2002-2003 Ford Falcon Service & Repair Manual

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. G17365 en 01/2003 2003.0 BA Falcon

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

100-00-6 General Information 100-00-6 DESCRIPTION AND OPERATION (Continued) 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

100-00-7 General Information 100-00-7 DESCRIPTION AND OPERATION (Continued) 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

100-00-8 General Information 100-00-8 DESCRIPTION AND OPERATION (Continued) 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

100-00-9 General Information 100-00-9 DESCRIPTION AND OPERATION (Continued) 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 G17372 en 01/2003 2003.0 BA Falcon

100-00-10 General Information 100-00-10 DESCRIPTION AND OPERATION (Continued) 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. G17372 en 01/2003 2003.0 BA Falcon

2002-2003 Ford Falcon Service & Repair Manual

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