2003 Ford BA Falcon Service Repair Manual.pdf

100-00-1 General Information 100-00-1
SECTION : 100-00 General Information
VEHICLE APPLICATION : 2003.0 BA Falcon
CONTENTS PAGE
DESCRIPTION AND OPERATION
About this Manual .................................................................................................................100-00-3
Introduction ..........................................................................................................................100-00-3
Replacement Parts...............................................................................................................100-00-3
Special Tools........................................................................................................................100-00-3
Important Safety Instructions ...............................................................................................100-00-3
Warnings, Cautions and Notes in This Manual....................................................................100-00-3
How to Use This Manual......................................................................................................100-00-3
Samples ...............................................................................................................................100-00-4
Health and Safety Precautions .............................................................................................100-00-4
Introduction ..........................................................................................................................100-00-4
Acids and Alkalis..................................................................................................................100-00-4
Air Bags................................................................................................................................100-00-4
Air Conditioning Refrigerant.................................................................................................100-00-5
Adhesives and Sealers ........................................................................................................100-00-5
Antifreeze .............................................................................................................................100-00-6
Asbestos ..............................................................................................................................100-00-6
Battery Acids ........................................................................................................................100-00-6
Brake and Clutch Linings and Pads.....................................................................................100-00-6
Brakes Fluids (Polyalkylene Glycols)...................................................................................100-00-6
Brazing .................................................................................................................................100-00-6
Chemical Materials...............................................................................................................100-00-6
Chlorofluorocarbons (CFC) ..................................................................................................100-00-7
Clutch Fluids ........................................................................................................................100-00-7
Clutch Linings and Pads ......................................................................................................100-00-7
Corrosion Protection Materials.............................................................................................100-00-7
Cutting..................................................................................................................................100-00-7
Dewaxing .............................................................................................................................100-00-7
Dusts ....................................................................................................................................100-00-7
Electric Shock ......................................................................................................................100-00-7
Engine Oils...........................................................................................................................100-00-7
Exhaust Fumes ....................................................................................................................100-00-8
Fibre Insulation.....................................................................................................................100-00-8
Fire .......................................................................................................................................100-00-8
First Aid ................................................................................................................................100-00-8
Fluoroelastomer ...................................................................................................................100-00-8
Foams - Polyurethane..........................................................................................................100-00-8
Freon....................................................................................................................................100-00-8
Fuels ....................................................................................................................................100-00-8
Gas Cylinders.......................................................................................................................100-00-9
Gases...................................................................................................................................100-00-9
Gaskets (Fluoroelastomer)...................................................................................................100-00-9
General Workshop Tools and Equipment ............................................................................100-00-9
High Pressure Air, Lubrication and Oil Test Equipment ....................................................100-00-10
Halon..................................................................................................................................100-00-10
Legal Aspects.....................................................................................................................100-00-10
Lubricants and Greases.....................................................................................................100-00-10
Noise ..................................................................................................................................100-00-10
Noise Insulation Materials..................................................................................................100-00-10
01/2003 2003.0 BA Falcon

(Continued)
O-Rings (Fluoroelastomer).................................................................................................100-00-10
Paints .................................................................................................................................100-00-10
Pressurized Equipment ......................................................................................................100-00-11
Solder.................................................................................................................................100-00-11
Solvents .............................................................................................................................100-00-11
Sound Insulation ................................................................................................................100-00-11
Suspended Loads ..............................................................................................................100-00-11
Transmission Brake Bands ................................................................................................100-00-11
Underseal...........................................................................................................................100-00-11
Viton ...................................................................................................................................100-00-11
Welding ..............................................................................................................................100-00-12
Warning Symbols on Vehicles ...........................................................................................100-00-12
White Spirit.........................................................................................................................100-00-13
Standard Workshop Practices ............................................................................................100-00-13
Vehicle in Workshop ..........................................................................................................100-00-13
Alternative Fuel ..................................................................................................................100-00-14
Alternative Fuel — Do’s.....................................................................................................100-00-14
Alternative Fuel — Do Nots ...............................................................................................100-00-14
Towing the Vehicle.............................................................................................................100-00-14
Connecting a Slave Battery Using Jumper Cables............................................................100-00-14
Component Cleaning .........................................................................................................100-00-15
Calibration of Essential Measuring Equipment ..................................................................100-00-15
Solvents, Sealers and Adhesives .......................................................................................100-00-15
Introduction ........................................................................................................................100-00-15
General Specifications .......................................................................................................100-00-16
Road/Roller Testing ............................................................................................................100-00-16
Pre-Test Checks ................................................................................................................100-00-16
Starting the Engine ............................................................................................................100-00-16
On Road or Roller Test Check:..........................................................................................100-00-17
Brake Testing .....................................................................................................................100-00-17
01/2003 2003.0 BA Falcon

DESCRIPTION AND OPERATION
NOTE: Notes are used to provide additional essential
About this Manual
information required to carry out a complete and
satisfactory repair.
Introduction
As you read through this manual, you will come
This manual has been written in a format that is
across WARNINGS, CAUTIONS and NOTES.
designed to meet the needs of Ford technicians
worldwide. The objective is to use common formats A warning, caution or note is placed at the beginning
and include similar content in each manual worldwide. of a series of steps if it applies to multiple steps. If the
warning, caution or note only applies to one step, it is
This manual provides general descriptions for
placed at the beginning of the specific step (after the
accomplishing service and repair work with tested,
step number).
effective techniques. Following them will help assure
reliability. How to Use This Manual
Replacement Parts This manual covers service and repair procedures.
Ford and Motorcraft parts are made to the same This manual is structured into groups and sections,
exacting standards as the original factory fitted with specific system sections collected together under
components. For this reason, it is recommended that their relevant group.
only genuine Ford or Motorcraft parts are installed A group covers a specific portion of the vehicle. The
during service or repair. manual is divided into five groups, General
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
Where appropriate, instructions will be given for the
operation of all motor vehicles as well as the personal
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
columns: CONDITIONS and
CAUTION: Cautions are used to indicate that
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
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DESCRIPTION AND OPERATION (Continued)
direction to another test step or specific corrective Before using any product the Materials Safety Data
actions. Sheet supplied by the manufacturer or supplier should
be consulted.
The boxed numbers indicate the order in which the
described action is to be performed. Acids and Alkalis
Component Tests
See also Battery Acids.
A component test is used when a component is tested
For example caustic soda, sulphuric acid.
in multiple pinpoint tests, or if a procedure is too
complicated to be formatted within a single page of Used in batteries and cleaning materials.
the pinpoint test. Irritant and corrosive to the skin, eyes, nose and
Graphics throat. Cause burns. Can destroy ordinary protective
clothing.
Test graphics show the measurement or test to be
performed in a test step. Avoid splashes to the skin, eyes and clothing. Wear
suitable protective impervious apron, gloves and
A representative tester graphic is used for voltmeters
goggles. Do not breath mists.
and ohmmeters.
Make sure access to eye wash bottles, shower and
If multiple measurements are made in a single
soap are readily available for splashing accidents.
graphic, the test leads are drawn with a solid line until
the test lead splits to indicate the multiple Display Eye Hazard sign.
measurements, at which point dashed lines are used.
Air Bags
Breakout box-type testers are represented by a
double circle test pin. Test pins are labelled with the See also Fire, Chemical Materials
pin number. Highly flammable, explosive – observe No Smoking
policy.
Samples
Used as a safety restraint system mounted in the
Special Tools and Torque Figures steering wheel and passenger side of the instrument
Any requirement for special tools will picture the tool, panel and side impact Airbags.
showing it in use and with its tool number shown. The inflator contains a high-energetic propellant
Torque settings will be given at the relevant point in which, when ignited, produces a VERY HOT GAS
the procedure. (2500°C).
The gas generant used in air bags is Sodium Azide.
This material is hermetically sealed in the module and
is completely consumed during deployment. No
attempt should be made to open an air bag inflator as
this will lead to the risk of exposure to Sodium Azide.
If a gas generator is ruptured, full protective clothing
should be worn when dealing with the spillage.
After normal deployment, gloves and safety goggles
should be worn during the handling process.
Deployed air bags should be disposed of in a plastic
bag in accordance with local regulations at an
approved chemical waste site.
Following any direct contact with gas generant.
wash affected areas thoroughly with water.
Health and Safety Precautions seek medical assistance if necessary.
Air Bags - Do’s
Introduction
do store modules in an upright position.
Many of the procedures associated with vehicle
do keep modules dry.
maintenance and repair involve physical hazards or
do carry modules with the cover side pointing
other risks to health. This subsection lists,
away from the body.
alphabetically, some of these hazardous operations
and the materials and equipment associated with do place modules with their cover side upwards.
them. Precautions necessary to avoid these hazards
do carefully inspect modules for damage.
are identified.
do stand to one side when connecting modules.
The list is not exhaustive and all operations and
do make sure all test equipment is properly
procedures, and the handling of materials, should be
calibrated and maintained.
carried out with health and safety in mind.
do wash hands after handling deployed air bags.
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Air Bags - Do Nots Solvent-based Adhesives/Sealers - See
Solvents
do not store highly flammable material together
with modules or gas generators.
Follow manufacturers instructions.
do not store gas generators at temperatures
Water-based Adhesives/Sealers
exceeding 80°C.
do not store modules upside down. Those based on polymer emulsions and rubber
latexes may contain small amounts of volatile toxic
do not attempt to open a gas generator housing.
and harmful chemicals. Skin and eye contact should
do not expose gas generators to open flame or
be avoided and adequate ventilation provided during
sources of heat.
use.
do not place anything on top of a module cover.
Hot Melt Adhesives
do not use damaged modules.
In the solid state, they are safe. In the molten state
do not touch a fired module or gas generator for
they may cause burns and health hazards may arise
at least 10 minutes.
from the inhalation of toxic fumes.
do not use any electrical probes on the wiring
Use appropriate protective clothing and a
circuit.
thermostatically controlled heater with a thermal
Air Conditioning Refrigerant cut-out and adequate extraction.
See also Chlorofluorocarbon, Chemical Materials Resin-based Adhesives/Sealers, for example
Highly flammable, combustible – observe No Smoking Epoxide and Formaldehyde Resin-based
policy.
Mixing should be carried out in well ventilated areas,
Skin contact may result in frostbite. as harmful or toxic volatile chemicals may be
Instructions given by the manufacturer must be released.
followed. Avoid naked lights, wear suitable protective Skin contact with uncured resins and hardeners can
gloves and goggles. result in irritation, dermatitis, and absorption of toxic or
If refrigerant comes into contact with the skin or eyes, harmful chemicals through the skin. Splashes can
rinse the affected areas with water immediately. Eyes damage the eyes.
should also be rinsed with an appropriate irrigation Provide adequate ventilation and avoid skin and eye
solution and should not be rubbed. SEEK MEDICAL contact.
ASSISTANCE IF NECESSARY.
Anaerobic, Cyanoacrylate (super-glues) and
Air Conditioning Refrigerant - Do Nots other Acrylic Adhesives
do not expose refrigerant bottles to sunlight or
Many are irritant, sensitizing or harmful to the skin and
heat. respiratory tract. Some are eye irritants.
do not stand refrigerant bottles upright; when
Skin and eye contact should be avoided and the
filling, hold them with the valve downwards.
manufacturers instructions followed.
do not expose refrigerant bottles to frost. Cyanoacrylate adhesives (super-glues) MUST NOT
do not drop refrigerant bottles. contact the skin or eyes. If skin or eye tissue is
bonded, cover with a clean moist pad and SEEK
do not vent refrigerant to atmosphere under any
IMMEDIATE MEDICAL ATTENTION. Do not attempt
circumstance.
to pull tissue apart. Use in well ventilated areas as
do not mix refrigerants, for example R12 (Freon)
vapours can cause irritation to the nose and eyes.
and R134a.
For two-pack systems see Resin-based and
Adhesives and Sealers Isocyanate Adhesives/Sealers.
See also Fire, Chemical Materials Isocyanate (Polyurethane) Adhesives/Sealers
Highly flammable, flammable, combustible – observe
See also Resin-based Adhesives
No Smoking policy.
Individuals suffering from asthma or respiratory
Generally should be stored in No Smoking areas.
allergies should not work with or near these materials
Cleanliness and tidiness in use should be observed,
as sensitivity reactions can occur.
for example disposable paper covering benches;
Over exposure is irritating to the eyes and respiratory
should be dispensed from applicators where possible;
system. Excessive concentrations may produce
containers, including secondary containers, should be
effects on the nervous system including drowsiness.
labelled appropriately.
In extreme cases, loss of consciousness may result.
Long term exposure to vapour concentrations may
result in adverse health effects.
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Prolonged contact with the skin may have a defatting Brakes Fluids (Polyalkylene Glycols)
effect which may lead to skin irritation and in some
See also Fire.
cases, dermatitis.
Splashes to the skin and eyes are extremely irritating.
Splashes entering the eye will cause discomfort and
Avoid skin and eye contact as far as possible.
possible damage.
Inhalation vapour hazards do not arise at ambient
Any spraying should preferably be carried out in
temperatures because of the very low vapour
exhaust ventilated booths, removing vapours and pressure.
spray droplets from the breathing zone.
Brazing
Wear appropriate gloves, eye and respiratory
protection. See Welding.
Antifreeze Chemical Materials
See also Fire, Solvents. See also Legal Aspects.
For example isopropanol, ethylene glycol, methanol.
Chemical materials such as solvents, sealers,
Highly flammable, flammable, combustible. adhesives, paints, resin foams, battery acids,
antifreeze, brake fluids, fuels, oils and grease should
Used in vehicle coolant systems, brake air pressure
always be used with caution and stored and handled
systems, screenwash solutions.
with care. They may be toxic, harmful, corrosive,
Vapours may be given off from coolant antifreeze
irritant or highly flammable and give rise to hazardous
(glycol) when heated. Avoid breathing these vapours.
fumes and dusts.
Antifreeze may be absorbed through the skin in toxic
The effects of excessive exposure to chemicals may
or harmful quantities. Antifreeze, if swallowed, can be
be immediate or delayed; briefly experienced or
fatal and MEDICAL ATTENTION SHOULD BE
permanent; cumulative; superficial; life threatening; or
SOUGHT IMMEDIATELY.
may reduce life expectancy.
These products must not be used in any cooling or
industrial water system which is connected or linked Chemical Materials - Do’s
to general, food preparation or drinking water
Do carefully read and observe hazard and
supplies.
precaution warnings given on material containers
(labels) and in any accompanying leaflets, posters
Asbestos
or other instructions. Material health and safety
See also Warning Symbols on Vehicles at the end of data sheets can be obtained from manufacturers.
this subsection.
Do remove chemical materials from the skin and
Breathing asbestos dust may cause lung damage or, clothing as soon as practicable after soiling.
in some cases, cancer. Change heavily soiled clothing and have it
Used in brake and clutch linings, transmission brake cleaned.
bands and gaskets. Ford original production and Do organise work practices and protective
genuine replacement items for this model are clothing to avoid soiling of the skin and eyes;
asbestos free. breathing vapours, aerosols, dusts or fumes;
The use of drum cleaning units, vacuum cleaning or inadequate container labelling; fire and explosion
damp wiping is preferred. hazards.
Asbestos dust waste should be dampened, placed in Do wash before job breaks, before eating,
a sealed container and marked for safe disposal. If smoking, drinking or using toilet facilities when
any cutting or drilling is attempted on materials handling chemical materials.
containing asbestos the item should be dampened Do keep work areas clean, uncluttered and free of
and only hand tools or low speed power tools used. spills.
Do store chemical materials according to national
Battery Acids
and local regulations.
See also Acids and Alkalis.
Do keep chemical materials out of the reach of
Gases released during charging are explosive. Never children.
use naked flames or allow sparks near charging or
Chemical Materials - Do Nots
recently charged batteries.
Make sure there is adequate ventilation. Do not mix chemical materials except under the
manufacturers instructions; some chemicals can
Brake and Clutch Linings and Pads form other toxic or harmful chemicals, give off
toxic or harmful fumes or become explosive when
See Asbestos.
mixed together.
Do not spray chemical materials, particularly
G17372 en 01/2003 2003.0 BA Falcon

those based on solvents, in confined spaces, for Cutting
example when people are inside a vehicle.
See Welding.
Do not apply heat or flame to chemical materials
except under the manufacturers instructions. Dewaxing
Some are highly flammable and some may
See Solvents and Fuels (Kerosene).
release toxic or harmful fumes.
Do not leave containers open. Fumes given off Dusts
can build up to toxic, harmful or explosive
Powder, dusts or clouds may be irritant, harmful or
concentrations. Some fumes are heavier than air
toxic. Avoid breathing dusts from powdery chemical
and will accumulate in confined areas such as
materials or those arising from dry abrasion
pits.
operations. Wear respiratory protection if ventilation is
Do not transfer chemical materials to unlabelled
inadequate.
containers.
Fine dusts of combustible material can present an
Do not clean hands or clothing with chemicals.
explosion hazard. Avoid explosive limits and sources
Chemicals, particularly solvents and fuels, will dry
of ignition.
skin and may cause irritation leading to dermatitis
or be absorbed through the skin in toxic or Electric Shock
harmful quantities.
Electric shock can result from the use of faulty
Do not use emptied containers for other materials electrical equipment or from the misuse of equipment
except when they have been cleaned under
in good condition.
supervised conditions.
Make sure that electrical equipment is maintained in
Do not sniff or smell chemical materials. Brief good condition and frequently tested. Faulty
exposure to high concentrations of fumes can be
equipment should be labelled and preferably removed
toxic or harmful.
from the work station.
Chlorofluorocarbons (CFC) Make sure that flexes, cables, plugs and sockets are
not frayed, kinked, cut, cracked or otherwise
There is concern in the scientific community that
damaged.
CFCs and Halons are depleting the upper ozone layer
Make sure that electrical equipment and flexes do not
which filters out harmful ultraviolet radiation.
come into contact with water.
Decreased filtration of ultraviolet radiation may result
in increases in skin cancer, cataracts and immune Make sure that electrical equipment is protected 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
chemicals and particles such as carbon oxides,
sprayed in conditions of adequate ventilation and not
nitrogen oxides, aldehydes, lead and aromatic
in confined spaces.
G17372 en 01/2003 2003.0 BA Falcon

hydrocarbons. Engines should be run only under Foams - Polyurethane
conditions of adequate exhaust extraction or general
See also Fire.
ventilation and not in confined spaces.
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
vapour/mists have cleared.
contact through careful organization of work practices
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.
vapours/mists have cleared should not be allowed.
Many of the materials found on or associated with the
Any heat cutting of cured foams or partially cured
repair of vehicles are highly flammable. Some give off
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.
Avoid skin contact with fuel where possible. Should
First Aid
contact occur, wash the affected skin with soap and
Apart from meeting any legal requirements it is water.
desirable for someone in the workshop to be trained
in First Aid procedures. Gasoline (Petrol)
Splashes in the eye should be flushed carefully with Highly flammable - observe No Smoking policy.
clean water for at least ten minutes.
Swallowing can result in mouth and throat irritation
Soiled skin should be washed with soap and water. and absorption from the stomach can result in
In case of cold burns, from alternative fuels, place drowsiness and unconsciousness. Small amounts can
affected area in cool to cold water. be fatal to children. Aspiration of liquid into the lungs,
through vomiting, is a very serious hazard.
Individuals affected by inhalation of gases and fumes
should be removed to fresh air immediately. If effects Gasolene dries the skin and can cause irritation and
persist, consult a doctor. dermatitis on prolonged or repeated contact. Liquid in
the eye causes severe smarting.
If liquids are swallowed inadvertently, consult a doctor
giving him the information on the container or label. Motor gasolene may contain appreciable quantities of
Do not induce vomiting unless this action is indicated benzene, which is toxic upon inhalation, and the
on the label. concentration of gasolene vapours must be kept very
low. High concentrations will cause eye, nose and
Fluoroelastomer throat irritation, nausea, headache, depression and
symptoms of drunkenness. Very high concentrations
See Viton.
will result in rapid loss of consciousness.
G17372 en 01/2003 2003.0 BA Falcon

Make sure there is adequate ventilation when checked for integrity following the specified
handling and using gasolene. Great care must be procedures.
taken to avoid the serious consequences of inhalation If the fuel tank is to be removed for service or repair
in the event of vapour build up arising from spillages the fuel must be evacuated using dedicated
in confined spaces. equipment and following the specified procedures.
Special precautions apply to cleaning and
Gas Cylinders
maintenance operations on gasolene storage tanks.
Gasolene should not be used as a cleaning agent. It See also Fire.
must not be siphoned by mouth. See First Aid. Gases such as oxygen, acetylene, argon and propane
are normally stored in cylinders at pressures of up to
Gas-oil (Diesel Fuel)
138 bar (2000 psi) and great care should be taken in
Combustible. handling these cylinders to avoid mechanical damage
to them or to the valve gear attached. The contents of
Gross or prolonged skin contact with high boiling point
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
direct sunlight. Fuel gases, for example acetylene and
Used also as heating fuel, solvent and cleaning agent.
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
Care should be exercised to prevent leaks from gas
swallowing. The main hazard from swallowing arises if
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.
General Workshop Tools and Equipment
Alternative Fuel
It is essential that all tools and equipment are
Highly flammable. Observe “NO SMOKING” signs. maintained in good condition and the correct safety
equipment is used where required.
Make sure there is adequate ventilation when working
on alternative fuelled vehicles. Great care must be Never use tools or equipment for any purpose other
taken to avoid the serious consequences of inhalation than that for which they were designed. Never
in the event of vapour build up in confined spaces. overload equipment such as hoists, jacks, axle and
chassis stands or lifting slings. Damage caused by
Inhalation in high concentrations may cause
overloading is not always immediately apparent and
dizziness, headache, nausea and loss of
may result in a fatal failure the next time that the
co-ordination. Very high concentrations may result in
equipment is used.
loss of consciousness.
Do not use damaged or defective tools or equipment,
Contact with liquidified petroleum gas (LPG) or
particularly high speed equipment such as grinding
compressed natural gas (CNG) to skin may cause
wheels. A damaged grinding wheel can disintegrate
cold burns and may cause frost bite.
without warning and cause serious injury.
Long sleeved cotton overalls, steel toe capped safety
Wear suitable eye protection when using grinding,
boots and rubber neoprene gloves should be worn
chiselling or sand blasting equipment.
during removal and installation of LPG/CNG fuel
system components. Wear a suitable breathing mask when using abrasive
blasting equipment, working with asbestos-based
LPG/CNG fuel leaks could cause a fire and be a
materials or using spraying equipment.
hazard to health that can lead to personal injury,
illness or even death. Make sure there is adequate ventilation to control
dusts, mists and fumes.
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
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Wash with soap and water to make sure all oil is
High Pressure Air, Lubrication and Oil
removed (skin cleansers and nail brushes will
Test Equipment
help). Preparations containing lanoline replace the
See also Lubricants and Greases. natural skin oils which have been removed.
Always keep high pressure equipment in good Do not use gasolene (petrol), kerosene (paraffin),
condition, and regularly maintained, particularly at diesel fuel (gas oil), thinners or solvents for
joints and unions. cleaning skin.
Never direct a high pressure nozzle, for example If skin disorders develop, obtain medical advice
diesel injector, at the skin as the fluid may penetrate without delay.
to the underlying tissue, and cause serious injury. Where practicable, degrease components prior to
handling.
Halon
Where there is a risk of eye contact, eye
See CFCs. protection should be worn, for example chemical
goggles or face shields; in addition an eye wash
Legal Aspects
facility should be provided.
There are many laws and regulations relating to
Environmental Precautions
health and safety in the use and disposal of materials
and equipment in a workshop. Burning used engine oil in small space heaters or
For a safe working environment and to avoid boilers can be recommended only for units of
environmental pollution, workshops should be familiar, approved design. If in doubt check with the
in detail, with the many health and safety laws and appropriate local authority and manufacturer of
regulations within their country, published by both approved appliances.
national and local authorities. Dispose of used oil and used oil filters through
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
Noise
Prolonged and repeated contact with mineral oil will
result in the removal of natural fats from the skin, Some operations may produce high noise levels
leading to dryness, irritation and dermatitis. In which could, in time, damage hearing. In these cases,
addition, used engine oil contains potentially harmful suitable ear protection must be worn.
contaminants which may cause skin cancer. Adequate
means of skin protection and washing facilities must Noise Insulation Materials
be provided.
See Foams, Fibre Insulation.
Do not employ used engine oils as lubricants or for
any application where appreciable skin contact is O-Rings (Fluoroelastomer)
likely to occur.
See Viton.
Health Protection Precautions
Paints
Avoid prolonged and repeated contact with oils,
See also Solvents, Chemical Materials.
particularly used engine oils.
Highly flammable, flammable - observe No Smoking
Wear protective clothing, including impervious
policy
gloves where practicable.
Do not put oily rags into pockets. One Pack
Avoid contaminating clothes, particularly Can contain harmful or toxic pigments, driers and
underpants, with oil. other components as well as solvents. Spraying
Heavily soiled clothing and oil-impregnated should be carried out only with adequate ventilation.
footwear should not be worn. Overalls must be
Two Pack
cleaned regularly.
First Aid treatment should be obtained Can also contain harmful and toxic unreacted resins
immediately for open cuts and wounds. and resin hardening agents. The manufacturers
instructions should be followed. See also Resin-based
Use barrier creams, applying them before each
Adhesives and Isocyanate Adhesives and Sealers
work period, to help the removal of oil from the
under Adhesives and Sealers.
skin.
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Spraying should preferably be carried out in Avoid splashes to the skin, eyes and clothing. Wear
exhausted ventilated booths removing vapour and protective gloves, goggles and clothing if necessary.
spray mists from the breathing zone. Individuals Make sure there is good ventilation when in use,
working in booths should wear appropriate respiratory avoid breathing fumes, vapours and spray mists and
protection. Those doing small scale repair work in the keep containers tightly sealed. Do not use in confined
open workshop should wear air-fed respirators. spaces.
When spraying materials containing solvents, for
Pressurized Equipment
example paints, adhesive, coatings, use extraction
See High Pressure Air, Lubrication and Oil Test ventilation or personal respiratory protection in the
Equipment. absence of adequate general ventilation.
Do not apply heat or flame except under specific and
Solder
detailed manufacturers instructions.
Solders are mixtures of metals such that the melting
point of the mixture is below that of the constituent Sound Insulation
metals (normally lead and tin). Solder application
See Fibre Insulation, Foams.
does not normally give rise to toxic lead fumes,
provided a gas/air flame is used. Oxy-acetylene Suspended Loads
flames should not be used, as they are much hotter
and will cause lead fumes to be produced.
CAUTION: Never improvise lifting tackle.
Some fumes may be produced by the application of
There is always a danger when loads are lifted or
any flame to surfaces coated with grease, and
suspended. Never work under an unsupported,
inhalation of these should be avoided.
suspended or raised load, for example a suspended
Removal of excess solder should be undertaken with engine.
care, to make sure that fine lead dust is not produced,
Always make sure that lifting equipment such as
which can give toxic effects if inhaled. Respiratory
jacks, hoists, axle stands and slings are adequate and
protection may be necessary.
suitable for the job, in good condition and regularly
Solder spillage and filings should be collected and maintained.
removed promptly to prevent general air
contamination by lead. Transmission Brake Bands
High standards of personal hygiene are necessary in See Asbestos.
order to avoid ingestion of lead or inhalation of solder
dust from clothing. Underseal
See Corrosion Protection.
Solvents
See also Chemical Materials, Fuels (Kerosene), Fire. Viton
For example acetone, white spirit, toluene, xylene, In common with many other manufacturers vehicles,
trichloroethane. some components fitted to the Ford range have
Used in cleaning and dewaxing materials, paints, O-rings, seals or gaskets which contain a material
plastics, resins and thinners. known as ‘Viton’.
Some may be highly flammable or flammable. Viton is a fluoroelastomer, that is a synthetic rubber
type which contains Fluorine. It is commonly used for
Skin contact will degrease the skin and may result in
O-rings, gaskets and seals of all types. Although Viton
irritation and dermatitis following repeated or
is the most well known fluoroelastomer, there are
prolonged contact. Some can be absorbed through
others, including Fluorel and Tecmoflon.
the skin in toxic or harmful quantities.
When used under design conditions fluoroelastomers
Splashes in the eye may cause severe irritation and
are perfectly safe. If, however, they are exposed to
could lead to loss of vision.
temperatures in excess of 400°C, the material will not
Brief exposure of high concentrations of vapours or
burn, but will decompose, and one of the products
mists will cause eye and throat irritation, drowsiness,
formed is hydrofluoric acid.
dizziness, headaches and, in the worst
This acid is extremely corrosive and may be absorbed
circumstances, unconsciousness.
directly, through contact, into the general body
Repeated or prolonged exposure to excessive but
system.
lower concentrations of vapours or mists, for which
O-rings, seals or gaskets which have been exposed to
there might not be adequate warning indications, can
very high temperatures will appear charred or as a
cause more serious toxic or harmful effects.
black sticky substance.
Aspiration into the lungs, for example through
DO NOT, under any circumstances touch them or the
vomiting, is the most serious consequence of
attached components.
swallowing.
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Enquiries should be made to determine whether Viton Gas Welding (and Cutting)
or any other fluoroelastomer has been used in the
Oxy-acetylene torches may be used for welding and
affected O-ring, seal or gasket. If they are of natural
cutting, and special care must be taken to prevent
rubber or nitrile there is no hazard. If in doubt, be
leakage of these gases, with consequent risk of fire
cautious as the material may be Viton or any
and explosion.
fluoroelastomer.
The process will produce metal spatter and eye and
If Viton or any other fluoroelastomers have been
skin protection is necessary.
used, the affected area should be decontaminated
The flame is bright, and eye protection should be
before the commencement of work.
used, but the ultra-violet emission is much less than
Disposable heavy duty plastic gloves should be worn
that from arc welding, and lighter filters may be used.
at all times, and the affected area washed down using
The process itself produces few toxic fumes, but such
wire wool and a limewater (calcium hydroxide)
fumes and gases may be produced from coatings on
solution to neutralise the acid before disposing of the
the work, particularly during cutting away of damaged
decomposed Viton residue and final cleaning of the
body parts, and inhalation of the fumes should be
area. After use, the plastic gloves should be discarded
avoided.
carefully and safely.
In brazing, toxic fumes may be produced from the
Welding metals in the brazing rod, and a severe hazard may
arise if brazing rods containing cadmium are used. In
See also Fire, Electric Shock, Gas Cylinders.
this event particular care must be taken to avoid
Welding processes include Resistance Welding (Spot
inhalation of fumes and expert advice may be
Welding), Arc Welding and Gas Welding.
required.
Resistance Welding Special precautions must be taken before any welding
or cutting takes place on vessels which have
This process may cause particles of molten metal to
contained combustible materials, for example boiling
be emitted at a high velocity, and the eyes and skin
or steaming out of fuel tanks .
must be protected.
Warning Symbols on Vehicles
Arc Welding
Decals showing warning symbols will be found on
This process emits a high level of ultra-violet radiation
various vehicle components.
which may cause arc-eye and skin burns to the
operator and to other persons nearby. Gas-shielded These decals must not be removed. The warnings are
welding processes are particularly hazardous in this for the attention of owners/operators and persons
respect. Personal protection must be worn, and carrying out service or repair operations on the
screens used to shield other people. vehicle.
CONTACT LENS WEARERS ARE ADVISED TO The most commonly found decals are reproduced
REVERT TO ORDINARY SPECTACLES WHEN ARC below together with an explanation of the warnings.
WELDING as the arc spectrum is believed to emit
microwaves which dry out the fluid between the lens
and the eye. This may result in blindness when the
lens is removed from the eye.
Metal spatter will also occur, and appropriate eye and
skin protection is necessary.
The heat of the welding arc will produce fumes and
gases from the metals being welded, the rods and
from any applied coatings or contamination on the
surfaces being worked on. These gases and fumes
may be toxic and inhalation of these should be
avoided. The use of extraction ventilation to remove
the fumes from the working area may be necessary
particularly in cases where the general ventilation is
poor, or where considerable welding work is
1. Components or assemblies displaying the caution
anticipated. In extreme cases or confined spaces
triangle and open book symbol advise
where adequate ventilation cannot be provided,
consultation of the relevant section of the owners
air-fed respirators may be necessary.
handbook before touching or attempting
adjustments of any kind.
G17372 en 01/2003 2003.0 BA Falcon

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.
G17373 en 01/2003 2003.0 BA Falcon

the battery is disconnected if working on the do not work on the fuel lines or system
engine. components unless the alternative fuel has been
evacuated and the pressure in the system is
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 CAUTION: A discharged battery condition
may have been caused by an electrical short
do not vent off LPG fuel
circuit. If this condition exists there will be an
do not use shop air pressure to force LPG fuel
apparently live circuit on the vehicle even when all
from the fuel tank
normal circuits are switched off. This can cause
do not use paint drying ovens above 40°C for any arcing when the jumper cables are connected.
alternative fuel vehicles. LPG and CNG fuel tanks
should be removed from the vehicles prior to CAUTION: While it is not recommended that
being put into paint drying ovens above 40°C the vehicle is jump started, it is recognized that
do not modify the system or install new this may occasionally be the only practical way to
components with parts not designed for gas mobilize a vehicle. In such an instance the
vehicles discharged battery must be recharged
immediately after jump starting to avoid
do not evacuate fuel tanks unless there is repair
permanent damage.
that requires removed of the fuel tank
G17373 en 01/2003 2003.0 BA Falcon

Always make sure that the jumper cables are Component Cleaning
adequate for the task. Heavy duty cables must be
To prevent ingress of dirt, accumulations of loose dirt
used.
and greasy deposits should be removed before
Always make sure that the slave battery is of the disconnecting or dismantling components or
same voltage as the vehicle battery. The batteries
assemblies.
must be connected in parallel.
Components should be thoroughly cleaned before
Always make sure that switchable electric circuits inspection prior to reassembly.
are switched off before connecting jumper cables.
This reduces the risk of arcing occurring when the Cleaning Methods:
final connection is made.
dry cleaning
removal of loose dirt with soft or cable brushes
scraping dirt off with a piece of metal or wood
wiping off with a rag
CAUTION: Compressed air is sometimes
‘wet’ so use with caution, especially on hydraulic
systems.
blowing dirt off with compressed air. (Eye
protection must be worn when using this method)
removal of dry dust using vacuum equipment.
This method should always be used to remove
friction lining material dust (asbestos particles)
steam cleaning
WARNING: Make sure that the ends of the
WARNING: Most solvents require careful
jumper cables do not touch each other or ground
handling and some are harmful. Refer to Health
against the vehicle body at any time while the
and Safety Precautions and to the manufacturers
cables are attached to the battery. A fully charged
literature for safety precautions. Failure to follow
battery, if shorted through jumper cables, can
these instructions may result in personal injury.
discharge at a rate well above 1000 amps causing
Various solvents are available which are suitable for
violent arcing and very rapid heating of the
component cleaning. Some components such as
jumper cables and terminals, and can even cause
brake hydraulic parts and electrical assemblies should
the battery to explode. Failure to follow these
be cleaned only with recommended solvents — refer
instructions may result in personal injury.
to Solvents, Sealers and Adhesives or to the section
Always connect the jumper cables in the following
of the manual relevant to the component.
sequence:
slave battery positive first then vehicle battery Calibration of Essential Measuring
positive Equipment
slave battery negative next and then vehicle
ground at least 12 inches (300 mm) from the WARNING: Failure to follow these
battery terminal, for example engine lifting eye instructions may result in personal injury or
Always reduce the engine speed to idle before damage to components.
disconnecting the jumper cables. It is of fundamental importance that certain essential
Before removing the jumper cables from the vehicle equipment, for example torque wrenches,
that had the discharged battery, switch on the heater multimeters, exhaust gas analysers or rolling roads,
blower (high) or the heated rear window, to reduce the are regularly calibrated in accordance with the
voltage peak when the cables are removed. manufacturers instructions.
Always disconnect the jumper cables in the reverse
Solvents, Sealers and Adhesives
order to the connecting sequence and do not short
the ends of the cables.
Introduction
Do not rely on the generator to restore a discharged
battery. For a generator to recharge a battery, it would
WARNING: Always handle all solvents,
take in excess of eight hours continuous driving with
sealers and adhesives with extreme care. Some
no additional loads placed on the battery.
contain chemicals or give off fumes which can be
dangerous to health. Always follow the
manufacturers instructions. If in doubt about any
G17374 en 01/2003 2003.0 BA Falcon

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