1984-1988 Ford Falcon XF Service & Repair Manual

FALCON FAIRLANE LTD XF, ZL, FE. -REPAIR MANUAL PART NO. W.M. 23 FORD MOTOR COMPANY OF AUSTRALIA LIMITED Registered Office: CAMPBELLFIELD, VICTORIA (Incorporated in Victoria) Copyright - Ford Motor Company of Australia Limited Reproduction in whole or in part prohibited without written approval. INDEX GROUP INTRODUCTION •• VEHICLE IDENTIFICATIO~ 1 BRAKES 2 SUSPENSION-STEERING-WHEELS & TYRES 3 REAR AXLE 4 CLUTCH-DRIVELINE 5 MANUAL TRANSMISSION 6 ' AUTOMATIC TRANSMISSION 7 ENGINE 8 j IGNITION SYSTEM 9 FUEL SYSTEM 10 COOLING SYSTEM 11 ·EXHAUST SYSTEM 12 CHARGING SYSTEM 13 STARTING SYSTEM 14 i LIGHTING & INSTRUMENTS 15 VENTILATION-HEATING-AIR CONDITIONING 16 AND ACCESSORIES . I BODY, DOORS AND WINDOWS ~ 17 I , TRIM AND SEATS 18 LUBRICATION & MAINTENANCE SCHEDULE 19 :.I MAINTENANCE OPERATIONS 20 'I !I SPECIAL TOOLS 21 . SCHEMATICS 22 EMISSION CONTROL SYSTEMS 23 ~ r. ~·

INTRODUCTION USING THIS MANUAL To provide simplicity and ease of use, this manual has been divided into 23 Groups with each group representing a major section of the vehicle. Each Group is then broken down into "Parts" which refer to a specific or localized part of the vehicle. Where applicable, Parts contain a Description, Operation, Diagnosis and Testing, Removal and Installation Disassembly and Assembly procedures for the component covered in the Part. Diagnosis Charts are also included to help system- atically locate and correct problems encountered. In most cases, specifications are included at the end of each Group together with any special tools recommended to perform the operation. IMPORT ANT SAFETY NOTICE Appropriate service methods and proper repair procedures are essential for the safe, reliable operation of all motor vehicles as well as the personal safety of the individual doing the work. This Repair Manual provides general directions for accomplishing service and repair work with tested, effective techniques. Following them will help assure reliability. There are numerous variations in procedures, techniques, tools, and parts for servicing vehicles, as well as in the skill of the individual doing the work. This manual cannot possibly anticipate all such variations and provide advice or cautions as to each. Accordingly, anyone who departs from the instruc- tions provided in this manual must first establish that he com- promises neither his personal safety, Australian Design Rules, nor the vehicle integrity by his choice of methods, tools, or parts. NOTICES, CAUTIONS, AND WARNINGS As you read through the procedures, you will come across NOTES, CAUTIONS, and WARNINGS. Each one is there tor a specific purpose. NOTES give you added information tt)at will help you to complete a particular procedure. CAUTIONS are given to prevent you from making an error that could damage the vehicle. WARNINGS remind you to be especially careful in those areas where carelessness can cause personal injury. The following list contains some general WARNINGS that you should follow when you work on a vehicle. • Always wear safety glasses for eye protection. • Use safety stands whenever a procedure requires you to be under the vehicle. • Be sure that the ignition switch is always in the OFF position, unless otherwise required by the procedure. • Set the parking brake when working on the vehicle. Set manual transmission in REVERSE or automatic transmission in PARK. • Operate the engine only in a well-ventilated area to avoid the danger of carbon monoxide. • Keep yourself and your clothing away from moving parts, when the engine is running, especially the tan and drive belts to alternator etc. • To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, and muffler. • Do not smoke while working on a vehicle. • To avoid injury, always remove rings, watches, loose hanging jewellery, and loose clothing before beginning to work on a vehicle. REPLACEMENT PARTS Replacement parts are made to the same exacting stan- dards and tolerances as the original factory-fitted components. Only genuine FORD and MOTORCRAFT replacement parts, or parts meeting specifications of the Ford Motor Company, should be used as service replacements. SPECIAL TOOLS AND EQUIPMENT Special Tools and Equipment may be required, to success- fully complete a particular repair operation. New and previously released tools are detailed in the Special Tools Section of this manual (Section 21). FORD SALES COMPANY OF AUSTRALIA LIMITED The illustrations, information and specifications presented and referred to herein were correct at the time this publica- tion was approved for printing. However, Ford Motor Com- pany of Australia Limited and/or Ford Sales Company of Australia Limited reserve(s) the right, subject to the laws of Australia and/or any applicable State or Territory thereof and/or the regulations of any competent authority which may apply from time to time, at their or its discretion, and without notice, to discontinue or change the specification or design of the products referred to herein and any options therefore at any time without incurring any liability whatsoever to any purchaser thereof. Reproduction in any manner, in whole or in part, is prohibited without the express permission in writing of Ford Sales Company of Australia Ltd., Customer Service Office, Sydney Road, Campbellfield, Victoria, 3061.

METRIC CONVERSION TABLE Dimensions and specifications contained in this manual are provided in metric form. To assist technicians who are not familiar with the metrication program, the following quick reference tables are provided: Divide LENGTH millimetres (mm) ......... . metres (m) .............. . metres (m) .............. . kilometres (km) .......... . AREA millimetres2 (mm2) ....... . centimetres2 (cm2) ....... . metres2 (m2) ............ . metres2 (m2) ............ . VOLUME by to get equivalent number of: 25.4 ... Inch 0.304 ... Foot 0.914 ... Yard 1.609 ... Mile 645.200 ... lnch2 6.450 ... lnch2 0.092 ... Foot2 0.836 ... Yard2 mm3 .................... 16,387.00 ... lnch3 cm3 . . . . . . . . . . . . . . . . . . . . 16.387 ... lnch3 litres (I) . . . . . . . . . . . . . . . . . 0.016 ... lnch3 litres (I) . . . . . . . . . . . . . . . . . 0.946 ... Quart litres (I) . . . . . . . . . . . . . . . . . 3. 785 ... Gallon metres3 (m3) . . . . . . . . . . . . . 0. 764 ... Yard3 MASS kilograms (kg) ........... . 0.453 ... Pound kilograms (kg) ........... . 907.180 ... Ton tonne (t) ................ . 0.907 ... Ton FORCE newtons (N) ............. . 9.807 ... Kilogram newtons ................ . 0.278 ... Ounce newtons ................ . 4.448 ... Pound Divide TEMPERATURE by to get equivalent number of: °C = ~ (°F - 32) Or °C = 0.556 (°F - 32) 9 °F =(~X 0 C) + 32or °F = (1 .8 x 0 C} + 32 5 ACCELERATION metre/sec 2 (m/s2) ......... 0.304 .... . .. Foot/sec2 metre/sec2 (m/s2) .... . .... 0.025 . .. .... lnch/sec2 TORQUE newton-metres (Nm) . . ..... 0.112 . ..... . Pound-inch newton-metres (Nm) ....... 1.355 ... .. .. Pound-foot POWER kilowatts (kW) ............ 0.746 ...... . Horsepower PRESSURE OR STRESS kilopascals (kPa) .......... 0.249 .. ..... Inches of water kilopascals (kPa) .......... 6.895 . ... .. . Pounds/sq. in. kilograms/cm2 ... . ........ 0.070 ... . ... Pounds/sq. in. ENERGY OF WORK joules (J) . . . . . . . . . . . . . . . . 1,055.000 BTU joules . . . . . . . . . . . . . . . . . . . 1.355 Foot-pound joules (J = one W's) ...... 3,600,000.000 Kilowatt-hour Or 3.6 x 10s LIGHT lumens/metre2 (lm.m2) ..... 1.076 .. .. .. . Foot candle FUEL PERFORMANCE kilometres/litre (km/1) ...... 0.425 ... .... Miles/gal. litres/kilometre (1/km) ...... 2.352 ....... Gal/mile VELOCITY kilometres/hr. (km/h) ....... 1.609 .. .. . . . Miles/hour

FALCON FAIRLANE LTD ~---------------1 REPAIR MANUAL VEHICLE GROUP IDENTIFICATION 1 PART 1-1 Vehicle Identification

1-1-1 Vehicle Identification VEHICLE IDENTIFICATION PART 1-1 SUBJECT VEHICLE IDENTIFICATION PLATE .... . Interpretation of Codes ............ . VEHICLE IDENTIFICATION PLATE PAGE 1-1-1 1-1-1 The vehicle identification plate is secured to the left hand side bulkhead of the engine compartment. The plate contains alphabetical and numerical codes which represent the model and type of variable components fitted to the vehicle. INTERPRETATION OF CODES Prefix: Manufacturers use only. Serial No.: Manufacturers use only. Sldo No.: Dealer Order No. Model: Digits 1 & 2 Digit 3 Product Line Model Year Body Style Series Digit 4 Digit 5 Engine Code Engine Displacement M 3.3 Litre Alloy Head II G 4.1 Litre Alloy Head II Y 4.1 Litre Alloy Head EFI The engine identification number is stamped on the engine cylinder block at the front top corner of the Right Hand Side. Trans Code - N 3 Speed Manual - Column Shift. 4 Speed Manual- Floor Shift. L K 5 Speed Manual - Floor Shift. R 3 Speed Auto - Column Shift. B 3 Speed Auto - Floor Shift. PREFIX BODY SER. NO. SIDO. NO. I II II MODEL E~N~G~IN~E~~T~R~A~NAS-. --=RR~AX~~ C I '--C-=:-:-----~1 ~--1 ~=--'1.__1 =, ....... FT.AX. TRIM PAINT BRK I II II 1 ..... 1 _ ____, e GVM. kg G. C . M_ BUILT I ~I II II.___..... J FORD MOTOR COMPANY OF AUSTRALIA LTD VEHICLE IDENTIFICATION PLATE SUBJECT AUSTRALIAN DESIGN RULES ....... . PAGE 1-1-2 1-1-3 APPROVED ACCESSORIES ......... . Trim F Fawn W Wedgewood S Med Slate Built Paint P Citrus Yellow Z Stark White 9 Sno White M Vanilla C Bahama Beige K Monza Red A Ice Blue (Met) X Atlantic Blue (Met) 3 Autumn Gold (Met) Y5 Olympic Gold (Met) 85 Deep Aqua (Met) C1 Sable (Met) R4 Regency (Met) V Charcoal (Met) 4 Silver Grey (Met) B Platinum (Met) E Gold Mist (Met) The build date is defined as the calendar month and the year in which the body shell and power train sub-assemblies are co-joined and the vehicle is driven or moved from the pro- duction line. l

Vehicle Identification 1-1-2 AUSTRALIAN DESIGN RULES Compliance Plate Australian Design Rules (A.D.R.) require vehicle manufacturers to comply with specific requirements regarding con- sumer, environment protection, and safety devices. A compliance plate is fitted to the vehicle and this contains codes which relate to specific design rules in effect at the time of vehicle manufacture. Legislation requires that no alteration be made to a vehicle that would result in the vehicle not complying with the Design Rules referred to on the compliance plate of the vehicle. To ensure continuing compliance it is imperative that the engine/emission system is serviced according to the specified procedure. Emission Decal Emission Control Information Decal is affixed to the vehicle firewall. Should this decal become mutilated or unreadable, a new decal must be obtained and affixed to the vehicle. To ensure continued compliance it is imperative that the engine and emission system is serviced according to the service procedures outlined in groups 20 and 23 of this manual. Should it become necessary to replace a component which effects vehicle emissions, it is mandatory that the replacement part be of the same calibration as the original part. No circumstances would permit the disconnection, alteration or modification, of any emission related component on vehicles marketed by Ford Sales Company of Australia Limited, except in accordance with the diagnostic, maintenance and repair procedures specified in the Com- pany's service materials. Any person who removes, modifies or otherwise renders ineffective any emission control components fitted to a vehicle could be contravening the relevant regulations and be guilty of an offence under the regulations. Any person who owns and/or operates such a vehicle could also be guilty of an offence under the regulations. FORD SEATS G. V.W. II ~ II MANUFACTURED TO COMPLY WITH AUSTRALIAN RULES BY FORD MOTOR CO. OF AUST. LTD. THIS PLATE IS AFFIXED WITH THE APPROVAL OF THE AUSTRALIAN MOTOR VEHICLE CERTIFICATION BOARD 0 Facsimile plate only. ~ ENGINE EXHAUST EMISSION CONTROL INFORMATION ENGINE MANUFACTURER• FORD MOTOR COMPIIINY ENGINE FAMILY IDENTIFICATION ' 4 ·1 LITRE DATE OF ENGINE MANUFACTURE IDLE SPEED · 115- 725 RPM IN NEUTRAL TUNE UP IGNITION TIMING • ~:ZJ>uC.r: _fD~A~ogt6~ WITH SPECIFICATIONS IDLE MIXTURE SETTING ' ~g.~~~Af.'UlflR DC~~~ SPARK PLUG AGR-42 GAP • ·032'TO · 03 6' DISTRIBUTOR: I DWELL • THIS E~NE WAS MANUFACTURED TO COMPl Y WITH AUSTRAUAN DESIGN RULE- ll FORO MOTOR COMMHY OF AUSTRALIA I OTA-tc41S - AA Facsimile decal only - Refer to decal fitted to the vehicle for actual specifications. G

1-1-3 Vehicle Identification FORD/MOTORCRAFT APPROVED ACCESSORIES The following are approved Ford Motor Company accessories for the models listed and all of which are available through authorised Ford dealers. DESCRIPTION Cable Battery Boost - Heavy Duty Demister Back Window - Electrical - Without Heated Backlite Horn - High/Low Note Horn - High Note Licence Plate Trim Licence Plate Frame Mat- Rubber- Front/Rear- Black Mat - Rubber - Front/Rear - Sandy Brown Mat- Deluxe- Rubber- Front- Black Mat- Deluxe - Rubber- Front- Sandy Brown Carpet - Front - Black Carpet - Front - Brown Carpet - Front - Light Brown Carpet - Front - Dusk Carpet - Front - Beige Carpet - Rear - Black Carpet - Rear - Brown Carpet - Rear - Light Brown Carpet - Rear - Dusk Carpet - Rear - Beige Rope Rail Kit Aerial - Motorised - Universal Rear Boot lid Release Kit - Electric Transmission Oil Cooler Spoiler - Rear Spring Kit - Rear Helper Sunvisor - Exterior - Steel Trailer Electrical Wiring Kit - Universal Type Trailer Socket - 7 Pin Flat Trailer Plug - 7 Pin Flat Adaptor - 7 Pin Flat (Car) to 7 Pin Round (Trailer) Venetian Shade - Interior - Black Venetian Shade - Interior - Black Venetian Shade - Interior - Black Weathershield RH - Tinted Green Weathershield LH - Tinted Green Weathershield Hardware Kit Lambskin Seat Cover - Front - White Lambskin Seat Cover - Front - Gold Lambskin Seat Cover- Front- Dusk Lambskin Seat Cover- Front- Bone Lambskin Seat Cover - Front - Cane Roof Rack - Universal Roof Rack - Crhome - Sedan Roof Rack - Chrome (RPO Option) Mudflap Kit- Front- Styled Mudflat Kit- Rear Mudflap Kit- Front & Rear- Conventional Rear Quarter Window Shade Kit Sump Guard Kit Instrument Cluster Kit - Sports Instrument Cluster Kit- Digital Headlamp Guard - Plastic Headlamp Guard - Plastic Bonnet Protector Wheel Covers 14" Trim Ring 14" Dust Deflector Kit Exhaust Outlet Extension 3.3 L MODEL APPLICATION ALL ALL ALL ALL ALL ALL ALL ALL ALL ALL ALL ALL ALL ALL ALL ALL ALL ALL ALL ALL XF Utility ALL ALL ALL XF Sedan XF Wagon ALL ALL ALL ALL ALL ALL Sedans XF Wagon XF Utility ALL ALL ALL ALL ALL ALL ALL ALL ALL ALL Sedans XF Wagon ALL ALL ALL ZL ALL ALL ALL XF ZL, FE XF ALL ALL XF Wagon ALL PART NUMBER R6 147 R6 172 C XE 13801 KT XD 13801 A R6 135 R6 136 R6 11 R6 152 R6 155 A R6 155 E R6 197 AUP R6 197 EUP R6 184 AUP R6 195 AUP R6 195 EUP R6 198 AUP R6 198 EUP R6 184 EUP R6 196 AUP R6 196 EUP XA 19010 A R6 330 R6 215 A R6 218 XD F 42210 A XD 5A589 B XD 18236 A R6 145 A R6 143 R6 144 R6 245 XD 18246 C XD 18247 B XD 18246 B XF 18492 A XF 18493 A XD 18A492 A XF F60000 A XF F60000 B XF F60000 C XF F60000 D XF F60000 E R6 306 XE 18320A XD 18320 B XF 16268 A XF 16360 A XD 16360 B ZJF 30602 KT XD 6K631 KT XF 10849 A KT XF 10849 B KT R6 93 R6 94 R6 42 R6 79/80/82183/95, R6 319 B R6 75/76, R6 320 B XD 19008 A CJ 5263 B

Vehicle Identification DESCRIPTION Exhaust Outlet Extension 4.1 L and E.F.I. Louvre - Rear Window Louvre- Rear Window Rear View Mirror Kit LH - Electric Hood Ornament Kit Scuff Plate Kit Tyre Pump Battery Charger Fabric Upholstery Protector Lashing Strap Fire Extinguisher First Aid Kit Bassinet Restraint Child Safety Seat Emblem Kit - Quarter Panel Air Conditioning Kit- Except E.F.I. Air Conditioning Kit- E.F.I. Heavy Duty Blower Motor Kit for A/C Petrol Cap- Locking Petrol Cap- Locking Insect Screen - Grille Tow Bar - Less Gooseneck Class A (RPO Option) Tow Bar - Less Gooseneck Class A (RPO Option) Tow Bar - Less Gooseneck Class A (RPO Option) Gooseneck - Towbar - Black - Class A Gooseneck - Towbar - Black - Class A Gooseneck - Towbar - Black - Class A Gooseneck - Towbar - Chrome - Class A Gooseneck - Towbar - Chrome - Class A Gooseneck - Towbar - Chrome - Class A Fog Lamp Kit Radio AM/FM Multiplex with Stereo Tape Player - Pioneer (RPO Option) Air Adjustable Shock Absorber Air Adjustable Shock Absorber Gas Bilstein Shock Absorbers - Front Gas Bilstein Shock Absorbers - Rear Door Bin - Black - GL Models Door Bin - Grey - GL Models Door Bin - Brown - GL Models Rear Speaker Kit - Pioneer Licence Plate Door Release Kit - Electric Foot Rest Kit - Driver Wheel Cover 14" (Fairmont) High Level Brake Light Kit Tripminder (High Series) Cruise Control MODEL APPLICATION ALL ALL Sedans XF Utility XF ALL ALL XE ALL ALL ALL ALL ALL ALL ALL ALL ALL ALL ALL ALL ALL ALL Sedans XF Wagon, Utility, Van ALL ALL Sedans XF Wagon XF Utility, Van ALL Sedans XF Wagon XF Utility, Van ALL Sedans XF Wagon XF Utility, Van ALL ALL ALL Sedans XF Wagon, Utility, Van ALL Sedans ALL ALL ALL ALL ALL XF Sedan ALL ALL ALL ALL ALL PART NUMBER XA 5263 B XD 18248 A XD 18248 B XF 17683 BKT R6 65 XD 54 13200 KT R6 63 R6 279 R'lo 20 R6 338 R6 331 AID KIT 19900 R6 356 R6 350 R6 323 XF 19B968 A XF 19B968 B XF 19949 KT AFC 92 AFC 93 XF 18690 A XF 19A009 A XF 19A009 B XF 19A009 C XF 19B011 A XF 19B011 B XF 19B011 C XF 19C011 A XF 19C011 B XF 19C011 C XF 15200 A XF 18805 A AAJ 100 AAJ 510 AAS 43 AAS44 R6 357 BL R6 357 G R6 357 BR TS 1612 XF 9E030 A XF 9735 KT XF 1130 B R6 105 XF 100929 A XF 10975 KT 1-1-4

FALCON FAIRLANE LTD ~~ ___ RE_P_A_IR_M_A_N_U_A_L __ ~I• BRAKES PART 2-1 General Brake Service PART 2-2 Dual Master Cylinder PART 2-3 Vacuum Brake Booster PART 2-4 Drum Brakes GROUP 2 PART 2-5 Front Disc Brake System- P.B.R. Caliper PART 2-6 Front Disc Brake System- Girlock Caliper PART 2-7 Rear Disc Brake System PART 2-8 Parking Brake PART 2-9 Specifications and Special Tools

1984-1988 Ford Falcon XF Service & Repair Manual

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