2002-2005 Ford Falcon (BA) Service & Repair Manual
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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
100-00-2 General Information 100-00-2
(Continued)
O-Rings (Fluoroelastomer) .................................................................................................100-00-10
Paints .................................................................................................................................100-00-10
Pressurized Equipment ......................................................................................................100-00-11
Solder .................................................................................................................................100-00-11
Solvents .............................................................................................................................100-00-11
Sound Insulation ................................................................................................................100-00-11
Suspended Loads ..............................................................................................................100-00-11
Transmission Brake Bands ................................................................................................100-00-11
Underseal ...........................................................................................................................100-00-11
Viton ...................................................................................................................................100-00-11
Welding ..............................................................................................................................100-00-12
Warning Symbols on Vehicles ...........................................................................................100-00-12
White Spirit .........................................................................................................................100-00-13
Standard Workshop Practices ............................................................................................100-00-13
Vehicle in Workshop ..........................................................................................................100-00-13
Alternative Fuel ..................................................................................................................100-00-14
Alternative Fuel — Do’s .....................................................................................................100-00-14
Alternative Fuel — Do Nots ...............................................................................................100-00-14
Towing the Vehicle .............................................................................................................100-00-14
Connecting a Slave Battery Using Jumper Cables ............................................................100-00-14
Component Cleaning .........................................................................................................100-00-15
Calibration of Essential Measuring Equipment ..................................................................100-00-15
Solvents, Sealers and Adhesives .......................................................................................100-00-15
Introduction ........................................................................................................................100-00-15
General Specifications .......................................................................................................100-00-16
Road/Roller Testing ............................................................................................................100-00-16
Pre-Test Checks ................................................................................................................100-00-16
Starting the Engine ............................................................................................................100-00-16
On Road or Roller Test Check: ..........................................................................................100-00-17
Brake Testing .....................................................................................................................100-00-17
01/2003 2003.0 BA Falcon
100-00-3 General Information 100-00-3
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
G17365 en 01/2003 2003.0 BA Falcon
100-00-4 General Information 100-00-4
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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100-00-5 General Information 100-00-5
DESCRIPTION AND OPERATION (Continued)
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.
G17372 en 01/2003 2003.0 BA Falcon
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What's Included?
Lifetime Access
Fast Download Speeds
Offline Viewing
Access Contents & Bookmarks
Full Search Facility
Print one or all pages of your manual
$31.99
The 2002-2005 Ford Falcon (BA) Service & Repair Manual is a comprehensive guide designed to help Ford Falcon (BA) owners maintain and repair their vehicles. This manual is specifically for the Falcon (BA) models produced between 2002 and 2005.
With detailed instructions and step-by-step procedures, this manual covers a wide range of topics, including engine, transmission, suspension, electrical system, and more. Whether you are a professional mechanic or a DIY enthusiast, this manual provides all the information you need to keep your Falcon (BA) in top condition.
Features of the 2002-2005 Ford Falcon (BA) Service & Repair Manual:
- Accurate and reliable information
- Easy-to-follow instructions
- Detailed diagrams and illustrations
- Exploded views of parts and components
- Troubleshooting guide
- Maintenance schedules
- Component locations
- Wiring diagrams
Whether you need to perform routine maintenance or tackle a major repair, this manual is your go-to resource. It provides the knowledge and confidence to work on your Ford Falcon (BA) with ease and efficiency.
