are air-tight. The surfaces of all components affected by the strong pressure variations in the intake system are especially subject to strong oscillations. The effects of temperature, such as warming of the air filter housing can cause changes in the rigidity of surfaces. In order to prevent solid body sound caused by surface oscillations of the intake system from being transmitted to the vehicle body, the following points must be observed during service: The whole intake system must be isolated from the bodywork and mounted in rubber bushes without tension. The air channels of the intake system must not contact the bodywork components. Insert foam insulation at points of contact with bodywork or other components.
Exhaust system Exhaust system construction
Item 1 2 3
Description Catalytic converter Front silencer Rear silencer
Exhaust systems must be installed without strain. NOTE: The rubber mountings in which an exhaust system is suspended also transmit oscillations and G00001 en
under some circumstances can also cause a noise problem. For this reason it is important that the exhaust system is installed free of strain. The rubber mountings must not be over-stretched. The exhaust manifold and catalytic converter (if it is mounted directly at the engine) must have a solid connection to the engine (no splits in brackets). 01/2003 2002.50 BA Falcon
501-25G-8
Body Repairs - Noise, Vibration and Harshness
501-25G-8
DESCRIPTION AND OPERATION (Continued) Simple problem testing: Remove all mountings from which the exhaust system is suspended. Support the exhaust system with rope at two positions at the most. Check the noise level in the passenger compartment during a road test. If this solves the problem, the exhaust mountings are the source of the noise. Put back the exhaust supports one at a time, and road test the vehicle after fitting each one. By proceeding in steps in this way, the mounting that is causing the noise in the passenger compartment can be found.
Correct installation of the windows. Correct installation of the seals. Further points Openings into the engine compartment Door and window sealing Heater and ventilation openings Sliding roof drainage hoses The side- and crossmembers in the body structure are often linking channels allowing sound transmission. Possible corrective measures are: Installation of dividing walls at critical points such as the joint between the sidemember and the A-pillar in order to ensure good air borne sound insulation. Bodywork Installation of foam plugs in affected areas. Filling hollow sections with foam. Function NOTE: NOTE: Foam pieces and foam filling are used Different types of demand are made on the in production to seal air borne sound transmission bodywork of a vehicle, particularly when it is being routes. If wind, tyre, engine or road noise is a driven. Predominant here are vibrations caused problem, the position of the pieces of foam should be mainly by other vehicle components, such as the checked. engine and mountings. The bodywork is therefore one of the most important vehicle components where NVF is concerned. The vehicle components described so far were, according to their function, individual self-contained noise sources. The bodywork however, connects and houses all the vehicle components. The bodywork is subject to vibration from both air borne sound and solid body sound. The bodywork must absorb all oscillations and impulses from all components and if possible transmit none of these to the vehicle interior. The largest proportion of NVH behaviour of a bodyshell is in the steel panels of the roof, sides and floor. They are strongly stimulated by the bodyshell structure and work like a loudspeaker transmitting noise.
Further demands on the bodywork Good crash behaviour Large interior space Corrosion resistance Low weight Good aerodynamic shape A compromise must be made on some of these points. One example is between high body rigidity for good NVH performance and good energy absorption in an accident by the use of crumple zones. Example: Watertight does not mean sound tight, therefore the following points must be taken into account:
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01/2003 2002.50 BA Falcon
501-26-1
Body Repairs- Tolerance Checks
501-26-1
SECTION 501-26: Body Repairs- Tolerance Checks VEHICLE APPLICATION : 2003.0 BA Falcon CONTENTS WELD INFORMATION Dimensional Check Underbody Plan View ............................................................................501-26-2 Dimensional Check Underbody Side View ............................................................................501-26-3 Dimensional Check Underbody Wagon Plan View ................................................................501-26-4 Dimensional Check Underbody Wagon Side View ................................................................501-26-5 Dimensional Check Front End ...............................................................................................501-26-6 Dimensional Check Rear End ................................................................................................501-26-7 Dimensional Check Wagon Liftgate Aperture ........................................................................501-26-8 Dimensional Check Body Shell Width Sedan ........................................................................501-26-9 Dimensional Check Body Shell Width Wagon .....................................................................501-26-10 Dimensional Check Front Door Aperture .............................................................................501-26-11 Dimensional Check Rear Door Aperture Sedan ..................................................................501-26-12 Dimensional Check Rear Door Aperture Wagon .................................................................501-26-13 Body Gap Dimensions Front End 1 .....................................................................................501-26-14 Body Gap Dimensions Front End 2 .....................................................................................501-26-15 Body Gap Dimensions Front Side .......................................................................................501-26-16 Body Gap Dimensions .........................................................................................................501-26-17 Body Gap Dimensions .........................................................................................................501-26-18 Body Gap Dimension Rear Quarter Panel ...........................................................................501-26-19 Body Gap Dimension Rear End ...........................................................................................501-26-20
01/2003 2003.0 BA Falcon
501-26-2
Body Repairs - Tolerance Checks
501-26-2
WELD INFORMATION
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01/2003 2003.0 BA Falcon
501-26-3
Body Repairs - Tolerance Checks
501-26-3
WELD INFORMATION (Continued)
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01/2003 2003.0 BA Falcon
501-26-4
Body Repairs - Tolerance Checks
501-26-4
WELD INFORMATION (Continued)
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01/2003 2003.0 BA Falcon
501-26-5
Body Repairs - Tolerance Checks
501-26-5
WELD INFORMATION (Continued)
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01/2003 2003.0 BA Falcon
501-26-6
Body Repairs - Tolerance Checks
501-26-6
WELD INFORMATION (Continued)
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01/2003 2003.0 BA Falcon
501-26-7
Body Repairs - Tolerance Checks
501-26-7
WELD INFORMATION (Continued)
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01/2003 2003.0 BA Falcon
501-26-8
Body Repairs - Tolerance Checks
501-26-8
WELD INFORMATION (Continued)
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01/2003 2003.0 BA Falcon
501-26-9
Body Repairs - Tolerance Checks
501-26-9
WELD INFORMATION (Continued)
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01/2003 2003.0 BA Falcon
501-26-10
Body Repairs - Tolerance Checks
501-26-10
WELD INFORMATION (Continued)
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01/2003 2003.0 BA Falcon
501-26-11
Body Repairs - Tolerance Checks
501-26-11
WELD INFORMATION (Continued)
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01/2003 2003.0 BA Falcon
501-26-12
Body Repairs - Tolerance Checks
501-26-12
WELD INFORMATION (Continued)
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01/2003 2003.0 BA Falcon
501-26-13
Body Repairs - Tolerance Checks
501-26-13
WELD INFORMATION (Continued)
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01/2003 2003.0 BA Falcon
501-26-14
Body Repairs - Tolerance Checks
501-26-14
WELD INFORMATION (Continued)
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01/2003 2003.0 BA Falcon
501-26-15
Body Repairs - Tolerance Checks
501-26-15
WELD INFORMATION (Continued)
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01/2003 2003.0 BA Falcon
501-26-16
Body Repairs - Tolerance Checks
501-26-16
WELD INFORMATION (Continued)
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01/2003 2003.0 BA Falcon
501-26-17
Body Repairs - Tolerance Checks
501-26-17
WELD INFORMATION (Continued)
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01/2003 2003.0 BA Falcon
501-26-18
Body Repairs - Tolerance Checks
501-26-18
WELD INFORMATION (Continued)
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01/2003 2003.0 BA Falcon
501-26-19
Body Repairs - Tolerance Checks
501-26-19
WELD INFORMATION (Continued)
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01/2003 2003.0 BA Falcon
501-26-20
Body Repairs - Tolerance Checks
501-26-20
WELD INFORMATION (Continued)
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01/2003 2003.0 BA Falcon
501-27-1
Front End Sheet Metal Repairs
501-27-1
SECTION 501-27: Front End Sheet Metal Repairs VEHICLE APPLICATION : 2003.0 BA Falcon CONTENTS WELD INFORMATION Radiator Cross Member 1 ......................................................................................................501-27-2 Radiator Cross Member 1a ....................................................................................................501-27-3 Towel Rail Replacement ........................................................................................................501-27-3 Radiator Cross Member 2 ......................................................................................................501-27-4 Radiator Cross Member 3 ......................................................................................................501-27-4 Apron and Side Member ........................................................................................................501-27-5 Front Apron LHS ....................................................................................................................501-27-5 Front Apron RHS ...................................................................................................................501-27-6 Fender to Body LHS ..............................................................................................................501-27-6 Fender to Body RHS ..............................................................................................................501-27-7 Front Apron LHS 1 .................................................................................................................501-27-7 Front Apron RHS 1 ................................................................................................................501-27-8
01/2003 2003.0 BA Falcon
501-27-2
Front End Sheet Metal Repairs
501-27-2
WELD INFORMATION
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01/2003 2003.0 BA Falcon
501-27-3
Front End Sheet Metal Repairs
501-27-3
WELD INFORMATION (Continued)
Towel Rail Replacement The Towel Rail on the front upper X member must be replaced if damaged. It MUST NOT be straightened or panel beaten. This is critical for correct function of the crash severity sensor which plays a major part in activating the front airbags in a crash.
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01/2003 2003.0 BA Falcon
501-27-4
Front End Sheet Metal Repairs
501-27-4
WELD INFORMATION (Continued)
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01/2003 2003.0 BA Falcon
501-27-5
Front End Sheet Metal Repairs
501-27-5
WELD INFORMATION (Continued)
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01/2003 2003.0 BA Falcon
501-27-6
Front End Sheet Metal Repairs
501-27-6
WELD INFORMATION (Continued)
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01/2003 2003.0 BA Falcon
501-27-7
Front End Sheet Metal Repairs
501-27-7
WELD INFORMATION (Continued)
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01/2003 2003.0 BA Falcon
501-27-8
Front End Sheet Metal Repairs
501-27-8
WELD INFORMATION (Continued)
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01/2003 2003.0 BA Falcon
501-28-1
Roof Sheet Metal Repairs
501-28-1
SECTION 501-28: Roof Sheet Metal Repairs VEHICLE APPLICATION : 2003.0 BA Falcon CONTENTS WELD INFORMATION Sedan Roof Panels 1 .............................................................................................................501-28-2 Sedan Roof Panels 2 .............................................................................................................501-28-2 Sedan Roof Panels 3 .............................................................................................................501-28-3 Sedan Roof Panels 4 .............................................................................................................501-28-3 Sedan Roof Panels 5 .............................................................................................................501-28-4 Sedan Roof Panels 6 .............................................................................................................501-28-4 Sedan Roof Panels 7 .............................................................................................................501-28-5 Wagon Roof Panels 1 ............................................................................................................501-28-5 Wagon Roof Panels 2 ............................................................................................................501-28-6 Wagon Roof Panels 3 ............................................................................................................501-28-6 Wagon Roof Panels 4 ............................................................................................................501-28-7 Wagon Roof Panels 5 ............................................................................................................501-28-7
01/2003 2003.0 BA Falcon
501-28-2
Roof Sheet Metal Repairs
501-28-2
WELD INFORMATION
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01/2003 2003.0 BA Falcon
501-28-3
Roof Sheet Metal Repairs
501-28-3
WELD INFORMATION (Continued)
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01/2003 2003.0 BA Falcon
501-28-4
Roof Sheet Metal Repairs
501-28-4
WELD INFORMATION (Continued)
G000001 en
01/2003 2003.0 BA Falcon
501-28-5
Roof Sheet Metal Repairs
501-28-5
WELD INFORMATION (Continued)
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01/2003 2003.0 BA Falcon
501-28-6
Roof Sheet Metal Repairs
501-28-6
WELD INFORMATION (Continued)
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01/2003 2003.0 BA Falcon
501-28-7
Roof Sheet Metal Repairs
501-28-7
WELD INFORMATION (Continued)
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01/2003 2003.0 BA Falcon
501-29-1
Side Panel Sheet Metal Repairs
501-29-1
SECTION 501-29: Side Panel Sheet Metal Repairs VEHICLE APPLICATION : 2003.0 BA Falcon CONTENTS WELD INFORMATION Sedan Body Side 1 ................................................................................................................501-29-3 Sedan Body Side 2 ................................................................................................................501-29-3 Sedan Body Side 3 ................................................................................................................501-29-4 Sedan Body Side 4 ................................................................................................................501-29-4 Sedan Body Side 5 ................................................................................................................501-29-5 Sedan Body Side 6 ................................................................................................................501-29-5 Wagon Body Side 1 ...............................................................................................................501-29-6 Wagon Body Side 2 ...............................................................................................................501-29-6 Wagon Body Side 3 ...............................................................................................................501-29-7 Wagon Body Side 4 ...............................................................................................................501-29-7 Wagon Body Side 5 ...............................................................................................................501-29-8 Wagon Body Side 6 ...............................................................................................................501-29-8 Wagon Body Side 7 ...............................................................................................................501-29-9 Wagon Body Side 8 ...............................................................................................................501-29-9 Wagon Body Side 9 .............................................................................................................501-29-10 Wagon Body Side 10 ...........................................................................................................501-29-10 Wagon Body Side 11 ...........................................................................................................501-29-11 Wagon Body Side 12 ...........................................................................................................501-29-11 Wagon Body Side 13 ...........................................................................................................501-29-12 Wagon and Sedan Side Impact Crash Sensor Bracket .......................................................501-29-12 Wagon Liftgate 1 ..................................................................................................................501-29-13 Wagon Liftgate 2 ..................................................................................................................501-29-14 Front Door 1 .........................................................................................................................501-29-14 Front Door 2 .........................................................................................................................501-29-15 Front Door 3 .........................................................................................................................501-29-15 Front Door 4 .........................................................................................................................501-29-16 Front Door 5 .........................................................................................................................501-29-16 Front Door 6 .........................................................................................................................501-29-17 01/2003 2003.0 BA Falcon
501-29-2
Side Panel Sheet Metal Repairs
501-29-2
(Continued) Front Door 7 .........................................................................................................................501-29-17 Sedan Rear Door 1 ..............................................................................................................501-29-18 Sedan Rear Door 2 ..............................................................................................................501-29-18 Sedan Rear Door 3 ..............................................................................................................501-29-19 Wagon Rear Door 1 .............................................................................................................501-29-19 Wagon Rear Door 2 .............................................................................................................501-29-20 Wagon Rear Door 3 .............................................................................................................501-29-20 Wagon Rear Door 4 .............................................................................................................501-29-21 SWB Sedan Side Floor Plan Assembly 1 ............................................................................501-29-21 SWB Sedan Side Floor Plan Assembly 2 ............................................................................501-29-22 Wagon Side Floor Plan Assembly 1 ....................................................................................501-29-22 Wagon Side Floor Plan Assembly 2 ....................................................................................501-29-23 Ute Side Floor Plan Assembly 1 ..........................................................................................501-29-23 Ute Side Floor Plan Assembly 2 ..........................................................................................501-29-24 Ute Body Side 1 ...................................................................................................................501-29-24 Ute Body Side 2 ...................................................................................................................501-29-25 Ute Body Side 3 ...................................................................................................................501-29-25 Ute Body Side 4 ...................................................................................................................501-29-26 Ute Body Side 5 ...................................................................................................................501-29-26
01/2003 2003.0 BA Falcon
501-29-3
Side Panel Sheet Metal Repairs
501-29-3
WELD INFORMATION
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01/2003 2003.0 BA Falcon
501-29-4
Side Panel Sheet Metal Repairs
501-29-4
WELD INFORMATION (Continued)
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01/2003 2003.0 BA Falcon
501-29-5
Side Panel Sheet Metal Repairs
501-29-5
WELD INFORMATION (Continued)
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01/2003 2003.0 BA Falcon
501-29-6
Side Panel Sheet Metal Repairs
501-29-6
WELD INFORMATION (Continued)
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01/2003 2003.0 BA Falcon
501-29-7
Side Panel Sheet Metal Repairs
501-29-7
WELD INFORMATION (Continued)
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01/2003 2003.0 BA Falcon
501-29-8
Side Panel Sheet Metal Repairs
501-29-8
WELD INFORMATION (Continued)
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01/2003 2003.0 BA Falcon
501-29-9
Side Panel Sheet Metal Repairs
501-29-9
WELD INFORMATION (Continued)
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01/2003 2003.0 BA Falcon
501-29-10
Side Panel Sheet Metal Repairs
501-29-10
WELD INFORMATION (Continued)
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01/2003 2003.0 BA Falcon
501-29-11
Side Panel Sheet Metal Repairs
501-29-11
WELD INFORMATION (Continued)
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01/2003 2003.0 BA Falcon
501-29-12
Side Panel Sheet Metal Repairs
501-29-12
WELD INFORMATION (Continued)
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01/2003 2003.0 BA Falcon
501-29-13
Side Panel Sheet Metal Repairs
501-29-13
WELD INFORMATION (Continued) Side Impact Crash Sensor Bracket The side impact crash sensor bracket must be replaced if damaged. It MUST NOT be straightened or panel beaten. This is critical for correct function of the crash severity sensor which plays a major part in activating the side impact airbags in a crash. In the event of having to replace the side impact sensor bracket, the bracket should be spotwelded in six places to the Full Length Reinforcement (Item 1 in the illustration). If a spotwelder is not available, it is then necessary to drill three 4mm diameter holes on each flange of the bracket, (6 in total) and puddle MIG weld to fill the holes and fuse with the full length reinforcement.
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01/2003 2003.0 BA Falcon
501-29-14
Side Panel Sheet Metal Repairs
501-29-14
WELD INFORMATION (Continued)
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01/2003 2003.0 BA Falcon
501-29-15
Side Panel Sheet Metal Repairs
501-29-15
WELD INFORMATION (Continued)
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01/2003 2003.0 BA Falcon
501-29-16
Side Panel Sheet Metal Repairs
501-29-16
WELD INFORMATION (Continued)
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01/2003 2003.0 BA Falcon
501-29-17
Side Panel Sheet Metal Repairs
501-29-17
WELD INFORMATION (Continued)
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01/2003 2003.0 BA Falcon
501-29-18
Side Panel Sheet Metal Repairs
501-29-18
WELD INFORMATION (Continued)
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01/2003 2003.0 BA Falcon
501-29-19
Side Panel Sheet Metal Repairs
501-29-19
WELD INFORMATION (Continued)
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01/2003 2003.0 BA Falcon
501-29-20
Side Panel Sheet Metal Repairs
501-29-20
WELD INFORMATION (Continued)
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01/2003 2003.0 BA Falcon
501-29-21
Side Panel Sheet Metal Repairs
501-29-21
WELD INFORMATION (Continued)
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01/2003 2003.0 BA Falcon
501-29-22
Side Panel Sheet Metal Repairs
501-29-22
WELD INFORMATION (Continued)
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01/2003 2003.0 BA Falcon
501-29-23
Side Panel Sheet Metal Repairs
501-29-23
WELD INFORMATION (Continued)
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01/2003 2003.0 BA Falcon
501-29-24
Side Panel Sheet Metal Repairs
501-29-24
WELD INFORMATION (Continued)
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01/2003 2003.0 BA Falcon
501-29-25
Side Panel Sheet Metal Repairs
501-29-25
WELD INFORMATION (Continued)
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01/2003 2003.0 BA Falcon
501-30-1
Rear End Sheet Metal Repairs
501-30-1
SECTION 501-30: Rear End Sheet Metal Repairs VEHICLE APPLICATION : 2003.0 BA Falcon CONTENTS WELD INFORMATION Petrol Rear Floorpan Assembly .............................................................................................501-30-3 Petrol Rear Floor Pan Assembly - View A .............................................................................501-30-3 Petrol Rear Floor Pan Assembly - View B .............................................................................501-30-4 Petrol Rear Floorpan Sill Assembly .......................................................................................501-30-4 Petrol Rear Floorpan Sill Assembly - View A ........................................................................501-30-5 Petrol Rear Floorpan Sill Assembly - View B ........................................................................501-30-5 Petrol Rear Floorpan Sill Assembly - View C ........................................................................501-30-6 Rear Sill to Rear Floorpan Assembly .....................................................................................501-30-6 Rear Sill to Rear Floorpan - View A .......................................................................................501-30-7 Rear Sill to Rear Floorpan - View B .......................................................................................501-30-7 Rear Sill to Rear Floorpan - View C ......................................................................................501-30-8 Dedicated LPG Rear Floorpan Assembly 1 ...........................................................................501-30-8 Dedicated LPG Rear Floorpan Assembly - View A ...............................................................501-30-9 Dedicated LPG Rear Floorpan Assembly - View B ...............................................................501-30-9 Dedicated LPG Rear Floorpan Sill Assembly ......................................................................501-30-10 Dedicated LPG Rear Floorpan Sill View A ..........................................................................501-30-10 Dedicated LPG Rear Floorpan Sill View B ..........................................................................501-30-11 Dedicated LPG Rear Floorpan Sill Assembly ......................................................................501-30-11 Dedicated LPG Rear Floorpan Sill Assembly View A ..........................................................501-30-12 Petrol/Dedicated LPG Rear Bumper Mount Assembly - LH ................................................501-30-12 Petrol/Dedicated LPG Rear Bumper Mount Assembly - RH ...............................................501-30-13 Dedicated LPG Rear Floor Corssmember Assembly ..........................................................501-30-13 Dedicated LPG Rear Floor Corssmember Assembly ..........................................................501-30-14 Rear Floorpan Reinforcement Member View A ...................................................................501-30-14 Rear Floorpan Reinforcement Member View B ...................................................................501-30-15 Petrol Rear Floorpan Sill Assembly .....................................................................................501-30-15 Rear Sill to Rear Floorpan View A .......................................................................................501-30-16 Wagon Rear Side Support 1 ................................................................................................501-30-16 01/2003 2003.0 BA Falcon
501-30-2
Rear End Sheet Metal Repairs
501-30-2
(Continued) Wagon Rear Side Support 2 ................................................................................................501-30-17 Wagon Rear Side Support 3 ................................................................................................501-30-17 Wagon Rear Side Support 4 ................................................................................................501-30-18 Wagon Rear Cross Members 1 ...........................................................................................501-30-18 Wagon Rear Cross Members 2 ...........................................................................................501-30-19 Wagon Rear Floorpan 1 .......................................................................................................501-30-19 Wagon Rear Floorpan 2 .......................................................................................................501-30-20 Wagon Rear Floorpan Bumper Mounting 1 .........................................................................501-30-20 Wagon Rear Floorpan Bumper Mounting 2 .........................................................................501-30-21 Wagon Rear Cross Member ................................................................................................501-30-21 Wagon Rear Sill to Floorpan ................................................................................................501-30-22
01/2003 2003.0 BA Falcon
501-30-3
Rear End Sheet Metal Repairs
501-30-3
WELD INFORMATION
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01/2003 2003.0 BA Falcon
501-30-4
Rear End Sheet Metal Repairs
501-30-4
WELD INFORMATION (Continued)
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01/2003 2003.0 BA Falcon
501-30-5
Rear End Sheet Metal Repairs
501-30-5
WELD INFORMATION (Continued)
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01/2003 2003.0 BA Falcon
501-30-6
Rear End Sheet Metal Repairs
501-30-6
WELD INFORMATION (Continued)
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01/2003 2003.0 BA Falcon
501-30-7
Rear End Sheet Metal Repairs
501-30-7
WELD INFORMATION (Continued)
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01/2003 2003.0 BA Falcon
501-30-8
Rear End Sheet Metal Repairs
501-30-8
WELD INFORMATION (Continued)
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01/2003 2003.0 BA Falcon
501-30-9
Rear End Sheet Metal Repairs
501-30-9
WELD INFORMATION (Continued)
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01/2003 2003.0 BA Falcon
501-30-10
Rear End Sheet Metal Repairs
501-30-10
WELD INFORMATION (Continued)
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01/2003 2003.0 BA Falcon
501-30-11
Rear End Sheet Metal Repairs
501-30-11
WELD INFORMATION (Continued)
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01/2003 2003.0 BA Falcon
501-30-12
Rear End Sheet Metal Repairs
501-30-12
WELD INFORMATION (Continued)
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01/2003 2003.0 BA Falcon
501-30-13
Rear End Sheet Metal Repairs
501-30-13
WELD INFORMATION (Continued)
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01/2003 2003.0 BA Falcon
501-30-14
Rear End Sheet Metal Repairs
501-30-14
WELD INFORMATION (Continued)
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01/2003 2003.0 BA Falcon
501-30-15
Rear End Sheet Metal Repairs
501-30-15
WELD INFORMATION (Continued)
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01/2003 2003.0 BA Falcon
501-30-16
Rear End Sheet Metal Repairs
501-30-16
WELD INFORMATION (Continued)
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01/2003 2003.0 BA Falcon
501-30-17
Rear End Sheet Metal Repairs
501-30-17
WELD INFORMATION (Continued)
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01/2003 2003.0 BA Falcon
501-30-18
Rear End Sheet Metal Repairs
501-30-18
WELD INFORMATION (Continued)
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01/2003 2003.0 BA Falcon
501-30-19
Rear End Sheet Metal Repairs
501-30-19
WELD INFORMATION (Continued)
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01/2003 2003.0 BA Falcon
501-30-20
Rear End Sheet Metal Repairs
501-30-20
WELD INFORMATION (Continued)
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01/2003 2003.0 BA Falcon
501-30-21
Rear End Sheet Metal Repairs
501-30-21
WELD INFORMATION (Continued)
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01/2003 2003.0 BA Falcon
501-30-22
Rear End Sheet Metal Repairs
501-30-22
WELD INFORMATION (Continued)
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01/2003 2003.0 BA Falcon
501-31-1
Body Welding and High Strength Steel
501-31-1
SECTION 501-31: Body Welding and High Strength Steel VEHICLE APPLICATION : 2003.0 BA Falcon CONTENTS GENERAL PROCEDURES Welding Requirements ...........................................................................................................501-31-2 Protection of Electronics ........................................................................................................501-31-2 Precautions ............................................................................................................................501-31-2 High Strength Steels ..............................................................................................................501-31-2 High Strength Low Alloy Steels (HSLA) .................................................................................501-31-2 Heating HSLA Steel ...............................................................................................................501-31-2 Welding HSLA Steels .............................................................................................................501-31-2 WELD INFORMATION HSLA Steel Location - Front End Section .............................................................................501-31-4 HSLA Steel Location - Side Section ......................................................................................501-31-5 HSLA Steel Location - Sedan Rear Section - Petrol .............................................................501-31-6 HSLA Steel Location - Sedan Rear Section - DLPG .............................................................501-31-7 HSLA Steel Location -Wagon Rear Side Member Reinforcement ........................................501-31-8 HSLA Steel Location - Sedan Floor and Members ................................................................501-31-9 HSLA Steel Location - Wagon Floor and Members .............................................................501-31-10 HSLA Steel Location - Ute Floor and Members ..................................................................501-31-11 HSLA Steel Location - Doors ...............................................................................................501-31-12 HSLA Steel Location - Wagon Side and Rear .....................................................................501-31-13 HSLA Steel Location - Dash and Cowl ................................................................................501-31-14
01/2003 2003.0 BA Falcon
501-31-2
Body Welding and High Strength Steel
501-31-2
GENERAL PROCEDURES
Welding Requirements
Steels
There are a number of different types of Steels used in the body and frame panels. In most cases the All normal shop safety practices should be observed. material can be repaired or welded in the same Protective clothing, adequate ventilation and proper manner as normal mild steel panels. The exception to fire- fighting equipment are essential when performing this is the heat sensitive High Strenght Low Alloy any welding operation. Steels (HSLA). The recommended welding method for fitment of replacement panels is resistance spot welding or MIG WARNING: The Towel Rail on the front upper puddle or plug welding. For weld type and location, X member must be replaced if damaged. It MUST refer to interpretation of weld symbols in the following NOT be straightened or panel beaten. pages. This is critical for correct function of the crash severity sensor which plays a major part in Oxyacetylene fusion welding may be used for butt welds except where high strength low alloy steels are activating the front airbags in a crash. being welded (see section on H.S.L.A. steels). Safety
Protection of Electronics
High Strength Low Alloy Steels (HSLA)
To reduce vehicle weight while maintaining structural strength, Ford Motor Company has used High Strength Low Alloy steels (HSLA). Electric welding operations include resistance spot welding, MIG welding, TIG welding, conventional arc Whilst these steels appear to be the same as other steels, HSLA steels are thinner and they have a low welding and plasma cutting. alloy content which makes them heat sensitive. The The following rules must be followed when any location of panels made from this material is shown in electric welding operation is performed in the repair of the following pages. a vehicle. NOTE: The door beam (side intrusion bar) fitted to 1. Disconnect battery, both leads, earth lead first. side doors is manufactured from Ultra HSLA and must 2. Remove connections to all electronic control units. not be heated or straightened under any 3. Where the welding is to be close to the electronic circumstances. These parts are critical to driver/passenger safety in both side impact and control unit, remove the ECU if there is any steering column rearward displacement. If a door possibility that heat could affect the unit. beam is damaged, fitment of a new door shell is When Applying Heat: necessary. Electronic control units are extremely heat sensitive, any operation that could raise the temperature of the Heating HSLA Steel unit or its surrounds to 80 degrees Celsius or above, Cold working is best for straightening bent parts. The should not take place until the ECU is removed from application of heat may anneal (soften) HSLA Steel the vehicle. and should be avoided if possible. If heat must be Operations such as oxy welding, oxy or plasma applied to relieve stress in structural components, the cutting, electric welding of all types and normal steel must not be heated over 700°C (dull red) and grinding operations could all be reasons for concern. this temperature can only be applied for a maximum The location of electronic control units is shown in the of three minutes. A temperature sensitive crayon must following pages. be used for marking when heating this material, including all welding, cutting, grinding and buffing Precautions operations. It is recommended to replace assemblies 1. Never start the engine without securely connected of HLSA components rather than separate panels to restore the vehicle to original performance. battery terminals, and never disconnect the battery whilst the engine is running or the ignition Welding HSLA Steels is turned on. 2. Never disconnect or reconnect the wiring harness The only methods of welding that are acceptable for this material are resistance spot, MIG and plug of an electronic control unit with the ignition conventional arc welding. turned on. 3. Be certain that all plugs of the wiring harness are Oxyacetylene welding or cutting must never be used on this material. properly connected before connecting battery. 4. When disconnecting battery always remove earth The recommended welding method is: lead first, connect in the reverse order. 5. Under no circumstances should the battery be shorted to earth. Welding:
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Body Welding and High Strength Steel
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GENERAL PROCEDURES (Continued) 1. Spot welds should be replaced with spot welds where possible. Where spot welding equipment is not available or the location is not accessible, panels should be MIG puddle or plug welded. 2. MIG welding is preferred over conventional arc welding, when welding HSLAor mild steel panels. The wire used should be 0.8mm or 0.9mm and conform to the classifications AWS A5.18-69, E70S-6 or E70S-4. 3. Conventional arc welding must be carried out using 2.5mm diameter rods conforming to classification AS1552-73, E4841 or AWS A5.1-78, E7014. NOTE: All areas to be welded must be treated with a zinc rich weld through primer to restore maximum corrosion resistance.
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Body Welding and High Strength Steel
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WELD INFORMATION
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Body Welding and High Strength Steel
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WELD INFORMATION (Continued)
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Body Welding and High Strength Steel
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WELD INFORMATION (Continued)
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Body Welding and High Strength Steel
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WELD INFORMATION (Continued)
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Body Welding and High Strength Steel
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WELD INFORMATION (Continued)
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Body Welding and High Strength Steel
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WELD INFORMATION (Continued)
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Body Welding and High Strength Steel
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WELD INFORMATION (Continued)
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Body Welding and High Strength Steel
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WELD INFORMATION (Continued)
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Body Welding and High Strength Steel
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WELD INFORMATION (Continued)
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Body Welding and High Strength Steel
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WELD INFORMATION (Continued)
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Body Welding and High Strength Steel
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WELD INFORMATION (Continued)
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Paint Preparation and Application
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SECTION : 501-32 Paint Preparation and Application VEHICLE APPLICATION : 2003.0 BA Falcon CONTENTS
PAGE
DESCRIPTION AND OPERATION Paint Preparation and Application ........................................................................................501-32-2 Paint Colour Codes ..............................................................................................................501-32-2 Checking Paint Condition .....................................................................................................501-32-2 Safety Precautions ...............................................................................................................501-32-2 Factory Finish .......................................................................................................................501-32-3 Two Pack Paints - Surface Preparation ...............................................................................501-32-3 Mixing ...................................................................................................................................501-32-4 Application ............................................................................................................................501-32-4 After Spraying ......................................................................................................................501-32-4 Painting Plastic Bumper Bars ..............................................................................................501-32-5 Repairing Color Coat Plastic Bumpers ................................................................................501-32-6 Painting Plastic Components - General Hints ......................................................................501-32-6 Plastics Including Nylon .......................................................................................................501-32-6 Top Coat - DG Solid Colors .................................................................................................501-32-7 Pearl/Metalic Clear Over Base .............................................................................................501-32-7 Clear Coat ............................................................................................................................501-32-7 Flexible Additive ...................................................................................................................501-32-7
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Paint Preparation and Application
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DESCRIPTION AND OPERATION
Paint Preparation and Application Paint Colour Codes The paint colour code is indicated on the vehicle Compliance Plate and the corresponding colour is shown on the chart below. Name Winter White Venom Barossa Congo Green Galaxy Monsoon Meteorite Organza Sparkling Burgundy Liquid Silver Silhouette Taxi Yellow Taxi Orange No Paint
Colour A1 VI B7 DG GY MN K6 DZ B5 LD ST 22 44
Code 24 5 6 10 11 7 12 3 9 1 13 27 28 99
Checking Paint Condition Before attempting repainting, determine the surface and overall condition of the existing paint. Horizontal surfaces usually show the greatest surface deterioration. Carefully inspect the hood and roof panel to determine the overall condition of the paint. Clean the areas to be inspected and look carefully for any signs of surface deterioration, or any other form of film breakdown such as checking, cracking, or humidity blistering. In particular, note the gloss level. Low glass indicates surface irregularities caused by such defects as checking or blistering. Look for evidence of brittleness or poor adhesion, or excessive chipping. If in doubt about the condition of the paint, scrape the finish slightly with a pen knife and examine further. If a complete repaint job is necessary, plan a painting sequence, primarily for the sake of continuity so as to avoid dry joint overlaps and minimize unnecessary work, before beginning to spray.
1. Remove the defect by light sanding with 1200 grit paper, using water or mineral spirits as a lubricant. 2. Apply a white or light coloured medium grit machine polishing compound to the painted surface with a brush. 3. Polish the entire panel surface using an 1850 rpm wheel and a carpet pad (approximately 16mm nap)or lambswool pad. 4. Buff the surface with a clean lambs wool pad. Normally, modern paint finishes do not need polishing to improve their gloss; however, the foregoing procedure can be used to restore the original luster to the film after weathering, or to improve the surface smoothness of the finish on the entire car.
Safety Precautions Follow the safety directions supplied by the paint manufacturer. Products containing isocyanates may cause skin irritations or respiratory complaints.
Personnel Persons with a history of asthma or other respiratory problems or known to be sensitised to isocyanates should not be engaged in any work involving the handling of isocyanates. Spray painters required to handle isocyanate-containing products should be made aware of this fact. Any person showing symptoms of possible reaction to isocyanates should obtain immediate medical advice.
Protective Clothing and Equipment Wear a positive pressure air supplied respirator meeting the requirements of AS1716-1984 and impervious gloves at all times when spraying paint products containing isocyanates. The respirator must include a face mask fully protecting the eyes, otherwise chemical goggles complying with Australian Standard AS 1337-1974 “C” are required. Dust respirators must not be relied upon at any time and chemical absorption type canisters are not recommended due to their limited effective life.
Handling
Both base and hardener must be stored and handled in compliance with the current regulations applying to flammable or highly flammable liquids. Repair by Polishing All mixing and handling of hardener and paint Repair of minor dirt or fallout, sags, mars, scratches, containing hardener is to be carried out under working dry spray, overspray and orange peel can be conditions that prevent skin contact and inhalation of accomplished by machine without the necessity of vapours, e.g. wear impervious gloves in a ventilated repainting. booth fitted with an effective filtered exhaust system. Repairs of this type should apply to an entire panel In addition, any paint product containing isocyanates, while spot repairs should be attempted only in isolated for example hardener or mixture of hardener and areas. base, must be dealt with in the following manner. The suggested polish repair procedure consists of: Containers must be kept tightly closed when not in use and not allowed to come into contact with water G456450 en
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DESCRIPTION AND OPERATION (Continued) at any time. Isocyanates react with water, which destroys their effectiveness. Gas is involved when the isocyanate reacts with water. If a closed container shows signs of internal pressure, cover it completely with a cloth and remove the lid slowly to prevent splashing or violent expulsion of the lid. If using only portion of the hardener in a can, reseal and use the balance of the contents within 36 hours, as it will deteriorate on exposure to air. Store in a cool, dry place. Accidental spillages should be absorbed into dry sand or earth, removed from the work area and covered with water for 24 hours. Treat empty hardener containers in the same manner. Do not allow materials of this type to enter drains. Dispose of treated waste as directed by the relevant waste disposal authorities.
Application Isocyanate paint must only be applied in a spray booth fitted with an effective filtered exhaust system. The operator must wear the protective equipment prescribed in these guidelines and comply with local legislation applicable to the spray painting of motor vehicles. Additionally, particular care must be paid to other people in the vicinity. The work area should be isolated from other people during all activities associated with the mixing, handling and application of isocyanate paint until all vapour and spray mist, etc. has been effectively dissipated. Whenever unlidding, mixing or the clean-up of liquid residues is taking place, the area in use must be well ventilated by an exhaust system sufficient to capture all vapour or spray mists generated and conduct them away to a safe discharge point. Where the air flow velocity in the work area is below 1 metre per second, at least one hour should be allowed before the exhaust ventilation is switched off. Wet sanding is the preferred method. Sanding of isocyanate films should be carried out under the same conditions as apply to spraying, as the dust may irritate operators susceptible to isocyanate contact.
First Aid If affected by inhalation of vapour or spray mist, remove to fresh air. If breathing difficulty persists or occurs later, consult a doctor and have label information available. In case of eye contact, flush immediately with plenty of water for 15 minutes; call a doctor. In case of skin contact, remove contaminated clothing and wash skin thoroughly with soap and water. Immerse contaminated clothing in water for 24 hours and do not re-use until it has been laundered.
refinishing is to be the in-field equivalent of the factory finish. Two part urethane finishes are recommended.
Two Pack Paints - Surface Preparation Essential Requirements and General Hints 1. Wash door jambs, engine compartment, etc with high pressure hose before sanding and priming. This will remove all dust and dirt likely to contaminate the top coat. 2. Wash surface thoroughly with a grease and wax solvent before sanding and application of primer. Sanding will not remove wax and grease. Instead, it spreads it from one panel to another, leading to poor adhesion, and cratering if sealed in the primer. 3. Strain lumpy primers and filler before adding hardener. Lumps will not catalyze and will remain soft. These soft areas will show after top coating. 4. Wet sand primers and top coats containing isocyanates. Dust particles containing isocyanates can be hazardous to health. 5. Use solvents sparingly over primers and fillers. It can take up to two hours for cleaning solvents to evaporate. If sealed in with the top coat it can cause “whirl” marks to appear in the paint film. 6. Mask off vehicle openings, door jambs, engine compartments, wheel arches, etc. This will reduce the risk of dust and dirt blowing out during top coat spraying. 7. Never apply two pack primers over unsanded surfaces, especially existing finishes. Adhesion will be poor. The primer edge will not feather properly and will lift or swell when top coated. 8. Never use conventional etch primers under two pack primers. Two pack primers have good adhesion to all bare metals but not to conventional etch primers. 9. Never attempt to use two pack primers or fillers to seal down cracked or crazed surfaces or film thicknesses exceeding 250 microns. Unless stripped, this type of surface will continue to crack under any primer and will eventually pull open the new top coat. 10. Never use polyester spray fillers on wet or humid days. Polyester spray fillers are very moisture absorbent and will blister easily. They should be dry sanded and primed as soon as possible after application. 11. Never use too coarse a paper on final sand of primer before application of top coat. They have low film build and will not fill coarse scratch marks. 12. Do not exceed these levels of coarseness.
Factory Finish The vehicle is finished in either baked polyester solid colour or baked acrylic clear over base coat colour; all G456450 en
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DESCRIPTION AND OPERATION (Continued) Base coat ...................800 grit weld 2K acrylic enamel ......600 grit weld 13. Never allow water to dry on panel before application of any paint material. When water evaporates, it leaves behind mineral salts. In wet weather, these salts absorb moisture and will swell under the paint film causing blistering.
8. Never attempt to alter colour after hardener has been added. This will throw out mixing ratios resulting in poor product performance. 9. Never wash base coats with solvent before application of clear. Base coat will wash off. 10. Never apply heavy wet coats. This can result in possible “solvent boil” and “runs”. 11. Never recoat base coat with itself after two hours, Mixing without detail sanding. Adhesion between the two 1. Use a measuring gauge when adding hardener layers of base coat will be very poor. and reducer. Ratios either under or over will lead 12. Never apply more than four full coats of base to poor product performance. coat. As there is no hardener in base coat, thick 2. Replace lids on cans of hardener immediately film build will remain soft, with the result that the after use. Hardeners are hydro-scopic (will absorb clear coat will remain soft and spongy. moisture from the air), sometimes going “milky” 13. Never apply two pack materials at temperatures and causing top coats to look “gritty” or “seedy” below 7 degrees C. Two pack materials cease to when sprayed. cure below 7 degrees C, but will recommence as 3. Strain two pack top coats and sealers through a the temperature rises, resulting in possible loss of 150 micron filter before application. This will gloss. remove any foreign matter that may be in the 14. Never apply two pack materials in excessive paint, eliminating the need to denib and buff later. humidity outside a spray booth. This practice could result in loss of gloss and/or humidity Application blistering. 1. Use correct air pressure (normally 350-420 KPa). 15. Never attempt to spray material which has started Too low an air pressure will give poor atomization to “gel”. Pot life has ended. Application properties and will result in a peely finish. Too high leads to and product performance will be poor, even if excessive overspray and dry finishes. extra reducer is added. 2. Use the recommended drying speed of hardener After Spraying and reducer for different temperatures. This will give the best application results. Always check the 1. Never leave a newly painted vehicle in the rain or product data sheets. dew for at least: 3. Give transparent sealer time to “tack off” before 24 hours .........Air Dry applying top coat. Top coats may split if applied 6 hours ...........After full bake cycle too soon. 2. Failure to observe these times may result in loss 4. Apply clear coat over base coat as soon as of gloss and/or “humidity blistering” and water possible as adhesion between base and clear spotting. may be reduced, if delay is excessive, i.e. more than about 12-15 minutes. (Refer to paint supplies 3. Never let respray stand for more than 5 minutes before baking. Surface will “skin” trapping in literature for optional timing between base coat solvent. Heat will not reflow the surface but will and clear coat). force the solvent out too quickly, resulting in 5. Wear the correct safety equipment when spraying possible “solvent boil”. materials containing isocyanates. Contact with 4. Never bake for more than 40 minutes or at isocyanates may result in respiratory problems. temperatures above 70 degrees C as this will 6. Never apply transparent sealer over fresh acrylic damage plastic parts and fillers and cause failure lacquer top coats or lacquer primers, a minimum of electronic components. of one month is required to release all solvents from these materials. Sealed in solvent, prevented 5. Do not use polishes containing wax or silicone for at least: from evaporating by the sealer will result in sink back, possible blistering and lack of adhesion. 1 month .........After Air Dry 7. Never allow transparent sealer to dry longer than 1 week ...........After full bake cycle two hours before top coating. Excessive drying 6. While solvent is still evaporating from a paint film, can cause “fry”; first recoat with sealer then top the surface is “open”, risking penetration from coat. silicone, waxes, etc., resulting in possible loss of gloss.
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DESCRIPTION AND OPERATION (Continued) Painting Plastic Bumper Bars Recommended Materials 1. The following procedures have been performed using the PPG line of products referred to below. Other commercial equivalents may be satisfactorily substituted. 2. Front and rear bars installed on falcon are made from high impact strength Polypropylene/EPDM plastic. 3. It is essential that approved methods, materials, paints, etc. or the equivalent of these be employed when paint repair operations are performed and when preparing new parts for installation. The approved products are: PPG - GRS BODYKLEEN - 920 - 35609 PPG - GRS DEGRESING AGENT - 499 - D0846 FOR PLASTICS PPG - GRS PLASTIC ADHESION - 499 - D8020 PROMOTER PPG - GRS PLASTICISER - 499 - D0814 FLEXIBLE ADDITIVE FOR TWO COMPONENT PRODUCTS PPG - GRS B.C. BASECOAT - 452 LINES PPG - GRS MEDIUM THINNER - 920 - D0871 PPG - GRS 2K CLEARCOAT - 455 - D0800 PPG - GRS D.G 2K ACRYLIC - 402 - LINE ENAMEL PPG - GRS 2K MEDIUM - 980 - D0841 HARDENER PPG - GRS MEDIUM THINNER - 920 - D0871 PPG - GRS D839 PRIMA PRIMER - 467 - D0839 PPG - MIRLON ABRASIVE PADS. - 947 - 48673 PPG - A652 IVIPLAST FILLER - 468 - A652 *PPG and GRS are registered trade marks of PPG industries Australia Pty. Ltd. 4. Correct cleaning is important prior to painting plastic parts. It will be necessary to remove dirt, grease, mould release agents (if part is new) and other contaminants prior to painting.
Preparation
6. Allow 15-20 seconds contact time then dry off with a separate clean cloth. 7. Repeat the process three times. NOTE: Do not allow Bodykleen or D846 to dry on surface.
Colour Finishing of Replacement Bumper bars 1. Replacement bumper bars are supplied with front cover unpainted and require refinishing from primer to topcoat before installation. The valance should be cleaned by wiping with a clean rag soaked in D846 Degreasing Agent for Plastics allowing contact with the surface for 10-15 seconds then wiping dry with a new dry clean cloth. Repeat procedure. Apply a double coat of D820 Plastic adhesion promoting primer. Allow 15-20 minutes drying time before top coating. NOTE: Correct cleaning is important prior to painting plastic parts. Observe safety procedures and obtain the required respirator as these products contain isocyanate.
Solid Colour 1. To the matched colour add D814 Plasticiser then hardener and reducer in the following ratios: 402 line colour D814 Plasticiser D841 medium hardener
—
3 parts by volume 499 - D0814 1 parts by volume 980 - D0841 2 parts by volume
Stir thoroughly and strain. Put on the air supplied respirator. Using a 1.3-1.6 fluid nozzle on a conventional or H.V.L.P spray gun apply one medium wet coat. Allow a 3-5 minute flash off and apply 1 full wet coat. If low baking, this can be done immediately at 60° for 30 minutes. If air drying allow 8 hours to dry. (Correct film thickness is 40-50 microns).
1. Remove any waterborne contaminants with PPG Bodykleen 920-35609. Mix 1 part Bodykleen to 4 Base coat Metallic/Pearl Colour and Clearcoat parts warm water. 2. Apply mixed Bodykleen to plastic part with a 1. Thin the matched Basecoat colour with 100% non-metallic pad such as PPG Grey Mirlon pad or D871 Thinner 920 line and stir thoroughly. equivalent. 2. Strain material and using a 1.3-1.6 fluid nozzle on 3. Lightly scuff all parts that are to be painted. a conventional or H.V.L.P spray gun apply one 4. Rinse the part with clean water and dry off. even, medium wet coat. Allow to flash for 10-15 minutes. 5. Apply D846 Degreasing agent for plastics directly from container on a clean cloth, washing the entire surface. G456450 en
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DESCRIPTION AND OPERATION (Continued) 3. Spray two to three medium wet coats to achieve CAUTION: Drying of all products may be coverage. Allow 15-20 minutes prior to clear accelerated by heat but to avoid distortion coating. unsupported bumpers should not be heated in an 4. Mix clearcoat with D814 Plasticiser then hardener oven or by infrared lamp above 60 degrees. and reducer in the following ratios: It will be necessary to remove dirt, grease, mould release agents (if part is new) and other contaminants D800 Clearcoat 455 - D0800 3 parts by prior to painting. volume Preparation D814 Plasticiser 499 - D0814 1 parts by volume 1. Remove any waterborne contaminants with PPG D841 medium 980 - D0841 2 parts by Bodykleen 920-35609. Mix 1 part Bodykleen to 4 hardener volume parts warm water. 5. Stir thoroughly and strain. Put on the air supplied 2. Apply mixed Bodykleen to plastic part with a non-metallic pad such as PPG Grey Mirlon pad or respirator. equivalent. 6. Using a 1.3-1.6 fluid nozzle on a conventional or 3. Lightly scuff all parts that are to be painted. H.V.L.P spray gun apply one even, medium wet coat to the Base coat. Allow to flash for 3-5 4. Rinse the part with clean water and dry off. minutes. 5. Apply D846 Degreasing agent for plastics directly 7. Apply a further full wet coat. Allow a 3-5 minute from container on a clean cloth, washing the flash off and apply 1 full wet coat. If low baking, entire surface. this can be done immediately at 60° for 30 6. Allow 15-20 seconds contact time then dry off with minutes. If air-drying, allow 8 hours to dry. a separate clean cloth. (Correct film thickness is 40-50 microns). 7. Repeat the process three times. Repairing Color Coat Plastic Bumpers NOTE: Do not allow Bodykleen or D846 to dry on surface. Superficial damage to the paint film and or plastic surface may be rectified by sanding and repainting. For shallow paint damage, follow the procedure listed Painting Plastic Components - General Hints under colour finishing of replacement Bumper Bars using P800 paper to sand down imperfections and It will be necessary to remove dirt grease, mould using, a Grey Mirlon pad with soapy water or P1200 release agents (if part is new)and other contaminates paper scuff, and key existing paint work. prior to painting. GRS Base coat and clear coat can be spot repaired Preparation by blending away the base coat colour but spraying the complete bumper with clear coat. Solid colour are 1. Remove any waterborne contaminates with Dulux sprayed as complete panels. Body Kleen 920-35609 1 part Body Kleen:9 parts If the damage extends to the plastic surface this must warm water. be primed with D820 Plastic adhesion primer after the 2. Apply mixed Body Kleen to plastic part with a non correct cleaning procedure. Any small nicks or metallic pad (3M Scotchbrite pad -or equivalent). scrapes can be filled with PPG Iviplast 66 (A652) filler 3. Lightly scuff all parts that are to be painted. for plastics applied over the D820 Adhesion primer. 4. Rinse the part with clean water and dry off. Final sand the Iviplast 66 with P240-320 dry. 5. Apply Universal Cleaner (920-39237)directly from If Primer filler is required, use D839 Prima Primer container on a clean cloth, washing the entire flexibalised, in the ratio of: surface. D839 Prima 467 -D0839 4 Parts 6. Allow 15-20 seconds contact time then dry off with D814 Plasticiser 499- D0814 1 Part a separate clean cloth. D841 medium 980- D0841 1 Part 7. Repeat process three times. hardener NOTE: Do not allow Body Kleen or Universal Primer Use a 1.6-2.0 mm gun set up. Apply 2 coats to dry on surface. maximum with 5-7 minutes flash off between coats. NOTE: Process to remove solvent borne Bake for 30 minutes at 60 degrees or air dry for 8 contaminants. hours prior to sanding. Final Sand with, P600 wet or P400dry for solid colours, and P800 wet or P500-600 Plastics Including Nylon dry for metallic or pearl colours. D820 Plastic adhesion Primer 449-D0820 (Primer is transparent red colour) G456450 en
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DESCRIPTION AND OPERATION (Continued) Gun Setup
Gravity: 1.4-1.8mm Air Pressure: 350-400 kpa Mixing Not required, supplied ready for use. Application Apply to 2 uniform light coats to all parts to be top coated. Allow to air dry for 15-20 mins. (20ºC) Before applying 2k topcoats. Do not apply heavy builds. Does not require priming. Apply topcoat direct to the scuffed and cleaned surface.
Clear Coat D800 Clearcoat 455 - D0800 D814 Plasticiser 499 - D0814 D841 medium hardener 980 - D0841 Selection of Reducer and Hardener will depend on application conditions. Refer to paint manufacturers recommendations. Spray Gun Set up Mixing
Top Coat - DG Solid Colors 402 line colour 402 line D814 Plasticiser 499- D0814 D841 medium hardener 980- D0841 Selection of Reducer and Hardener will depend on application conditions. Refer to paint manufacturers recommendations. Spray Gun Set up Mixing
Gravity: 1.3-1.5mm Air Pressure: 350-400kpa Mix as follows using a 2K measuring stick.
402 line colour — 3 parts by volume D814 Plasticiser 499 - D0814 1 parts by volume D841 medium 980 - D0841 2 parts by volume hardener Bake for 30 minutes at 60ºC or air dry over night at 20ºC. NOTE: When catalysed these products contain isocyanate. Refer previous Safety Precautions in this section.
Pearl/Metalic Clear Over Base PPG - GRS B.C. BASECOAT - 452 LINE PPG - GRS MEDIUM THINNER - 920 - D0871 Selection of Thinner will depend on application conditions. Refer to paint manufacturers recommendations Spray Gun Set up Mixing
Application
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Gravity: 1.3-1.5mm Suction:1.4-1.8mm Air Pressure: 350-400kpa 1 part GRS B.C. Basecoat with 1-part GRS Medium thinner by volume. Flexible additive is not required for the base coat. Apply light to medium coats of colour to achieve coverage allowing 10-15 minutes between coats at 20ºC. Allow 15-20 minutes air flash before applying clear coat.
Application:
D800 Clearcoat D814 Plasticiser D841 medium hardener
Gravity: 1.3-1.5mm Air Pressure: 350-400kpa Mix as follows using a GRS 2K measuring stick. Flexibalised D800 (455-D0800) Apply 2 wet even coats keeping air flash times to 3-5 minutes. Bake for 30 minutes at 60ºC or air dry over night at 20ºC. 455 - D0800 3 parts by volume 499 - D0814 1 parts by volume 980 - D0841 2 parts by volume
NOTE: When catalyzed these product contain isocyanate. Observe previous Safety Precautions in this section.
Flexible Additive The amount of Flexible Additive added to the 2K solid colours or MS Supreme will depend on the flexibility of the plastic. Always add flexible additive to the base then catalyse entire paint mix with hardener in the recommended ratio.
For Semi Rigid Plastics 1. Mix as follows: 2K Solid Colour 426 Line or MS Supreme 455-39900 5 parts Flexible Additive 499-35484 1 part Then catalyse and reduce as recommended above.
For Flexible Plastics 1. Mix as follows: 2K Solid Colour 426 Line or MS Supreme 455-39900 2 parts Flexible Additive 499-35484 1 part Then catalyse and reduce as recommended above.
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