Ford Falcon Ba Series 2003 2005 Service Repair Manual

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SECTION : 100-00 General Information VEHICLE APPLICATION : 2003.0 BA Falcon CONTENTS

PAGE

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

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

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DESCRIPTION AND OPERATION

About this Manual Introduction This manual has been written in a format that is designed to meet the needs of Ford technicians worldwide. The objective is to use common formats and include similar content in each manual worldwide.

This manual provides general descriptions for accomplishing service and repair work with tested, effective techniques. Following them will help assure reliability.

NOTE: Notes are used to provide additional essential information required to carry out a complete and satisfactory repair.

As you read through this manual, you will come across WARNINGS, CAUTIONS and NOTES. A warning, caution or note is placed at the beginning of a series of steps if it applies to multiple steps. If the warning, caution or note only applies to one step, it is placed at the beginning of the specific step (after the step number).

How to Use This Manual

Replacement Parts

This manual covers service and repair procedures.

This manual is structured into groups and sections, with specific system sections collected together under their relevant group.

A group covers a specific portion of the vehicle. The manual is divided into five groups, General Information, Chassis, Powertrain, Electrical and Body Special Tools and Paint. The number of the group is the first The Special Tool(s) Table provided at the beginning number of a section number. of each procedure shows all special tools required to Pages at the start of the manual list all sections carry out a repair. Where possible, illustrations are available. Each section has a contents list detailing provided to assist in identifying the special tool General Specifications, Description and Operation required. and Service Adjustment and Checks.

Special tools may be ordered from: If components need to be removed or disassembled in sequence, the sequence will be identified Australia numerically in a graphic and the corresponding text SPX AUSTRALIA will be numbered accordingly (refer to ‘Samples’).

Tel: +61 (03) 9544 6222 All left and right-hand references to the vehicle are Fax: +61 (03) 9544 5222 taken from a position sitting in the driver seat looking forward.

Important Safety Instructions All left and right-hand references to the engine are taken from a position at the flywheel looking towards Appropriate service methods and correct repair the front camshaft pulley. procedures are essential for the safe, reliable operation of all motor vehicles as well as the personal Where appropriate, instructions will be given for the use of WDS, diagnostic equipment. safety of the individual carrying out the work.

Inspection and Verification This manual cannot possibly anticipate all such variations and provide advice or cautions as to each. Visual Inspection Charts, Symptom Charts and other Anyone who departs from the instructions provided in information charts (such as diagnostic routines), this manual must first establish that he compromises supplement test procedures with technical neither his personal safety nor the vehicle integrity by specifications, or navigate the user to a specific test his choice of methods, tools or parts. procedure.

Sympton Chart Warnings, Cautions and Notes in This The symptom chart indicates symptoms, sources and Manual actions to address a condition.

Pinpoint Tests WARNING: Warnings are used to indicate that failure to follow a procedure correctly may For electrical systems, pinpoint test steps are used to result in personal injury. identify the source of a concern in a logical, step-by-step manner. Pinpoint tests have two CAUTION: Cautions are used to indicate that columns: CONDITIONS and DETAILS/RESULTS/ACTIONS. failure to follow a procedure correctly may result in damage to the vehicle or equipment being The CONDITIONS column is used exclusively for used. graphics and icons (with or without captions) and the DETAILS/RESULTS/ACTIONS column provides Ford and Motorcraft parts are made to the same exacting standards as the original factory fitted components. For this reason, it is recommended that only genuine Ford or Motorcraft parts are installed during service or repair.

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DESCRIPTION AND OPERATION (Continued) direction to another test step or specific corrective actions.

The boxed numbers indicate the order in which the described action is to be performed.

Component Tests A component test is used when a component is tested in multiple pinpoint tests, or if a procedure is too complicated to be formatted within a single page of the pinpoint test.

Graphics Test graphics show the measurement or test to be performed in a test step.

A representative tester graphic is used for voltmeters and ohmmeters.

If multiple measurements are made in a single graphic, the test leads are drawn with a solid line until the test lead splits to indicate the multiple measurements, at which point dashed lines are used.

Breakout box-type testers are represented by a double circle test pin. Test pins are labelled with the pin number.

Samples Special Tools and Torque Figures Any requirement for special tools will picture the tool, showing it in use and with its tool number shown.

Torque settings will be given at the relevant point in the procedure.

Health and Safety Precautions Introduction Many of the procedures associated with vehicle maintenance and repair involve physical hazards or other risks to health. This subsection lists, alphabetically, some of these hazardous operations and the materials and equipment associated with them. Precautions necessary to avoid these hazards are identified.

The list is not exhaustive and all operations and procedures, and the handling of materials, should be carried out with health and safety in mind.

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Before using any product the Materials Safety Data Sheet supplied by the manufacturer or supplier should be consulted.

Acids and Alkalis See also Battery Acids.

For example caustic soda, sulphuric acid.

Used in batteries and cleaning materials.

Irritant and corrosive to the skin, eyes, nose and throat. Cause burns. Can destroy ordinary protective clothing.

Avoid splashes to the skin, eyes and clothing. Wear suitable protective impervious apron, gloves and goggles. Do not breath mists.

Make sure access to eye wash bottles, shower and soap are readily available for splashing accidents.

Display Eye Hazard sign.

Air Bags See also Fire, Chemical Materials Highly flammable, explosive – observe No Smoking policy.

Used as a safety restraint system mounted in the steering wheel and passenger side of the instrument panel and side impact Airbags.

The inflator contains a high-energetic propellant which, when ignited, produces a VERY HOT GAS (2500°C).

The gas generant used in air bags is Sodium Azide.

This material is hermetically sealed in the module and is completely consumed during deployment. No attempt should be made to open an air bag inflator as this will lead to the risk of exposure to Sodium Azide.

If a gas generator is ruptured, full protective clothing should be worn when dealing with the spillage.

After normal deployment, gloves and safety goggles should be worn during the handling process.

Deployed air bags should be disposed of in a plastic bag in accordance with local regulations at an approved chemical waste site.

Following any direct contact with gas generant. wash affected areas thoroughly with water. seek medical assistance if necessary.

Air Bags - Do’s do store modules in an upright position. do keep modules dry. do carry modules with the cover side pointing away from the body. do place modules with their cover side upwards. do carefully inspect modules for damage. do stand to one side when connecting modules. do make sure all test equipment is properly calibrated and maintained. do wash hands after handling deployed air bags.

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DESCRIPTION AND OPERATION (Continued) Air Bags - Do Nots do not store highly flammable material together with modules or gas generators. do not store gas generators at temperatures exceeding 80°C. do not store modules upside down. do not attempt to open a gas generator housing. do not expose gas generators to open flame or sources of heat. do not place anything on top of a module cover. do not use damaged modules. do not touch a fired module or gas generator for at least 10 minutes. do not use any electrical probes on the wiring circuit.

Air Conditioning Refrigerant See also Chlorofluorocarbon, Chemical Materials Highly flammable, combustible – observe No Smoking policy.

Skin contact may result in frostbite.

Instructions given by the manufacturer must be followed. Avoid naked lights, wear suitable protective gloves and goggles.

If refrigerant comes into contact with the skin or eyes, rinse the affected areas with water immediately. Eyes should also be rinsed with an appropriate irrigation solution and should not be rubbed. SEEK MEDICAL ASSISTANCE IF NECESSARY.

Air Conditioning Refrigerant - Do Nots do not expose refrigerant bottles to sunlight or heat. do not stand refrigerant bottles upright; when filling, hold them with the valve downwards. do not expose refrigerant bottles to frost. do not drop refrigerant bottles. do not vent refrigerant to atmosphere under any circumstance. do not mix refrigerants, for example R12 (Freon) and R134a.

Adhesives and Sealers See also Fire, Chemical Materials Highly flammable, flammable, combustible – observe No Smoking policy.

Generally should be stored in No Smoking areas.

Cleanliness and tidiness in use should be observed, for example disposable paper covering benches; should be dispensed from applicators where possible; containers, including secondary containers, should be labelled appropriately.

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Solvent-based Adhesives/Sealers - See Solvents Follow manufacturers instructions.

Water-based Adhesives/Sealers Those based on polymer emulsions and rubber latexes may contain small amounts of volatile toxic and harmful chemicals. Skin and eye contact should be avoided and adequate ventilation provided during use.

Hot Melt Adhesives In the solid state, they are safe. In the molten state they may cause burns and health hazards may arise from the inhalation of toxic fumes.

Use appropriate protective clothing and a thermostatically controlled heater with a thermal cut-out and adequate extraction.

Resin-based Adhesives/Sealers, for example Epoxide and Formaldehyde Resin-based Mixing should be carried out in well ventilated areas, as harmful or toxic volatile chemicals may be released.

Skin contact with uncured resins and hardeners can result in irritation, dermatitis, and absorption of toxic or harmful chemicals through the skin. Splashes can damage the eyes.

Provide adequate ventilation and avoid skin and eye contact.

Anaerobic, Cyanoacrylate (super-glues) and other Acrylic Adhesives Many are irritant, sensitizing or harmful to the skin and respiratory tract. Some are eye irritants.

Skin and eye contact should be avoided and the manufacturers instructions followed.

Cyanoacrylate adhesives (super-glues) MUST NOT contact the skin or eyes. If skin or eye tissue is bonded, cover with a clean moist pad and SEEK IMMEDIATE MEDICAL ATTENTION. Do not attempt to pull tissue apart. Use in well ventilated areas as vapours can cause irritation to the nose and eyes.

For two-pack systems see Resin-based and Isocyanate Adhesives/Sealers.

Isocyanate (Polyurethane) Adhesives/Sealers See also Resin-based Adhesives Individuals suffering from asthma or respiratory allergies should not work with or near these materials as sensitivity reactions can occur.

Over exposure is irritating to the eyes and respiratory system. Excessive concentrations may produce effects on the nervous system including drowsiness.

In extreme cases, loss of consciousness may result.

Long term exposure to vapour concentrations may result in adverse health effects.

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DESCRIPTION AND OPERATION (Continued) Prolonged contact with the skin may have a defatting effect which may lead to skin irritation and in some cases, dermatitis.

Splashes entering the eye will cause discomfort and possible damage.

Any spraying should preferably be carried out in exhaust ventilated booths, removing vapours and spray droplets from the breathing zone.

Wear appropriate gloves, eye and respiratory protection.

Antifreeze See also Fire, Solvents.

For example isopropanol, ethylene glycol, methanol.

Highly flammable, flammable, combustible.

Used in vehicle coolant systems, brake air pressure systems, screenwash solutions.

Vapours may be given off from coolant antifreeze (glycol) when heated. Avoid breathing these vapours.

Antifreeze may be absorbed through the skin in toxic or harmful quantities. Antifreeze, if swallowed, can be fatal and MEDICAL ATTENTION SHOULD BE SOUGHT IMMEDIATELY. These products must not be used in any cooling or industrial water system which is connected or linked to general, food preparation or drinking water supplies.

Asbestos See also Warning Symbols on Vehicles at the end of this subsection.

Breathing asbestos dust may cause lung damage or, in some cases, cancer.

Used in brake and clutch linings, transmission brake bands and gaskets. Ford original production and genuine replacement items for this model are asbestos free.

The use of drum cleaning units, vacuum cleaning or damp wiping is preferred.

Asbestos dust waste should be dampened, placed in a sealed container and marked for safe disposal. If any cutting or drilling is attempted on materials containing asbestos the item should be dampened and only hand tools or low speed power tools used.

Battery Acids See also Acids and Alkalis.

Gases released during charging are explosive. Never use naked flames or allow sparks near charging or recently charged batteries.

Make sure there is adequate ventilation.

Brake and Clutch Linings and Pads See Asbestos.

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Brakes Fluids (Polyalkylene Glycols) See also Fire.

Splashes to the skin and eyes are extremely irritating.

Avoid skin and eye contact as far as possible.

Inhalation vapour hazards do not arise at ambient temperatures because of the very low vapour pressure.

Brazing See Welding.

Chemical Materials See also Legal Aspects.

Chemical materials such as solvents, sealers, adhesives, paints, resin foams, battery acids, antifreeze, brake fluids, fuels, oils and grease should always be used with caution and stored and handled with care. They may be toxic, harmful, corrosive, irritant or highly flammable and give rise to hazardous fumes and dusts.

The effects of excessive exposure to chemicals may be immediate or delayed; briefly experienced or permanent; cumulative; superficial; life threatening; or may reduce life expectancy.

Chemical Materials - Do’s Do carefully read and observe hazard and precaution warnings given on material containers (labels) and in any accompanying leaflets, posters or other instructions. Material health and safety data sheets can be obtained from manufacturers.

Do remove chemical materials from the skin and clothing as soon as practicable after soiling.

Change heavily soiled clothing and have it cleaned.

Do organise work practices and protective clothing to avoid soiling of the skin and eyes; breathing vapours, aerosols, dusts or fumes; inadequate container labelling; fire and explosion hazards.

Do wash before job breaks, before eating, smoking, drinking or using toilet facilities when handling chemical materials.

Do keep work areas clean, uncluttered and free of spills.

Do store chemical materials according to national and local regulations.

Do keep chemical materials out of the reach of children.

Chemical Materials - Do Nots Do not mix chemical materials except under the manufacturers instructions; some chemicals can form other toxic or harmful chemicals, give off toxic or harmful fumes or become explosive when mixed together.

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DESCRIPTION AND OPERATION (Continued) those based on solvents, in confined spaces, for example when people are inside a vehicle.

Do not apply heat or flame to chemical materials except under the manufacturers instructions.

Some are highly flammable and some may release toxic or harmful fumes.

Do not leave containers open. Fumes given off can build up to toxic, harmful or explosive concentrations. Some fumes are heavier than air and will accumulate in confined areas such as pits.

Do not transfer chemical materials to unlabelled containers.

Do not clean hands or clothing with chemicals.

Chemicals, particularly solvents and fuels, will dry skin and may cause irritation leading to dermatitis or be absorbed through the skin in toxic or harmful quantities.

Do not use emptied containers for other materials except when they have been cleaned under supervised conditions.

Do not sniff or smell chemical materials. Brief exposure to high concentrations of fumes can be toxic or harmful.

Cutting See Welding.

Dewaxing See Solvents and Fuels (Kerosene).

Dusts Powder, dusts or clouds may be irritant, harmful or toxic. Avoid breathing dusts from powdery chemical materials or those arising from dry abrasion operations. Wear respiratory protection if ventilation is inadequate.

Fine dusts of combustible material can present an explosion hazard. Avoid explosive limits and sources of ignition.

Electric Shock

Electric shock can result from the use of faulty electrical equipment or from the misuse of equipment in good condition.

Make sure that electrical equipment is maintained in good condition and frequently tested. Faulty equipment should be labelled and preferably removed from the work station.

Chlorofluorocarbons (CFC) Make sure that flexes, cables, plugs and sockets are not frayed, kinked, cut, cracked or otherwise There is concern in the scientific community that damaged.

CFCs and Halons are depleting the upper ozone layer Make sure that electrical equipment and flexes do not which filters out harmful ultraviolet radiation.

Decreased filtration of ultraviolet radiation may result come into contact with water. in increases in skin cancer, cataracts and immune Make sure that electrical equipment is protected by system suppression in humans, as well as decreased the correct rated fuse. productivity of crops and aquatic systems.

Never misuse electrical equipment and never use CFCs are used primarily as refrigerants in vehicle air equipment which is in any way faulty. The results conditioning systems and as aerosol propellants. could be fatal.

Halons are used as fire extinguishants.

Make sure that the cables of mobile electrical Ford supports worldwide elimination of CFC usage equipment cannot get trapped and damaged, such as and it is recommended that Company subsidiaries in a vehicle hoist. and affiliates should phase out CFC usage as soon as Make sure that the designated electrical workers are acceptable substitutes are commercially available. trained in basic First Aid. In cases of electrocution: Clutch Fluids switch off the power supply before approaching See Brake fluids. the victim.

Clutch Linings and Pads if this is not possible push or drag the victim from the source of electricity using dry non-conductive See Asbestos. material.

Corrosion Protection Materials commence resuscitation if trained to do so.

SUMMON MEDICAL ASSISTANCE. See also Solvents, Fire.

Highly flammable, flammable – observe No Smoking Engine Oils policy.

See Lubricants and Grease.

These materials are varied and the manufacturers instructions should be followed. They may contain Exhaust Fumes solvents, resins or petroleum products. Skin and eye These contain asphyxiating, harmful and toxic contact should be avoided. They should only be sprayed in conditions of adequate ventilation and not chemicals and particles such as carbon oxides, nitrogen oxides, aldehydes, lead and aromatic in confined spaces.

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DESCRIPTION AND OPERATION (Continued) hydrocarbons. Engines should be run only under conditions of adequate exhaust extraction or general ventilation and not in confined spaces.

Foams - Polyurethane

First Aid

Avoid skin contact with fuel where possible. Should contact occur, wash the affected skin with soap and water.

See also Fire.

Used in sound and noise insulation. Cured foams Gasolene (petrol) engine used in seat and trim cushioning.

There may not be adequate warning of odour or of Follow manufacturers instructions. irritation before toxic or harmful effects arise. These Unreacted components are irritating and may be may be immediate or delayed. harmful to the skin and eyes. Wear gloves and goggles.

Diesel engine Individuals with chronic respiratory diseases, asthma, Soot, discomfort and irritation usually give adequate bronchial medical problems, or histories of allergic warning of hazardous fume concentrations. diseases should not work in or near uncured materials.

Fibre Insulation The components, vapours or spray mists can cause See also Dusts. direct irritation, sensitivity reactions and may be toxic Used in noise and sound insulation. or harmful.

The fibrous nature of surfaces and cut edges can Vapours and spray mists must not be inhaled. These cause skin irritation. This is usually a physical and not materials must be applied with adequate ventilation a chemical effect. and respiratory protection. Do not remove the respirator immediately after spraying, wait until the Precautions should be taken to avoid excessive skin contact through careful organization of work practices vapour/mists have cleared. and the use of gloves.

Burning of the uncured components and the cured foams can generate toxic and harmful fumes.

Fire Smoking, naked flames or the use of electrical equipment during foaming operations and until See also Welding, Foams, Legal Aspects.

Many of the materials found on or associated with the vapours/mists have cleared should not be allowed. repair of vehicles are highly flammable. Some give off Any heat cutting of cured foams or partially cured foams should be conducted with extraction ventilation. toxic or harmful fumes if burnt.

See also the vehicle Body Repair Manual.

Observe strict fire safety when storing and handling flammable materials or solvents, particularly near Freon electrical equipment or welding processes.

See Air Conditioning Refrigerant.

Make sure, before using electrical or welding equipment, that there is no fire hazard present.

Fuels Have a suitable fire extinguisher available when using See also, Fire, Legal Aspects, Chemicals and welding or heating equipment.

Solvents.

Apart from meeting any legal requirements it is desirable for someone in the workshop to be trained in First Aid procedures.

Splashes in the eye should be flushed carefully with clean water for at least ten minutes.

Soiled skin should be washed with soap and water.

In case of cold burns, from alternative fuels, place affected area in cool to cold water.

Individuals affected by inhalation of gases and fumes should be removed to fresh air immediately. If effects persist, consult a doctor.

If liquids are swallowed inadvertently, consult a doctor giving him the information on the container or label.

Do not induce vomiting unless this action is indicated on the label.

Fluoroelastomer See Viton.

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Gasoline (Petrol) Highly flammable - observe No Smoking policy.

Swallowing can result in mouth and throat irritation and absorption from the stomach can result in drowsiness and unconsciousness. Small amounts can be fatal to children. Aspiration of liquid into the lungs, through vomiting, is a very serious hazard.

Gasolene dries the skin and can cause irritation and dermatitis on prolonged or repeated contact. Liquid in the eye causes severe smarting.

Motor gasolene may contain appreciable quantities of benzene, which is toxic upon inhalation, and the concentration of gasolene vapours must be kept very low. High concentrations will cause eye, nose and throat irritation, nausea, headache, depression and symptoms of drunkenness. Very high concentrations will result in rapid loss of consciousness.

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DESCRIPTION AND OPERATION (Continued) Make sure there is adequate ventilation when handling and using gasolene. Great care must be taken to avoid the serious consequences of inhalation in the event of vapour build up arising from spillages in confined spaces.

Special precautions apply to cleaning and maintenance operations on gasolene storage tanks.

Gasolene should not be used as a cleaning agent. It must not be siphoned by mouth. See First Aid.

checked for integrity following the specified procedures.

If the fuel tank is to be removed for service or repair the fuel must be evacuated using dedicated equipment and following the specified procedures.

Gas Cylinders

See also Fire.

Gases such as oxygen, acetylene, argon and propane are normally stored in cylinders at pressures of up to Gas-oil (Diesel Fuel) 138 bar (2000 psi) and great care should be taken in Combustible. handling these cylinders to avoid mechanical damage Gross or prolonged skin contact with high boiling point to them or to the valve gear attached. The contents of each cylinder should be clearly identified by gas oils may also cause serious skin disorders appropriate markings. including skin cancer.

Cylinders should be stored in well ventilated Kerosene (Paraffin) enclosures, and protected from ice and snow, or Used also as heating fuel, solvent and cleaning agent. direct sunlight. Fuel gases, for example acetylene and propane, should not be stored in close proximity to Flammable - observe No Smoking policy. oxygen cylinders.

Irritation of the mouth and throat may result from swallowing. The main hazard from swallowing arises if Care should be exercised to prevent leaks from gas cylinders and lines, and to avoid sources of ignition. liquid aspiration into the lungs occurs.

Only trained personnel should undertake work Liquid contact dries the skin and can cause irritation involving gas cylinders. or dermatitis. Splashes in the eye may be slightly irritating.

Gases In normal circumstances the low volatility does not See Gas Cylinders. give rise to harmful vapours. Exposure to mists and vapours from kerosene at elevated temperature Gaskets (Fluoroelastomer) should be avoided (mists may arise in dewaxing).

See Viton.

Avoid skin and eye contact and make sure there is adequate ventilation.

Alternative Fuel Highly flammable. Observe “NO SMOKING� signs.

Make sure there is adequate ventilation when working on alternative fuelled vehicles. Great care must be taken to avoid the serious consequences of inhalation in the event of vapour build up in confined spaces.

Inhalation in high concentrations may cause dizziness, headache, nausea and loss of co-ordination. Very high concentrations may result in loss of consciousness.

Contact with liquidified petroleum gas (LPG) or compressed natural gas (CNG) to skin may cause cold burns and may cause frost bite.

Long sleeved cotton overalls, steel toe capped safety boots and rubber neoprene gloves should be worn during removal and installation of LPG/CNG fuel system components.

LPG/CNG fuel leaks could cause a fire and be a hazard to health that can lead to personal injury, illness or even death.

If a leak is detected, under no circumstances attempt to seal the leak by tightening the union/connection until the fuel in the system or component is depressurised. Once tightened the system should be G17372 en

General Workshop Tools and Equipment

It is essential that all tools and equipment are maintained in good condition and the correct safety equipment is used where required.

Never use tools or equipment for any purpose other than that for which they were designed. Never overload equipment such as hoists, jacks, axle and chassis stands or lifting slings. Damage caused by overloading is not always immediately apparent and may result in a fatal failure the next time that the equipment is used.

Do not use damaged or defective tools or equipment, particularly high speed equipment such as grinding wheels. A damaged grinding wheel can disintegrate without warning and cause serious injury.

Wear suitable eye protection when using grinding, chiselling or sand blasting equipment.

Wear a suitable breathing mask when using abrasive blasting equipment, working with asbestos-based materials or using spraying equipment.

Make sure there is adequate ventilation to control dusts, mists and fumes.

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DESCRIPTION AND OPERATION (Continued) High Pressure Air, Lubrication and Oil Test Equipment See also Lubricants and Greases.

Always keep high pressure equipment in good condition, and regularly maintained, particularly at joints and unions.

Never direct a high pressure nozzle, for example diesel injector, at the skin as the fluid may penetrate to the underlying tissue, and cause serious injury.

Halon See CFCs.

Legal Aspects There are many laws and regulations relating to health and safety in the use and disposal of materials and equipment in a workshop.

For a safe working environment and to avoid environmental pollution, workshops should be familiar, in detail, with the many health and safety laws and regulations within their country, published by both national and local authorities.

Wash with soap and water to make sure all oil is removed (skin cleansers and nail brushes will help). Preparations containing lanoline replace the natural skin oils which have been removed.

Do not use gasolene (petrol), kerosene (paraffin), diesel fuel (gas oil), thinners or solvents for cleaning skin.

If skin disorders develop, obtain medical advice without delay.

Where practicable, degrease components prior to handling.

Where there is a risk of eye contact, eye protection should be worn, for example chemical goggles or face shields; in addition an eye wash facility should be provided.

Environmental Precautions

Burning used engine oil in small space heaters or boilers can be recommended only for units of approved design. If in doubt check with the appropriate local authority and manufacturer of approved appliances.

Dispose of used oil and used oil filters through authorized waste disposal contractors or licensed Lubricants and Greases waste disposal sites, or to the waste oil reclamation Avoid all prolonged and repeated contact with mineral trade. If in doubt, contact the relevant local authority oils. All lubricants and greases may be irritating to the for advice on disposal facilities. eyes and skin.

It is illegal to pour used oil on to the ground, down sewers or drains, or into water courses.

Used Engine Oil Prolonged and repeated contact with mineral oil will result in the removal of natural fats from the skin, leading to dryness, irritation and dermatitis. In addition, used engine oil contains potentially harmful contaminants which may cause skin cancer. Adequate means of skin protection and washing facilities must be provided.

Do not employ used engine oils as lubricants or for any application where appreciable skin contact is likely to occur.

Health Protection Precautions Avoid prolonged and repeated contact with oils, particularly used engine oils.

Wear protective clothing, including impervious gloves where practicable.

Do not put oily rags into pockets.

Avoid contaminating clothes, particularly underpants, with oil.

Heavily soiled clothing and oil-impregnated footwear should not be worn. Overalls must be cleaned regularly.

First Aid treatment should be obtained immediately for open cuts and wounds.

Use barrier creams, applying them before each work period, to help the removal of oil from the skin.

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Noise Some operations may produce high noise levels which could, in time, damage hearing. In these cases, suitable ear protection must be worn.

Noise Insulation Materials See Foams, Fibre Insulation.

O-Rings (Fluoroelastomer) See Viton.

Paints See also Solvents, Chemical Materials.

Highly flammable, flammable - observe No Smoking policy

One Pack Can contain harmful or toxic pigments, driers and other components as well as solvents. Spraying should be carried out only with adequate ventilation.

Two Pack Can also contain harmful and toxic unreacted resins and resin hardening agents. The manufacturers instructions should be followed. See also Resin-based Adhesives and Isocyanate Adhesives and Sealers under Adhesives and Sealers.

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General Information

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DESCRIPTION AND OPERATION (Continued) Spraying should preferably be carried out in exhausted ventilated booths removing vapour and spray mists from the breathing zone. Individuals working in booths should wear appropriate respiratory protection. Those doing small scale repair work in the open workshop should wear air-fed respirators.

Pressurized Equipment See High Pressure Air, Lubrication and Oil Test Equipment.

Solder Solders are mixtures of metals such that the melting point of the mixture is below that of the constituent metals (normally lead and tin). Solder application does not normally give rise to toxic lead fumes, provided a gas/air flame is used. Oxy-acetylene flames should not be used, as they are much hotter and will cause lead fumes to be produced.

Some fumes may be produced by the application of any flame to surfaces coated with grease, and inhalation of these should be avoided.

Removal of excess solder should be undertaken with care, to make sure that fine lead dust is not produced, which can give toxic effects if inhaled. Respiratory protection may be necessary.

Solder spillage and filings should be collected and removed promptly to prevent general air contamination by lead.

High standards of personal hygiene are necessary in order to avoid ingestion of lead or inhalation of solder dust from clothing.

Avoid splashes to the skin, eyes and clothing. Wear protective gloves, goggles and clothing if necessary.

Make sure there is good ventilation when in use, avoid breathing fumes, vapours and spray mists and keep containers tightly sealed. Do not use in confined spaces.

When spraying materials containing solvents, for example paints, adhesive, coatings, use extraction ventilation or personal respiratory protection in the absence of adequate general ventilation.

Do not apply heat or flame except under specific and detailed manufacturers instructions.

Sound Insulation See Fibre Insulation, Foams.

Suspended Loads CAUTION: Never improvise lifting tackle.

There is always a danger when loads are lifted or suspended. Never work under an unsupported, suspended or raised load, for example a suspended engine.

Always make sure that lifting equipment such as jacks, hoists, axle stands and slings are adequate and suitable for the job, in good condition and regularly maintained.

Transmission Brake Bands See Asbestos.

Underseal

Solvents

See Corrosion Protection.

See also Chemical Materials, Fuels (Kerosene), Fire.

For example acetone, white spirit, toluene, xylene, trichloroethane.

Used in cleaning and dewaxing materials, paints, plastics, resins and thinners.

Some may be highly flammable or flammable.

Skin contact will degrease the skin and may result in irritation and dermatitis following repeated or prolonged contact. Some can be absorbed through the skin in toxic or harmful quantities.

Splashes in the eye may cause severe irritation and could lead to loss of vision.

Brief exposure of high concentrations of vapours or mists will cause eye and throat irritation, drowsiness, dizziness, headaches and, in the worst circumstances, unconsciousness.

Repeated or prolonged exposure to excessive but lower concentrations of vapours or mists, for which there might not be adequate warning indications, can cause more serious toxic or harmful effects.

Aspiration into the lungs, for example through vomiting, is the most serious consequence of swallowing.

Viton

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In common with many other manufacturers vehicles, some components fitted to the Ford range have O-rings, seals or gaskets which contain a material known as ‘Viton’.

Viton is a fluoroelastomer, that is a synthetic rubber type which contains Fluorine. It is commonly used for O-rings, gaskets and seals of all types. Although Viton is the most well known fluoroelastomer, there are others, including Fluorel and Tecmoflon.

When used under design conditions fluoroelastomers are perfectly safe. If, however, they are exposed to temperatures in excess of 400°C, the material will not burn, but will decompose, and one of the products formed is hydrofluoric acid.

This acid is extremely corrosive and may be absorbed directly, through contact, into the general body system.

O-rings, seals or gaskets which have been exposed to very high temperatures will appear charred or as a black sticky substance.

DO NOT, under any circumstances touch them or the attached components.

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General Information

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DESCRIPTION AND OPERATION (Continued) Enquiries should be made to determine whether Viton or any other fluoroelastomer has been used in the affected O-ring, seal or gasket. If they are of natural rubber or nitrile there is no hazard. If in doubt, be cautious as the material may be Viton or any fluoroelastomer.

If Viton or any other fluoroelastomers have been used, the affected area should be decontaminated before the commencement of work.

Disposable heavy duty plastic gloves should be worn at all times, and the affected area washed down using wire wool and a limewater (calcium hydroxide) solution to neutralise the acid before disposing of the decomposed Viton residue and final cleaning of the area. After use, the plastic gloves should be discarded carefully and safely.

Gas Welding (and Cutting)

This process may cause particles of molten metal to be emitted at a high velocity, and the eyes and skin must be protected.

Oxy-acetylene torches may be used for welding and cutting, and special care must be taken to prevent leakage of these gases, with consequent risk of fire and explosion.

The process will produce metal spatter and eye and skin protection is necessary.

The flame is bright, and eye protection should be used, but the ultra-violet emission is much less than that from arc welding, and lighter filters may be used.

The process itself produces few toxic fumes, but such fumes and gases may be produced from coatings on the work, particularly during cutting away of damaged body parts, and inhalation of the fumes should be avoided.

In brazing, toxic fumes may be produced from the metals in the brazing rod, and a severe hazard may arise if brazing rods containing cadmium are used. In this event particular care must be taken to avoid inhalation of fumes and expert advice may be required.

Special precautions must be taken before any welding or cutting takes place on vessels which have contained combustible materials, for example boiling or steaming out of fuel tanks .

Arc Welding

Warning Symbols on Vehicles

This process emits a high level of ultra-violet radiation which may cause arc-eye and skin burns to the operator and to other persons nearby. Gas-shielded welding processes are particularly hazardous in this respect. Personal protection must be worn, and screens used to shield other people.

CONTACT LENS WEARERS ARE ADVISED TO REVERT TO ORDINARY SPECTACLES WHEN ARC WELDING as the arc spectrum is believed to emit microwaves which dry out the fluid between the lens and the eye. This may result in blindness when the lens is removed from the eye.

Metal spatter will also occur, and appropriate eye and skin protection is necessary.

The heat of the welding arc will produce fumes and gases from the metals being welded, the rods and from any applied coatings or contamination on the surfaces being worked on. These gases and fumes may be toxic and inhalation of these should be avoided. The use of extraction ventilation to remove the fumes from the working area may be necessary particularly in cases where the general ventilation is poor, or where considerable welding work is anticipated. In extreme cases or confined spaces where adequate ventilation cannot be provided, air-fed respirators may be necessary.

Decals showing warning symbols will be found on various vehicle components.

These decals must not be removed. The warnings are for the attention of owners/operators and persons carrying out service or repair operations on the vehicle.

The most commonly found decals are reproduced below together with an explanation of the warnings.

Welding See also Fire, Electric Shock, Gas Cylinders.

Welding processes include Resistance Welding (Spot Welding), Arc Welding and Gas Welding.

Resistance Welding

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1. Components or assemblies displaying the caution triangle and open book symbol advise consultation of the relevant section of the owners handbook before touching or attempting adjustments of any kind.

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DESCRIPTION AND OPERATION (Continued)

2. Components or assemblies displaying the warning 5. Displaying this symbol (normally in conjunction triangle with the ‘electrified’ arrow and open book with 5 above) warn of the presence of potentially symbol give warning of inherent high voltages. explosive matter within the immediate vicinity.

Never touch these with the engine running or the ignition switched on. See Electric Shock in this subsection.

6. Displaying this symbol warn that children should not be allowed in the immediate vicinity unsupervised.

3. Components or assemblies displaying this symbol White Spirit give warning that the component contains a corrosive substance. See Acids and Alkalis in this See Solvents. subsection.

Standard Workshop Practices Vehicle in Workshop

When working on a vehicle in the workshop always make sure that: the parking brake is applied or the wheels are securely chocked to prevent the vehicle moving forwards or backwards. the key is removed from key operated hood locks before any work is carried out around the front of the vehicle. if the engine is to be run, there is adequate ventilation, or an extraction hose to remove exhaust fumes.

4. Displaying the caution circle with a deleted lighted there is adequate room to raise the vehicle and match symbol, caution against the use of naked remove the wheels, if necessary. lights or flames within the immediate vicinity due fender covers are always fitted if any work is to be to the presence of highly flammable or explosive carried out in the engine compartment. liquids or vapours. See Fire in this subsection.

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General Information

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DESCRIPTION AND OPERATION (Continued) the battery is disconnected if working on the engine.

do not work on the fuel lines or system components unless the alternative fuel has been evacuated and the pressure in the system is reduced to atmospheric, or less CAUTION: When electric arc welding on a vehicle, always disconnect the generator wiring to do not use anything other than the specified leak prevent the possibility of a surge of current detector fluid to trace fuel leaks causing damage to the internal components of the Be aware of situations that may cause the LPG or generator.

CNG fuel system to vent off fuel, such as: If using welding equipment on the vehicle, a extremely hot days suitable fire extinguisher is readily available. parking by a space heater Alternative Fuel hoisting a vehicle up near a ceiling heater Only personnel fully trained to Ford and local WARNING: When servicing the fuel system standards are to work on alternative fuel vehicles. always follow the recommended procedures.

Towing the Vehicle Failure to follow these instructions may result in personal injury.

If the odour of liquified petroleum gas (LPG) or WARNING: When the vehicle is being towed compressed natural gas (CNG) is present in the air in the ignition switch must be in position II (steering the workshop, warn all persons in the area to: lock released and warning lights illuminated).

Only then will the steering, turn signal lamps, extinguish all flames and lighted tobacco. horn and stop lamps be operational. Failure to shut off electrical and air powered equipment. follow these instructions may result in personal evacuate the area. injury. ventilate the area.

When a vehicle with automatic transmission is towed, the gear selector must be in position N (Neutral). contact fire control authorities.

Never tow a vehicle with automatic transmission remove the vehicle to a dedicated, ventilated faster than 30 mph (50 km/h) or further than 30 miles area.

(50 km). If it is necessary to tow the vehicle a greater distance, the drive wheels must be lifted clear off the Alternative Fuel — Do’s ground. do work on the vehicle in a designated area that Alternatively the vehicle can be transported on a low is well ventilated and its access restricted to loader or a trailer. qualified personnel only install new warning labels to their original Connecting a Slave Battery Using Jumper locations Cables if possible always isolate the alternative fuel tank, run the vehicle on the alternative fuel until it WARNING: If the slave battery has recently automatically switches to its normal fuel prior to been charged and is gassing, cover the vent plugs taking the vehicle into the workshop/service area or covers with a damp cloth to reduce the risk of only use tested and approved components and explosion should arcing occur when connecting pipes when repairing or servicing LPG and CNG the jumper cables. Failure to follow these systems instructions may result in personal injury.

Alternative Fuel — Do Nots do not vent off LPG fuel do not use shop air pressure to force LPG fuel from the fuel tank do not use paint drying ovens above 40°C for any alternative fuel vehicles. LPG and CNG fuel tanks should be removed from the vehicles prior to being put into paint drying ovens above 40°C do not modify the system or install new components with parts not designed for gas vehicles do not evacuate fuel tanks unless there is repair that requires removed of the fuel tank

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CAUTION: A discharged battery condition may have been caused by an electrical short circuit. If this condition exists there will be an apparently live circuit on the vehicle even when all normal circuits are switched off. This can cause arcing when the jumper cables are connected.

CAUTION: While it is not recommended that the vehicle is jump started, it is recognized that this may occasionally be the only practical way to mobilize a vehicle. In such an instance the discharged battery must be recharged immediately after jump starting to avoid permanent damage.

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General Information

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DESCRIPTION AND OPERATION (Continued) Always make sure that the jumper cables are adequate for the task. Heavy duty cables must be used.

Always make sure that the slave battery is of the same voltage as the vehicle battery. The batteries must be connected in parallel.

Always make sure that switchable electric circuits are switched off before connecting jumper cables.

This reduces the risk of arcing occurring when the final connection is made.

Component Cleaning To prevent ingress of dirt, accumulations of loose dirt and greasy deposits should be removed before disconnecting or dismantling components or assemblies.

Components should be thoroughly cleaned before inspection prior to reassembly.

Cleaning Methods: dry cleaning removal of loose dirt with soft or cable brushes scraping dirt off with a piece of metal or wood wiping off with a rag CAUTION: Compressed air is sometimes ‘wet’ so use with caution, especially on hydraulic systems. blowing dirt off with compressed air. (Eye protection must be worn when using this method) removal of dry dust using vacuum equipment.

This method should always be used to remove friction lining material dust (asbestos particles) steam cleaning

WARNING: Make sure that the ends of the jumper cables do not touch each other or ground against the vehicle body at any time while the cables are attached to the battery. A fully charged battery, if shorted through jumper cables, can discharge at a rate well above 1000 amps causing violent arcing and very rapid heating of the jumper cables and terminals, and can even cause the battery to explode. Failure to follow these instructions may result in personal injury.

Always connect the jumper cables in the following sequence: slave battery positive first then vehicle battery positive slave battery negative next and then vehicle ground at least 12 inches (300 mm) from the battery terminal, for example engine lifting eye Always reduce the engine speed to idle before disconnecting the jumper cables.

Before removing the jumper cables from the vehicle that had the discharged battery, switch on the heater blower (high) or the heated rear window, to reduce the voltage peak when the cables are removed.

Always disconnect the jumper cables in the reverse order to the connecting sequence and do not short the ends of the cables.

Do not rely on the generator to restore a discharged battery. For a generator to recharge a battery, it would take in excess of eight hours continuous driving with no additional loads placed on the battery.

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WARNING: Most solvents require careful handling and some are harmful. Refer to Health and Safety Precautions and to the manufacturers literature for safety precautions. Failure to follow these instructions may result in personal injury.

Various solvents are available which are suitable for component cleaning. Some components such as brake hydraulic parts and electrical assemblies should be cleaned only with recommended solvents — refer to Solvents, Sealers and Adhesives or to the section of the manual relevant to the component.

Calibration of Essential Measuring Equipment WARNING: Failure to follow these instructions may result in personal injury or damage to components.

It is of fundamental importance that certain essential equipment, for example torque wrenches, multimeters, exhaust gas analysers or rolling roads, are regularly calibrated in accordance with the manufacturers instructions.

Solvents, Sealers and Adhesives Introduction WARNING: Always handle all solvents, sealers and adhesives with extreme care. Some contain chemicals or give off fumes which can be dangerous to health. Always follow the manufacturers instructions. If in doubt about any 01/2003 2003.0 BA Falcon

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General Information

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DESCRIPTION AND OPERATION (Continued) substance, particularly a solvent, DO NOT use it.

CAUTION: If in doubt about the suitability of any proprietary solvent or sealer for a particular application, contact the manufacturer of the product for information regarding storage, handling and application.

The Health and Safety Precautions subsection refers to some commonly used chemicals and materials, hazards associated with their use, and safety measures to be taken. Some of these chemicals may be included in the following list either in their own right or as an ingredient in a sealer or adhesive.

General Specifications Anti-Seize Compound Ford Spec.

SAM-1C-9107A SAM-1C-9107A ESE-M1244-A

General Spark plug threads Sealers Application For camshaft bearing caps For cylinder block For fitting rear lamp assembly For transmission housing (80 gram can)

Ford Spec.

ESK-M4G260-A WSK-M4G320-A WSK-M4G329-ABC Finis Code 6 160 443

Manufacturer and Identification Loctite 518 Hylosil 502

Adhesives Application PU for windscreen, side and rear glass

Road/Roller Testing Road or roller testing may be carried out for various reasons and a procedure detailing pre-test checks, through engine starting and stopping, pre-driving checks, on-test checks to final checks on completion of the test is given overleaf.

Unless complete vehicle performance is being checked, the full road test procedure need not be carried out. Instead, those items particularly relevant to the system/s being checked can be extracted.

Pre-Test Checks WARNING: If the brake system hydraulic fluid level is low, pedal travel is excessive or a hydraulic leak is found, do not attempt to road test the vehicle until the reason for the low fluid level, excessive pedal travel or hydraulic leak is found and rectified.

It is suggested that pre-test checks, and functional tests of those systems/circuits which affect the safe and legal operations of the vehicle, such as brakes, lights and steering, should always be carried out before the road or roller test.

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Ford Spec.

Finis Code 6 997 259 Engine oil level Engine coolant level Tires, for correct pressure, compatible types and tread patterns, and wear within limits.

There is sufficient fuel in the tank to complete the test.

All around the engine, transmission and under the vehicle for oil, coolant, hydraulic and fuel leaks.

Make a note of any apparent leaks and wipe off the surrounding areas to make it easier to identify the extent of the leak on completion of the test.

Starting the Engine NOTE: On initial drive away from cold and within the first 1.5 km (1 mile), do not depress accelerator pedal beyond half travel until the vehicle has attained a minimum speed of 25 km/h (15 miles/h). Never operate at high engine speed or with the accelerator pedal at full travel whilst the engine is cold.

With the ignition switched off, check: The handbrake is applied.

The gear lever is in neutral.

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DESCRIPTION AND OPERATION (Continued) All instrument gauges (except fuel gauge) read zero.

With the ignition switched on, check: Ignition controlled warning lights come on.

Engine temperature gauge registers a reading compatible with the engine temperature.

Fuel gauge registers a reading appropriate to the fuel level in the tank.

The operation of the handbrake warning light and fluid level warning indicator light.

On Road or Roller Test Check: CAUTION: If road testing, check the brake operation while still travelling at low speed before continuing with the test. If the brakes pull to one side, or appear to be otherwise faulty, do not continue with the road test until the fault has been found and rectified.

Clutch pedal operation is not stiff or heavy.

Initial gear engagement is smooth and there is no evidence of clutch drag.

Handbrake control operates smoothly and the handbrake releases quickly and completely.

Clutch takes up the drive smoothly, without slip or judder.

Gear changing is smooth, and there are no abnormal noises or vibrations from the transmission.

The engine power output is satisfactory, full power is achieved, acceleration is smooth and pedal operation not stiff or heavy, and engine speed returns to idle correctly.

There is no excessive or abnormally colored smoke from the engine under normal driving, heavy load or overrun conditions.

Steering operation, including power steering where fitted, is smooth, accurate, not excessively heavy or with excessive free play or vibration.

Does not pull to one side and self centres smoothly after cornering.

Speedometer, oil pressure warning lamp, coolant temperature gauge and tachometer (where fitted) register the correct readings or operate correctly.

Switches and controls operate smoothly and positively, warning or indicator lights operate correctly and the direction indicator control self cancels when the steering is returned to the straight ahead position.

Heating and ventilation systems work correctly and effectively.

Brake operation and efficiency.

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Brake Testing WARNING: When brake testing, avoid breathing the smoke or fumes from hot brakes, this may contain asbestos dust which is hazardous to health, see Health and Safety Precautions.

Avoid brake testing on busy roads where it can cause inconvenience or danger to other road users.

CAUTION: Brake testing which includes heavy brake applications should not be carried out with new brake pads/discs or linings/drums until the components have bedded-in. New brake friction components will not reach full efficiency until the bedding-in process is complete.

Test the brakes at several speeds within the normal operating range using both light and heavy pedal pressure. Note any tendency to snatch, pull or drag, and any undue delay in application or release.

Allow the vehicle to coast and note any tendency to pull to one side, or evidence that the brakes are binding.

After stopping the vehicle (not immediately after a period of heavy braking), carefully check the brake temperature. A disc which feels hot, or appreciably hotter than the others, indicates that the brake is binding.

After completion of the test, check for: Oil, coolant, hydraulic, air and fuel leaks.

Abnormal temperature of any moving components or assemblies, e.g. wheel hubs, transmission, axle etc., which might indicate overtightness or lack of lubrication.

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Identification Codes

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SECTION : 100-01 Identification Codes VEHICLE APPLICATION : 2003.0 BA Falcon CONTENTS

PAGE

DESCRIPTION AND OPERATION Identification Codes ..............................................................................................................100-01-2 Vehicle Identification Number ..............................................................................................100-01-2 Vehicle Compliance (VC) Label .............................................................................................100-01-5 Emission Decal ....................................................................................................................100-01-6

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Identification Codes

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DESCRIPTION AND OPERATION

Identification Codes Vehicle Identification Number The vehicle identification number (VIN) is a seventeen-digit combination of letters and numbers. The VIN is printed on a label located in the engine compartment or on the driver’s side A-pillar as shown. The VIN number is also found on the vehicle compliance (VC) label located in the same area.

Typical Identification Plate Locations

Identification Label (engine bay)

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Identification Codes

100-01-3

DESCRIPTION AND OPERATION (Continued) Identification Label (A-pillar)

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Identification Codes

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DESCRIPTION AND OPERATION (Continued) Body Style Code BODY TYPE XT Sedan XT Wagon Futura Sedan Futura Wagon XR Sedan XR Ute GT Sedan Fairmont Sedan Fairmont Wagon Fairmont Ghia Sedan Fairlane Ghia LTD XL Ute XLS Ute Model Code Body Type Sedan Wagon Sedan Wagon Sedan Sedan Wagon Sedan Sedan Sedan Ute Ute Ute Ute Ute

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Body Style XT XT Futura Futura XR FMT FMT FMT Ghia Fairlane Ghia LTD XL Tray XL SSB XR Tray XLS Tray XLS SSB

CODE SW WA SW WA SW CM SW SW WA SW LW LW CM CM Model Code 18333 18363 18334 18364 18335 18332 18332 18338 18349 18346 45313 45373 45375 45314 45374

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Identification Codes

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DESCRIPTION AND OPERATION (Continued)

Paint Colour and Code Colour Winter White Venom Ice Mint Silver Barossa Reb Congo Green Silhouette Blue Print Narooma Blue Phantom Mercury Silver Blue Pearl Acid Rush Citric Acid Blood Orange Victorian Taxi Yellow Taxi Orange Trim Colour and Code Colour Stone Warm Charcoal

Code A1 VF EI B7 DG ST UU NR P3 M7 CP RH JA HO 44 22

with the Design Rules referred to on the compliance label of the vehicle.

Such Laws must be complied with at all times.

Failure to do so may result in Substantial Financial Penalties. Where State/Territory Laws differ from the repair manual procedures, the Laws MUST take precedence.

To ensure continuing compliance it is imperative that the engine/emission system is serviced according to the specified procedure. A typical compliance plate is shown below.

Compliance Plate (engine bay)

Code S1 B1

Vehicle Compliance (VC) Label Australian Design Rules (A.D.R.) reuire vehicle manufacturere to comply with specific requirements regarding consumer, environment protection, and safety devices. A compliance plate is fitted to the vehicle and this contains codes which relate to specific design rules in effect at the time of vehicle manufacture.

Legiclation requires that no alteration be made to a vehicle that would result in the vehicle not complying G86657 en

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Identification Codes

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DESCRIPTION AND OPERATION (Continued) Compliance Plate (A-pillar)

Emission Decal Emission Control Information Decal is affixed to the underside of the bonnet. Should this decal become mutilated or unreadable, a new decal must be obtained and affixed to the vehicla. To ensure contained compliance it is imperative that the engine and emission system is serviced according to the service procedures outlined in this manual.

Should it become necessary to replace a component which affects vehicle emissions, it is mandatory that the replacement part be of the same calibration as the original part.

No circumstances would permit the disconnection, alteration or modification of any emission related component on vehicles marketed by Ford Sales Company of Australia Limited, except in accordance with the diagnostic, maintenance and repair procedures specified in the Company’s service materials.

Any person who removes, modifies or otherwise renders ineffective any emission control components fitted to a vehicle could be contravening the relevant regulations and be guilty of an offence under the regulations. Any person who owns and/or operates such a vehicle could also be guilty of an offence under the regulations.

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Jacking and Lifting

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SECTION : 100-02 Jacking and Lifting VEHICLE APPLICATION : 2003.0 BA Falcon CONTENTS

PAGE

DESCRIPTION AND OPERATION Jacking ..................................................................................................................................100-02-2 Jacking/Lifting Points - Sedan/Wagon .................................................................................100-02-2 Jacking/Lifting Points - Ute ..................................................................................................100-02-2

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Jacking and Lifting

100-02-2

DESCRIPTION AND OPERATION

Jacking

Jacking/Lifting Points - Ute

WARNING: Do not run the engine when jacking the vehicle. The wheels contacting the ground could cause the vehicle to move. Failure to follow these instructions may result in personal injury.

WARNING: Make sure the jack and jack stands are correctly located to prevent the vehicle from falling. Failure to follow these instructions may result in personal injury.

WARNING: Wheel chocks should be used to prevent the vehicle from rolling and falling off the jack. Failure to follow these instructions may result in personal injury.

1. The front jacking\lifting point for the ute is on the sill at the point where the rocker moulding has been cut away to expose the sill.

CAUTION: The service jack provided with the 2. The rear jacking\lifting point for the ute is on the vehicle is only intended to be used in an leaf spring hanger bracket. emergency for changing a deflated tire. Never use the service jack to hoist the vehicle for any other service. Refer to the Owner Guide when using the jack supplied with the vehicle.

Jacking/Lifting Points - Sedan/Wagon

1. The front jacking\lifting point for sedan and wagon is on the sill at the point where the rocker moulding has been cut away to expose the sill.

2. The rear jacking\lifting point for the sedan and wagon is on the sill at the point where the rocker moulding has been cut away to expose the sill.

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Noise, Vibration and Harshness

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SECTION : 100-04 Noise, Vibration and Harshness VEHICLE APPLICATION : 2003.0 BA Falcon CONTENTS

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DESCRIPTION AND OPERATION Noise, Vibration and Harshness (NVH) ................................................................................100-04-2 Acceptable Noise, Vibration and Harshness .......................................................................100-04-2 Diagnostic Theory ................................................................................................................100-04-2 Glossary of Terms ................................................................................................................100-04-2 DIAGNOSIS AND TESTING Noise, Vibration and Harshness (NVH) ................................................................................100-04-7 1: Customer Interview ........................................................................................................100-04-10 2: Pre-Drive Check .............................................................................................................100-04-10 3: Preparing for the Road Test ..........................................................................................100-04-10 4: Verify the Customer Concern ........................................................................................100-04-10 5: Road Test ......................................................................................................................100-04-10 6: Check OASIS/TSBs/Repair History ...............................................................................100-04-12 7: Diagnostic Procedure .....................................................................................................100-04-12 NVH Condition and Symptom Categories .........................................................................100-04-13 Symptom Charts ................................................................................................................100-04-14 Pinpoint Tests ....................................................................................................................100-04-35 Component Tests ...............................................................................................................100-04-49 GENERAL PROCEDURES Brake Disc Machining .........................................................................................................100-04-55 Powertrain/Drivetrain Mount Neutralizing ...........................................................................100-04-55 Exhaust System Neutralizing ..............................................................................................100-04-55 Wheel Bearing Check .........................................................................................................100-04-56

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100-04-2

Noise, Vibration and Harshness

100-04-2

DESCRIPTION AND OPERATION

Noise, Vibration and Harshness (NVH) Noise is any undesirable sound, usually unpleasant in nature. Vibration is any motion, shaking or trembling, that can be felt or seen when an object moves back and forth or up and down. Harshness is a ride quality issue where the vehicle’s response to the road transmits sharply to the customer. Harshness normally describes a firmer than usual response from the suspension system. Noise, vibration and harshness (NVH) is a term used to describe these conditions, which result in varying degrees of dissatisfaction. Although, a certain level of NVH caused by road and environmental conditions is normal. This section is designed to aid in the diagnosis, testing and repair of NVH concerns.

within an acceptable range.

Glossary of Terms Acceleration-Light An increase in speed at less than half throttle.

Acceleration-Medium An increase in speed at half to nearly full throttle, such as 0-97 km/h (0-60 mph) in approximately 30 seconds.

Acceleration-Heavy An increase in speed at one-half to full throttle, such as 0-97 km/h (0-60 mph) in approximately 20 seconds.

Acceptable Noise, Vibration and Harshness

Ambient Temperature The surrounding or prevailing temperature.

All internal combustion engines and drivelines produce some noise and vibration; operating in a real world environment adds noise that is not subject to control. Vibration isolators, mufflers and dampers reduce these to acceptable levels. A driver who is unfamiliar with a vehicle can think that some sounds are abnormal when actually the sounds are normal for the vehicle type. For example, Traction-Lok® differentials produce a slight noise on slow turns after extended highway driving. This is acceptable and has no detrimental effect on the locking axle function. As a technician, it is very important to be familiar with vehicle features and know how they relate to NVH concerns and their diagnosis. If, for example, the vehicle has automatic overdrive it is important to test drive the vehicle both in and out of overdrive mode.

Amplitude The quantity or amount of energy produced by a vibrating component (G force). An extreme vibration has a high amplitude. A mild vibration has a low amplitude.

Diagnostic Theory The shortest route to an accurate diagnosis results from: system knowledge, including comparison with a known good system. system history, including repair history and usage patterns. condition history, especially any relationship to repairs or sudden change. knowledge of possible sources. using a systematic diagnostic method that divides the system into related areas.

The diagnosis and correction of noise, vibration and harshness concerns requires: a road or system test to determine the exact nature of the concern. an analysis of the possible causes. testing to verify the cause. repairing any concerns found. a road test or system test to make sure the concern has been corrected or brought back to G72678 en

Backlash Gear teeth clearance.

Boom Low frequency or low pitched noise often accompanied by a vibration. Also refer to Drumming.

Bound Up An overstressed isolation (rubber) mount that transmits vibration/noise instead of absorbing it.

Brakes Applied When the service brakes are applied with enough force to hold the vehicle against movement with the transmission in gear.

Buffet/Buffeting Strong noise fluctuations (less than 1000 Hz) caused by gusting winds. An example would be wind gusts against the side glass.

Buzz A low-pitched sound (200-5000 Hz) like that from a bee. Often a metallic or hard plastic humming sound.

Also describes a high frequency (200–800 Hz) vibration. Vibration feels similar to an electric razor.

Camber The angle of the wheel in relation to the true vertical as measured looking from the front of the vehicle.

Camber is positive when the wheel angle is offset so that the top of the wheel is positioned away from the vehicle.

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DESCRIPTION AND OPERATION (Continued) Clonk A hydraulic knocking sound. Sound occurs with air pockets in a hydraulic system. Also described as hammering.

Clunk/Driveline Clunk A heavy or dull, short-duration, low-frequency sound.

Occurs mostly on a vehicle that is accelerating or decelerating abruptly. Also described as a thunk.

Coast/Deceleration Releasing the accelerator pedal at cruise, allowing the engine to reduce vehicle speed without applying the brakes.

Caster The angle of the steering knuckle in relation to the true vertical as measured looking from the side of the vehicle.

Coast/Neutral Coast Placing the transmission range selector in NEUTRAL (N) or depressing the clutch pedal while at cruise.

Constant Velocity (CV) Joint A joint used to absorb vibrations caused by driving power being transmitted at an angle.

Controlled Rear Suspension Height The height at which a designated vehicle element must be when driveline angle measurements are made.

Coupling Shaft The shaft between the transfer case and the front drive axle or, in a two-piece rear driveshaft, the front section.

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Description True vertical Positive caster Steering axis

Chatter A pronounced series of rapidly repeating rattling or clicking sounds.

Chirp A short-duration high-pitched noise associated with a slipping drive belt.

Chuckle A repetitious low-pitched sound. A loud chuckle is usually described as a knock.

Click A sharp, brief, non-resonant sound, similar to actuating a ball point pen.

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CPS Cycles per second. Same as hertz (Hz).

Cracks A mid-frequency sound, related to squeak. Sound varies with temperature conditions.

Creak A metallic squeak.

Cruise Constant speed on level ground; neither accelerating nor decelerating.

Cycle The process of a vibrating component going through a complete range of motion and returning to the starting point.

Decibel A unit of measurement, referring to sound pressure level, abbreviated dB. Drive Engine Run-Up (DERU) Test The operation of the engine through the normal rpm range with the vehicle standing still, the brakes 01/2003 2003.0 BA Falcon

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DESCRIPTION AND OPERATION (Continued) applied and the transmission engaged. This test is used for noise and vibration checks.

from side-to-side (wobble). Dynamically unbalanced wheel and tyre assemblies can cause wheel shimmy.

Driveline Angles The differences of alignment between the transmission output shaft, the driveshaft, and the rear axle pinion centerline.

Engine Imbalance A condition in which an engine’s center mass is not concentric to the rotation center, causing excessive motion.

Engine Misfire When combustion in one or more cylinders does not occur or occurs at the wrong time.

Engine Shake An exaggerated engine movement or vibration that directly increases in frequency as the engine speed increases. It is caused by non-equal distribution of mass in the rotating or reciprocating components.

Flexible Coupling A flexible joint.

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Description Engine Driveshaft Differential

Driveshaft The shaft that transmits power to the rear axle input shaft (pinion shaft). In a two-piece driveshaft, it is the rearmost shaft.

Drivetrain All power transmitting components from the engine to the wheels; includes the clutch or torque converter, the transmission, the transfer case, the driveshaft, and the front or rear drive axle.

Float A drive mode on the dividing line between cruise and coast where the throttle setting matches the engine speed with the road speed.

Flutter Mid to high (100-200 Hz) intermittent sound due to air flow. Similar to a flag flapping in the wind.

Frequency The rate at which a cycle occurs within a given time.

Gravelly Feel A grinding or growl in a component, similar to the feel experienced when driving on gravel.

Grind An abrasive sound, similar to using a grinding wheel, or rubbing sand paper against wood.

Drivetrain Damper A weight attached to the engine, the transmission, the Hiss transfer case, or the axle. It is tuned by weight and Steady high frequency (200–800 Hz) noise. Vacuum placement to absorb vibration. leak sound.

Drone A low frequency (100-200 Hz) steady sound, like a freezer compressor. Also described as a moan.

Hoot A steady low frequency tone (50-500 Hz), sounds like blowing over a long neck bottle.

Drumming A cycling, low-frequency (20–100 Hz), rhythmic noise often accompanied by a sensation of pressure on the ear drums. Also described as a low rumble, boom, or rolling thunder.

Howl A mid-range frequency (200-800 Hz) noise between drumming and whine. Also described as a hum.

Dynamic Balance The equal distribution of weight on each side of the centerline, so that when the wheel and tyre assembly spins, there is no tendency for the assembly to move G72678 en

Hum Mid-frequency (200-800 Hz) steady sound, like a small fan motor. Also described as a howl.

Hz Hertz; a frequency measured in cycles per second.

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DESCRIPTION AND OPERATION (Continued) Imbalance Out of balance; heavier on one side than the other. In a rotating component, imbalance often causes vibration.

Inboard Toward the centerline of the vehicle.

Intensity The physical quality of sound that relates to the strength of the vibration (measured in decibels). The higher the sound’s amplitude, the higher the intensity and vice versa.

Isolate To separate the influence of one component to another.

Knock A heavy, loud, repetitious sound, like a knock on the door.

Moan A constant, low-frequency (100–200 Hz) tone. Also described as a hum.

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Description Lateral runout Radial runout

Rattle A random and momentary or short duration noise.

Neutral Engine Run-Up (NERU) Test The operation of the engine through the normal rpm range with the vehicle standing still and the transmission disengaged. This test is used to identify engine related vibrations.

Rotary Blade Coupling (RBC) This part is attached to the rear axle on 4WD vehicles. It includes an internal hydraulic pump and clutch pack to control the torque supplied to the rear axle/wheels. It also has an internal electromagnetic clutch to lock to the RCB for the 4WD ON mode. This unit is not to be disassembled and if necessary a new unit must be installed.

Neutralize/Normalize To return to an unstressed position. Used to describe mounts. Refer to Bound Up.

Ring Gear The large, circular, driven gear in a ring and pinion gearset.

Outboard Away from the centerline of the vehicle.

Road Test The operation of the vehicle under conditions intended to produce the concern under investigation.

Ping A short duration, high-frequency sound, which has a slight echo.

Pinion Shaft The input shaft in a driving axle that is usually a part of the smaller driving or input hypoid gear of a ring and pinion gearset.

Pitch The physical quality of sound that relates to its frequency. Pitch increases as frequency increases and vice versa.

Pumping Feel A slow, pulsing movement.

Radial/Lateral Radial is in the plane of rotation; lateral is at 90 degrees to the plane of rotation.

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Roughness A medium-frequency vibration. A slightly higher frequency (20 to 50 Hz) than a shake. This type of vibration is usually related to drivetrain components.

Runout Lateral runout means measuring the movement or “wobble” of a wheel or tyre at the sidewall. Radial runout means measuring the out-of-round of the tyre tread surface.

Rustling Intermittent sound of varying frequency (100-200 Hz), sounds similar to shuffling through leaves.

Shake A low-frequency vibration (5–20 Hz), usually with visible component movement. Usually relates to tyres, wheels, brake drums or brake discs if it is vehicle 01/2003 2003.0 BA Falcon

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DESCRIPTION AND OPERATION (Continued) speed sensitive, or engine if it is engine speed sensitive. Also referred to as a shimmy or wobble.

warm. Also, irregular tyre wear patterns in the tyre tread resulting from wheel-locked skids.

Shimmy An abnormal vibration or wobbling, felt as a side-to-side motion of the steering wheel in the driveshaft rotation. Also described as waddle.

Shudder A low-frequency vibration that is felt through the steering wheel or seat during light brake application.

Tyre Force Vibration A tyre vibration caused by variations in the construction of the tyre that is noticeable when the tyre rotates against the pavement. This condition can be present on perfectly round tyres because of variations in the inner tyre construction. This condition can occur at wheel rotation frequency or twice rotation frequency.

Slap A resonance from flat surfaces, such as safety belt webbing or door trim panels.

Transient A noise or vibration that is momentary, a short duration.

Slip Yoke/Slip Spline The driveshaft coupling that allows length changes to occur while the suspension articulates and while the driveshaft rotates.

Two-Plane Balance Radial and lateral balance.

Squeak A high-pitched transient sound, similar to rubbing fingers against a clean window.

Squeal A long-duration, high-pitched noise.

Static Balance The equal distribution of weight around the wheel.

Statically unbalanced wheel and tyre assemblies can cause a bouncing action called wheel tramp. This condition will eventually cause uneven tyre wear.

Tap A light, rhythmic, or intermittent hammering sound, similar to tapping a pencil on a table edge.

Thump A dull beat caused by two items striking together.

Vibration Any motion, shaking or trembling, that can be felt or seen when an object moves back and forth or up and down.

Whine A constant, high-pitched noise. Also described as a screech.

Whistle High-pitched noise (above 500 Hz) with a very narrow frequency band. Examples of whistle noises are a turbocharger or airflow around an antenna.

Wind Noise Any noise caused by air movement in, out or around the vehicle.

WOT The acronym wide-open throttle is WOT.

Tick A rhythmic tap, similar to a clock noise.

Tip-In Moan A light moaning noise heard during light vehicle acceleration, usually between 40-100 km/h (25-65 mph).

TIR The acronym for the total indicated runout is TIR. Tyre Deflection The change in tyre diameter in the area where the tyre contacts the ground.

Tyre Flat Spots A condition commonly caused by letting the vehicle stand while the tyres cool off. This condition can be corrected by driving the vehicle until the tyres are G72678 en

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DIAGNOSIS AND TESTING

Noise, Vibration and Harshness (NVH) To assist the service advisor and the technician, a Write-up Job Aid and an NVH Diagnostic Guide are included with this material. The Write-up Job Aid serves as a place to record all important symptom information. NHV Diagnostic Guide serves as a place to record information reported on the Write-up Job Aid as well as data from the testing to be carried out.

To begin a successful diagnosis, fill out the NVH Diagnostic Guide, record the reported findings, then proceed to each of the numbered process steps to complete the diagnosis.

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DIAGNOSIS AND TESTING (Continued)

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DIAGNOSIS AND TESTING (Continued)

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DIAGNOSIS AND TESTING (Continued) 1: Customer Interview The diagnostic process starts with the customer interview. The service advisor must obtain as much information as possible about the concern and take a test drive with the customer. There are many ways a customer will describe NVH concerns and this will help minimize confusion arising from descriptive language differences. It is important that the concern is correctly interpreted and the customer descriptions are recorded. During the interview, ask the following questions: When was the concern first noticed?

Did the concern appear suddenly or gradually?

Did any abnormal occurrence coincide with or proceed its appearance?

Use the information gained from the customer to accurately begin the diagnostic process.

2: Pre-Drive Check It is important to do a pre-drive check before road testing the vehicle. A pre-drive check verifies that the vehicle is relatively safe to drive and eliminates any obvious faults on the vehicle.

The pre-drive check consists of a brief visual inspection. During this brief inspection, take note of anything that will compromise safety during the road test and make those repairs or adjustments before taking the vehicle on the road.

The engine speed is an important factor in arriving at a final conclusion. Therefore, connect an accurate tachometer to the engine, even if the vehicle has a tachometer. Use a tachometer that has clearly defined increments of less than 50 rpm. This ensures an exact engine speed reading.

4: Verify the Customer Concern Verify the customer concern by carrying out a road test, an engine run-up test, or both.

The decision to carry out a road test, an engine run-up test, or both depends on the type of NVH concern. A road test may be necessary if the symptom relates to the suspension system or is sensitive to torque. A drive engine run-up (DERU) or a neutral engine run-up (NERU) test identifies noises and vibrations relating to engine and drivetrain rpm.

Remember, a condition will not always be identifiable by carrying out these tests, however, they will eliminate many possibilities if carried out correctly.

5: Road Test NOTE: It may be necessary to have the customer ride along or drive the vehicle to point out the concern.

During the road test, take into consideration the customer’s driving habits and the driving conditions.

The customer’s concern just may be an acceptable operating condition for that vehicle.

The following is a brief overview of each test in the order in which it appears. A review of this information 3: Preparing for the Road Test helps to quickly identify the most appropriate process necessary to make a successful diagnosis. After Observe the following when preparing for the road reviewing this information, select and carry out the test: appropriate test(s), proceeding to the next step of this Review the information recorded on the NVH process.

Diagnostic Guide. It is important to know the The Slow Acceleration Test is normally the first specific concern the customer has with the test to carry out when identifying an NVH concern, vehicle. especially when a road test with the customer is Do not be misled by the reported location of the not possible. noise or vibration. The cause can actually be The Heavy Acceleration Test helps to determine if some distance away, transferred from another the concern is torque-related. part of the vehicle.

The Neutral Coast Down Speed Test helps to Remember that the vibrating source component determine if the concern is vehicle speed-related. (originator) may only generate a small vibration.

This small vibration can in turn cause a larger The Downshift Speed Test helps to determine if vibration or noise to emanate from another the concern is engine speed-related. receiving component (reactor), due to contact with The Steering Input Test helps to determine how other components (transfer path). the wheel bearings and other suspension Conduct the road test on a quiet street where it is components contribute to a vehicle speed-related safe to duplicate the vibration or noise. The ideal concern. testing route is an open, low-traffic area where it The Brake Test helps to identify vibrations or is possible to operate the vehicle at the speed in noise that are brake-related. which the condition occurs.

The Road Test Over Bumps helps isolate a noise If possible, lower the radio antenna in order to that occurs when driving over a rough or bumpy minimize turbulence. Identify anything that could surface. potentially make noise or be a source of wind The Engine Run-Up Tests consist of the Neutral noise. Inspect the vehicle for add-on items that Run-up Test and the Engine Load Test. These create vibration/noise. Turn off the radio and the heating and cooling system blower.

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DIAGNOSIS AND TESTING (Continued) tests help to determine if the concern is engine speed-related.

The Neutral Run-up Test is used as a follow-up test to the Downshift Speed Test when the concern occurs at idle.

The Engine Load Test helps to identify vibration/noise sensitive to engine load or torque.

It also helps to reproduce engine speed-related concerns that cannot be duplicated when carrying out the Neutral Run-up Test or the Neutral Coast Down Test.

The Engine Accessory Test helps to locate faulty belts and accessories that cause engine speed-related concerns.

The Vehicle Cold Soak Procedure helps to identify concerns occurring during initial start-up and when an extended time lapse occurs between vehicle usage.

Downshift Speed Test To carry out this test, proceed as follows: Shift into a lower gear than the gear used when carrying out the Slow Acceleration Test.

Drive at the engine rpm where the concern occurs.

The concern is engine speed related if duplicated while carrying out this test. This eliminates the tyres, wheels, brakes and the suspension components as sources.

If necessary, repeat this test using other gears and NEUTRAL to verify the results.

Proceed as necessary.

Steering Input Test

To carry out this test, proceed as follows: Drive at the speed where the concern occurs, while making sweeping turns in both directions.

Slow Acceleration Test If the concern goes away or gets worse, the To carry out this test, proceed as follows: wheel bearings, hubs, U-joints (contained in the Slowly accelerate to the speed where the reported axles of 4WD applications), and tyre tread wear concern occurs. Note the vehicle speed, the are all possible sources. engine rpm and, if possible, determine the Proceed as necessary. vibration frequency.

Brake Test Attempt to identify from what part of the vehicle the concern is coming.

To carry out this test, proceed as follows: Attempt to identify the source of the concern.

Warm the brakes by slowing the vehicle a few Proceed as necessary. times from 80–32 km/h (50–20 mph) using light braking applications. At highway speeds of 89–97 Heavy Acceleration Test km/h (50–60 mph), apply the brake using a light pedal force.

To carry out this test, proceed as follows: Accelerate to 89–97 km/h (55–60 mph).

Accelerate hard from 0-64 km/h (0-40 mph).

Lightly apply the brakes and slow the vehicle to Decelerate in a lower gear.

30 km/h (20 mph).

The concern is torque-related if duplicated while A brake vibration noise can be felt in the steering carrying out this test. wheel, seat or brake pedal. A brake noise can be Proceed as necessary. heard upon brake application and diminish when Neutral Coast Down Speed Test the brake is release.

To carry out this test, proceed as follows: Drive at a higher rate of speed than where the concern occurred when carrying out the Slow Acceleration Test.

Place the transmission in NEUTRAL and coast down past the speed where the concern occurs.

The concern is vehicle speed-related if duplicated while carrying out this test. This eliminates the engine and the torque converter as sources.

If the concern was not duplicated while carrying out this test, carry out the Downshift Speed Test to verify if the concern is engine speed-related.

Proceed as necessary.

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Road Test Over Bumps To carry out this test, proceed as follows: Drive the vehicle over a bump or rough surface one wheel at a time to determine if the noise is coming from the front or the back and the left or the right side of the vehicle.

Proceed as necessary.

Neutral Engine Run-up (NERU) Test To carry out this test, proceed as follows: Install a tachometer.

Increase the engine rpm up from an idle to approximately 3,500 rpm while in PARK on front wheel drive vehicles with automatic transmissions, or NEUTRAL for all other vehicles. Note the

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DIAGNOSIS AND TESTING (Continued) engine rpm and, if possible, determine the vibration frequency.

Attempt to identify what part of the vehicle the concern is coming from.

Attempt to identify the source of the concern.

Proceed as necessary.

Drive Engine Run-Up (DERU) Load Test To carry out this test, proceed as follows: WARNING: Block the front and rear wheels, and apply the parking brake and the service brake, or injury to personnel can result.

CAUTION: Do not carry out the Engine Load Test for more than five seconds or damage to the transmission or transaxle can result.

Block the front and rear wheels.

Apply the parking brake and the service brake.

Install a tachometer.

Shift the transmission into DRIVE, and increase and decrease the engine rpm between an idle to approximately 2,000 rpm. Note the engine rpm and, if possible, determine the vibration frequency.

Repeat the test in REVERSE. If the vibration or noise is duplicated when carrying out this test, inspect the engine and transmission or transaxle mounts.

If the concern is definitely engine speed-related, carry out the Engine Accessory Test to narrow down the source.

Proceed as necessary.

Engine Accessory Test To carry out this test, proceed as follows: WARNING: Block the front and rear wheels, and apply the parking brake and the service brake, or injury to personnel can result.

CAUTION: Limit engine running time to one minute or less with belts removed or serious engine damage will result.

NOTE: A serpentine drive belt decreases the usefulness of this test. In these cases, use a vibration analyzer, such as the EVA, to pinpoint accessory vibrations. An electronic listening device, such as an EngineEAR, will also help to identify noises from specific accessories.

Remove the accessory drive belts.

Increase the engine rpm to where the concern occurs.

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If the vibration/noise is duplicated when carrying out this test, the belts and accessories are not sources.

If the vibration/noise was not duplicated when carrying out this test, install each accessory belt, one at a time, to locate the source.

Vehicle Cold Soak Procedure To carry out this procedure, proceed as follows: Test preparations include matching customer conditions (if known). If not known, document the test conditions: gear selection and engine rpm.

Monitor the vibration/noise duration with a watch for up to three minutes.

Park the vehicle where testing will occur. The vehicle must remain at or below the concern temperature (if known) for 6-8 hours.

Before starting the engine, conduct a visual inspection under the hood.

Turn the key on, but do not start the engine.

Listen for the fuel pump, anti-lock brake system (ABS) and air suspension system noises.

Start the engine.

CAUTION: Never probe moving parts.

Isolate the vibration/noise by carefully listening.

Move around the vehicle while listening to find the general location of the vibration/noise. Then, search for a more precise location by using a stethoscope or EngineEAR. Refer to Idle Noise/Vibration in the Symptom Chart to assist with the diagnosis.

6: Check OASIS/TSBs/Repair History After verifying the customer concern, check for OASIS reports, TSBs and the vehicle repair history for related concerns. If information relating to a diagnosis/repair is found, carry out the procedure(s) specified in that information.

If no information is available from these sources, carry out the vehicle preliminary inspection to eliminate any obvious faults.

7: Diagnostic Procedure Qualifying the concern by the particular sensation present can help narrow down the concern. Always use the “symptom” to “system” to “component” to “cause” diagnosis technique. This diagnostic method divides the problem into related areas to correct the customer concern.

Verify the “symptom”.

Determine which “system(s)” can cause the “symptom”.

If a vibration concern is vehicle speed related, the tyre and wheel rpm/frequency or driveshaft frequency should be calculated.

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DIAGNOSIS AND TESTING (Continued) If a vibration concern is engine speed related, the engine, engine accessory or engine firing frequencies should be calculated.

After determining the “system”, use the diagnostic tools to identify the worn or damaged “components”.

After identifying the “components”, try to find the “cause” of the failure.

Once the concern is narrowed down to a symptom/condition, proceed to NVH Condition and Symptom Categories.

2.

NVH Condition and Symptom Categories Operating Condition—Vehicle is Not Moving 1. Static operation Noise occurs during part/system functioning.

Goto Squeak and Rattle.

2. While cranking 1. Grinding or whine, differential ring gear or starter motor pinion noise. Goto Engine Noise/Vibration.

2. Rattle. Exhaust hanger, exhaust heat shield or A/C line noise. Goto Squeak and Rattle.

3. Vibration. Acceptable condition.

3. At idle Idle noise. Goto Idle Noise/Vibration.

Idle vibration or shake. Goto Idle Noise/Vibration.

4. During gear selection 1. Vehicle parked on a steep incline. Acceptable noise.

2. Vehicle parked on a flat surface. Goto Driveline Noise/Vibration.

3. Vehicle with a manual transmission. Goto Transmission (Manual) and Transfer Case Noise/Vibration.

3.

4.

5.

Operating Condition—Vehicle is Moving 1. Depends more on how the vehicle is operated 1. Speed-related Related to vehicle speed Pitch increases with vehicle speed.

Goto Tire Noise/Vibration.

Noise occurs at specific vehicle speed. A high-pitch noise (whine).

Goto Drivline Noise/Vibration.

Loudness proportional to vehicle speed. Low-frequency noise at high speeds, noise and loudness increase with speed. Goto Driveline Noise/Vibration.

A low-pitched noise (drumming). Goto Engine Noise/Vibration.

Vibration occurs at a particular speed (mph) regardless of acceleration or G72679 en

6.

7.

8.

deceleration. Goto Tire Noise/Vibration.

Noise varies with wind/vehicle speed and direction. Goto Air Leak and Wind Noise.

Related to engine speed.

Noise varies with engine rpm. Goto Engine Noise/Vibration.

Vibration occurs at a particular speed (mph) regardless of engine speed (rpm).

Acceleration Wide open throttle (WOT) Engine induced contact between components. Inspect and repair as necessary.

Noise is continuous throughout WOT. Exhaust system or engine ground out.

Goto Engine Noise/Vibration.

Light/moderate acceleration Tip-in moan. Engine/exhaust noise.

Goto Engine Noise/Vibration.

Knock-type noise. Goto Engine Noise/Vibration.

Driveline shudder. Goto Driveline Noise/Vibration.

Engine vibration. Goto Engine Noise/Vibration.

Turning noise. Goto Steering Noise/Vibration.

Braking.

Clicking sound is signaling ABS is active.

Acceptable ABS sound.

A continuous grinding/squeal. Goto Brake Noise/Vibration.

Brake vibration/shudder. Goto Brake Noise/Vibration.

Clutching.

A noise occurring during clutch operation.

Goto Transmission (Manual) and Transfer Case Noise/Vibration.

Vibration. Goto Transmission (Manual) and Transfer Case Noise/Vibration.

Shifting Noise or vibration condition related to the transmission (automatic). Goto Transmission (Automatic) Noise/Vibration.

Noise or vibration related to the transmission (manual). Goto Transmission (Manual) and Transfer Case Noise/Vibration.

Engaged in four-wheel drive. Goto Transmission (Manual) and Transfer Case Noise/Vibration.

Cruising speeds Accelerator pedal vibration. Goto Engine Noise/Vibration.

Driveline vibration. Goto Driveline Noise/Vibration.

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