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2003 Ford BA Falcon Service Manual.pdf

August 21, 2008 · Filed Under Ford  · Tags: , ,

Ford Falcon was made during 2002-2005 by Ford Motor Company of Australia, equipped with I6 4.0 L Barra E-Gas, 4.0 L Barra 182, 4.0 L Barra 245T or V8 5.4 L Barra 220, 5.4 L Boss 260 Engine with manual or automatic transmission, Ford Falcon shared same market with Holden Commodore.

This service manual as well as other free Ford repair manuals we collect, consists complete informations on servicing, maintaining, overhauling the Ford Falcon 2003 Model year, it’s a must have for Falcon-er !

Part of Table of Contents:

  • SECTION : 100-01 Identification Codes [ DESCRIPTION AND OPERATION ~ Identification Codes ~ Vehicle Identification Number ~ Vehicle Compliance (VC) Label ~ Emission Decal ]
  • SECTION : 100-02 Jacking and Lifting [ DESCRIPTION AND OPERATION ~ Jacking ~ Jacking/Lifting Points - Sedan/Wagon ~ Jacking/Lifting Points - Ute ]
  • SECTION : 100-04 Noise, Vibration and Harshness [ DESCRIPTION AND OPERATION ~ Noise, Vibration and Harshness (NVH) ~ Acceptable Noise, Vibration and Harshness ~ Diagnostic Theory ~ Glossary of Terms ~ DIAGNOSIS AND TESTING ~ Noise, Vibration and Harshness (NVH) ~ 1: Customer Interview ~ 2: Pre-Drive Check ~ 3: Preparing for the Road Test ~ 4: Verify the Customer Concern ~ 5: Road Test ~ 6: Check OASIS/TSBs/Repair History ~ 7: Diagnostic Procedure ~ NVH Condition and Symptom Categories ~ Symptom Charts ~ Pinpoint Tests ~ Component Tests ~ GENERAL PROCEDURES ~ Brake Disc Machining ~ Powertrain/Drivetrain Mount Neutralizing ~ Exhaust System Neutralizing ~ Wheel Bearing Check ]
  • SECTION : 204-00 Suspension System - General Information [ DESCRIPTION AND OPERATION ~ Suspension System - General Information ~ Front Wheel Alignment ~ Rear Wheel Alignment ~ DIAGNOSIS AND TESTING ~ Suspension System - General Information ~ Inspection and Verification ~ Symptom Chart ~ Shock Absorbers ~ GENERAL PROCEDURES ~ Toe Adjustment ~ Front Wheel Alignment ~ Toe & Steering Wheel Spoke Adjustments ~ Front Wheel Lock Angle Adjustment ~ Upper & Lower Ball Joint Inspection ~ XR Rear Camber Adjustment ~ RLCA (Rear Lower Control Arm) to Subframe Cambolt Adjustment ]
  • SECTION : 204-01 Front Suspension [ Specifications ~ DESCRIPTION AND OPERATION ~ Front Suspension ~ Suspension ~ DIAGNOSIS AND TESTING ~ Front Suspension ~ REMOVAL AND INSTALLATION ~ Lower Control Arm ~ Lower Control Arm Ball Joint ~ Upper Control Arm ~ Upper Control Arm Ball Joint ~ Stabilizer Bar ~ Stabilizer Bar Centre Bushing (Front or Rear Bar) ~ Stabilizer Bar Link Bushing ~ Lower Arm Bushing ~ Lower Arm - Large Bushing ~ Upper Arm Bushing ~ Front Wheel Spindle and Hub ~ Spring and/or Shock Absorber Assembly ]
  • SECTION : 204-02a Rear Suspension - IRS [ Specifications ~ DESCRIPTION AND OPERATION ~ Rear Suspension - IRS ~ Components ~ DIAGNOSIS AND TESTING ~ Inspection and Verification ~ Stabiliser Bar ~ Diagnosis ~ GENERAL PROCEDURES ~ FPV Cam bolt adjustment ~ RLCA to subframe cam adjustment ~ REMOVAL AND INSTALLATION ~ Upper Control Arm Assembly (UCA) ~ Front Lower Control Arm Assembly (FLCA) ~ Rear Lower Control Arm Assembly (RLCA) ~ Knuckle ~ Rear Lower Control Arm (RLCA) park brake cable bracket ~ Abutment bracket ~ Control Blade ~ Shock Absorber ~ Spring and Upper Spring Insulator ~ Stabiliser bar ~ Upper Stabiliser Bar Insulator ~ Jounce Bumper ~ Body Brace ~ IRS Module ]
  • SECTION : 204-02b Rear Suspension - Beam Axle [ Specifications ~ DESCRIPTION AND OPERATION ~ Rear Suspension - Beam Axle ~ Ute & Wagon Rear Suspension ~ Shock Absorbers ~ DIAGNOSIS AND TESTING ~ Rear Suspension ~ GENERAL PROCEDURES ~ Ride Height Procedure ~ Wheel Balancing ~ Hoisting Instructions ~ REMOVAL AND INSTALLATION ~ Shock Absorber - Ute/Wagon ~ Leaf Spring - Ute/Wagon ~ Leaf Spring Front Eye Bushing - Ute ~ Leaf Spring Front Eye Bushing - Wagon ]
  • SECTION : 204-04 Wheels and Tyres [ Specifications ~ DESCRIPTION AND OPERATION ~ Wheels and Tyres ~ Wheels ~ Tyres ~ Safety Precautions ~ DIAGNOSIS AND TESTING ~ Wheels and Tyres ~ Inspection and Verification ~ Symptom Chart ~ Component Tests ~ GENERAL PROCEDURES ~ Straightening Wheels, Rims or Components ~ Wheel and Tyre Assembly Balancing ~ REMOVAL AND INSTALLATION ~ Wheel ~ Tyre ]
  • SECTION : 205-00 Driveline System - General Information [ Specifications ~ DESCRIPTION AND OPERATION ~ Driveline System ~ General Specifications ~ Run in ~ Towing ~ Oil Changes ~ DIAGNOSIS AND TESTING ~ Driveline System ~ In Vehicle Diagnostics ~ Symptom Chart ~ Bearing Noise ~ Gear Tooth Contact Pattern Check ~ Shim and Backlash Changes ~ Driveline Vibration ~ Limited Slip Differentials (M78 & M86) ~ Inspection after Removal & Dismantling ]
  • SECTION : 205-01 Driveshaft [ Specifications ~ DESCRIPTION AND OPERATION ~ Driveshaft ~ Universal Joints ~ DIAGNOSIS AND TESTING ~ Driveshaft ~ Inspection and Verification ~ Symptom Chart ~ GENERAL PROCEDURES ~ Take - Off Shudder ~ REMOVAL AND INSTALLATION ~ Driveshaft Assembly ~ DISASSEMBLY AND ASSEMBLY ~ Flex Joint Replacement ~ Universal Joint Replacement ~ Centre Bearing Replacement ~ CV Joint Replacement ]
  • SECTION : 205-02A Rear Drive Axle / Differential Beam Axle [ Specifications ~ DESCRIPTION AND OPERATION ~ Rear Drive Axle / Differential - Beam Axle ~ Beam Axle Final Drive Identification ~ Conventional Differential ~ Limited Slip Differential ~ Differential Assembly and Pinion Bearings ~ Wheel Bearings ~ DIAGNOSIS AND TESTING ~ Rear Drive Axle / Differential - Beam Axle ~ GENERAL PROCEDURES ~ In Vehicle Inspection ~ Beam Axle Oil Change ~ Flange Runout Check ~ In Vehicle Torque Check ~ Limited Slip Differential - M78 & M86 Check ~ Limited Slip Differential Torque Check ~ Limited Slip Differential - M86 Inspection for Wear ~ Limited Slip Differential - M78 ~ IN-VEHICLE REPAIRS ~ Pinion Oil Seal Replacement ~ REMOVAL AND INSTALLATION ~ Axle Shaft Assembly ~ M86 Limited Slip Differential ~ Axle Housing and Differential Assembly ~ DISASSEMBLY AND ASSEMBLY ~ Rear Axle Wheel Bearing and Seal Replacement ~ Differential and Drive Pinion ~ Differential Bearing Preload Spacer Selection ~ Drive Pinion Position - Shim Selection ~ Drive Pinion and Bearings ~ Differential Installation and Backlash Check ~ Differential Case - Conventional Type M78 and M86 ~ Limited Slip Differential - M78 ~ Limited Slip Differential - M86 ]
  • SECTION : 205-02B Independent Rear Suspension - Full Floating Axle [ Specifications ~ DESCRIPTION AND OPERATION ~ Description And Operation ~ Drive Unit Identification ~ Drive Unit Differential ~ Conventional Differential ~ Limited Slip Differential ~ Diff and Pinion Bearings ~ M78 & M86 IRS (Sedan) ~ GENERAL PROCEDURES ~ Drive Unit Oil Change ~ In Vehicle Torque Check ~ Differential Case Preload Setting ~ Backlash and Tooth Contact Setting ~ IN-VEHICLE REPAIRS ~ Pinion Oil Seal Replacement ~ REMOVAL AND INSTALLATION ~ Half Shaft ~ Drive Unit Assembly ~ Differential Assembly ~ DISASSEMBLY AND ASSEMBLY ~ Inner Axle Shaft Seal Replacement ~ Pinion & Pinion Bearings ~ Drive Pinion Selection - Shim Selection ]
  • SECTION : 205-05 Rear Drive Halfshafts [ Specifications ~ DESCRIPTION AND OPERATION ~ Rear Drive Halfshafts ~ Halfshaft Handling ~ DIAGNOSIS AND TESTING ~ Rear Drive Halfshafts ~ REMOVAL AND INSTALLATION ~ Halfshaft ~ DISASSEMBLY AND ASSEMBLY ~ Halfshaft Joint ]
  • SECTION : 206-00 Brake System - General Information [ Specifications ~ DESCRIPTION AND OPERATION ~ Brake System ~ Load Proportioning Valve 1 Tonne Ute ~ DIAGNOSIS AND TESTING ~ Brake System ~ Inspection and Verification ~ Symptom Chart ~ Components Tests ~ GENERAL PROCEDURES ~ Hydraulic System Bleeding ~ Manual System Bleeding ~ System Pressure Bleeding ~ Service Precautions ~ Changing Brake Fluid ~ Brake Pedal Clearance Check ~ Caliper ~ Brake System Leak Check ]
  • SECTION : 206-03 Front Disk Brake [ Specifications ~ DESCRIPTION AND OPERATION ~ Front Disc Brake ~ Disc Pad Running Clearance ~ Wear Adjustment ~ Rotor ~ DIAGNOSIS AND TESTING ~ Front Disc Brake ~ REMOVAL AND INSTALLATION ~ Brake Pads ~ Front Brake Hose ~ Brake Caliper Body ~ Brake Disc ~ DISASSEMBLY AND ASSEMBLY ~ Brake Caliper ]
  • SECTION : 206-04 Rear Disc Brake [ Specifications ~ DESCRIPTION AND OPERATION ~ Rear Disc Brake. ~ Service Brake ~ Parking Brake ~ DIAGNOSIS AND TESTING ~ Brake Calipers ~ Inspection ~ REMOVAL AND INSTALLATION ~ Brake Caliper Body ~ Brake Caliper Assembly ~ Rear Brake Hose ~ Brake Pads ~ Brake Disc ~ Beam Axle Brake Disc ~ DISASSEMBLY AND ASSEMBLY ~ Brake Caliper ]
  • SECTION : 206-05 Parking Brake and Actuation [ Specifications ~ DESCRIPTION AND OPERATION ~ Parking Brake - Sedan ~ Parking Brake - Ute/Wagon ~ GENERAL PROCEDURES ~ Parking Brake Cable Adjustment ~ Parking Brake Shoe Adjustment ~ Major Parking Brake Service ~ REMOVAL AND INSTALLATION ~ Parking Brake Shoes ~ Parking Brake Handle ~ Parking Brake Lever (Wagon), Column Shift (Ute) ~ IRS Parking Brake Cable Routing ~ Beam Axle Parking Brake Cable Routing ]
  • SECTION : 206-06 Hydraulic Brake Actuation [ Specifications ~ DESCRIPTION AND OPERATION ~ Hydraulic Brake Actuation ~ Hydraulic Brake System ~ Dual Hydraulic Brake System ~ Brake Master Cylinder ~ Dual Master Cylinder Brake System (where fitted) ~ Power Brake Booster ~ Acronyms and Abbreviations ~ DIAGNOSIS AND TESTING ~ Hydraulic Brake Actuation ~ Inspection and Verification ~ Function Test ~ Symptom Chart ~ Connector Circuit Reference ~ Pinpoint Tests ~ GENERAL PROCEDURES ~ Adjustable Brake Indexing ~ System Bleeding ~ Power Brake Booster Testing ~ Hydraulic Line Repair ~ Brake Hose Replacement ~ Brake Tube Replacement ~ REMOVAL AND INSTALLATION ~ Brake Box Assembly ~ Brake Pedal Adjustment Motor ~ Brake Pedal Motor Cables ~ Brake Pedal Control Switch (where fitted) ~ Brake and Cruise Pedal Switch Setting ~ Brake Pedal Pad ~ Accelerator Pedal Pad ~ Power Brake Booster ~ Dual Master Cylinder ~ DISASSEMBLY AND ASSEMBLY ~ Electronic Throttle Control Module ~ Dual Master Cylinder ~ ]
  • SECTION : 206-06x Hydraulic Brake Actuation Load Proportioning Valve (1 tonne option) [ DESCRIPTION AND OPERATION ~ Hydraulic Brake Actuation - Load Proportioning Valve ~ REMOVAL AND INSTALLATION ~ Load Proportioning Valve ~ ]
  • SECTION : 206-09 Anti Lock Control [ DESCRIPTION AND OPERATION ~ Anti Lock Control ~ Applicable Models ~ General Description ~ Operation ~ Operating Modes ~ DIAGNOSIS AND TESTING ~ Anti Lock Control ~ Principles of Operation ~ Inspection and Verification ~ Diagnostic Trouble Code (DTC) Chart ~ Connector Circuit Reference ~ Pinpoint Tests ~ REMOVAL AND INSTALLATION ~ Rear ABS sensor - IRS ~ ABS Wheel Speed Sensor - Rear (Beam Axle) ~ Front ABS Wheel Sensors ~ Rear Tone Wheel ~ Front Tone Wheel ~ ABS Modulator Assembly ]
  • SECTION : 211-00 Steering System - General Information [ DESCRIPTION AND OPERATION ~ Service Kits ~ GENERAL PROCEDURES ~ Power Steering System Bleeding Air ~ Rack and Pinion Gear Rack Bearing Preload Adjustment ~ Steering Gear Lubrication ~ DISASSEMBLY AND ASSEMBLY ~ Steering System Exploded ]
  • SECTION : 211-02 Power Steering [ Specifications ~ DESCRIPTION AND OPERATION ~ Power Steering Pump - I6 ~ Power Steering Pump - V8 ~ Pump Identification ~ DIAGNOSIS AND TESTING ~ Power Steering Pump - I6 ~ Symptom Chart ~ GENERAL PROCEDURES ~ Start of Procedure ~ Remedying Pump Noise ~ Purging Power Steering System of Air ~ Flushing Power Steering Pump (I6) ~ Flushing Power Steering Gear (I6) ~ REMOVAL AND INSTALLATION ~ Steering Gear Cylinder Pipe and O - Ring Seals ~ Steering Gear Spool Shaft Seals and Bearings ~ Power Steering Pump (I6) ~ Power Steering Pump (V8) ~ Power Steering Pump Pulley (V8) ~ Steering Gear - I6 ~ Steering Gear - V8 ~ Steering Gear Bushing and Sleeve ~ Drive Belt (I6) ~ Quick Connect Power Steering Fitting (I6) ~ Power Steering Lines (I6) ~ Power Steering Lines (V8) ~ DISASSEMBLY AND ASSEMBLY ~ Resorvoir Assembly (I6) ~ Resorvoir Assembly (V8) ~ Control Valve Assembly (I6) ~ Drive Shaft Seal (I6) ~ Hydraulic Pump Assembly (I6) ]
  • SECTION : 211-03 Steering Linkage [ Specifications ~ DIAGNOSIS AND TESTING ~ Steering Linkage ~ REMOVAL AND INSTALLATION ~ Outer Tie - Rod ~ Inner Tie - Rod ~ Steering Gear Boot ]
  • SECTION : 211-04 Steering Column [ Specifications ~ DESCRIPTION AND OPERATION ~ Steering Column ~ Steering Column ~ Floor Plate & Intermediate Shaft ~ Steering Column Air Bag ~ Steering Column Lock ~ Adjustable Steering Column ~ Fixed Steering Column (Column Shift Automatic) ~ Steering Column - Accident Damage and Replacement ~ REMOVAL AND INSTALLATION ~ Steering Column Shrouds ~ Ignition Key Barrel ~ Passive-Anti-Theft-System (PATS) Unit, and key illumination ~ Adjustable Steering Column ~ Fixed Steering Column (Column Shift automatic) ~ Floor Plate & Intermediate Shaft ~ Driver Air Bag ~ Steering Wheel ~ DISASSEMBLY AND ASSEMBLY ~ Setting the Steering Column Adjustment Clamp ~ Adjustable Steering Column ~ Fixed Steering Column ~ Gear Shift Module ~ Centralizing the Clockspring ~ Floor Plate and Intermediate Shaft ]
  • SECTION : 211-05 Steering Column Switches [ DESCRIPTION AND OPERATION ~ Steering Column Switches ~ Steering Column Switches ~ DIAGNOSIS AND TESTING ~ Steering Column Switches ~ Inspection and Verification ~ Symptom Chart ~ Connector Circuit Reference ~ Pinpoint Tests ~ REMOVAL AND INSTALLATION ~ Steering Column Multifunction Switch ~ Ignition Key Barrel ~ Pedal Adjust Switch ]
  • SECTION : 303-00 Engine System - General Information [ DESCRIPTION AND OPERATION ~ Engine ~ DIAGNOSIS AND TESTING ~ Engine ~ Inspection and Verification ~ Symptom Chart ~ Components Tests ~ GENERAL PROCEDURES ~ Camshaft Journal - Diameter ~ Camshaft Journal - Clearance, Plastigage Method ~ Camshaft —8 End Play, OHC Engines ~ Camshaft - Lobe Surface ~ Camshaft - Runout ~ Crankshaft Main Bearing Journal - Diameter ~ Crankshaft Main Bearing Journal - Taper ~ Crankshaft Main Bearing Journal - Clearance ~ Crankshaft - End Play ~ Crankshaft - Runout ~ Crankshaft - Connecting Rod Journal Taper, Out of Round ~ Cylinder Bore - Taper ~ Cylinder Bore - Out-of-Round ~ Piston - Inspection ~ Piston - Pin to Bore Diameter ~ Piston - Diameter ~ Piston - to Cylinder Bore Clearance ~ Piston - Ring End Gap ~ Piston - Ring-to-Groove Clearance ~ Piston - Pin Diameter ~ Connecting Rod - Cleaning ~ Connecting Rod - Large End Bore ~ Connecting Rod - Bushing Diameter ~ Connecting Rod - Bend ~ Connecting Rod - Twist ~ Connecting Rod - Bearing Journal Clearance ~ Roller Follower - Inspection ~ Valve Rocker Arm/Lash Adjuster Assembly - Inspection ~ Hydraulic Lash Adjuster Diagnosis ~ Valve - Stem Diameter ~ Valve - Stem to Valve Guide Clearance ~ Valve - Inspection ~ Valve - Guide Inner Diameter ~ Valve - Guide Reaming ~ Valve - Spring Installed Length ~ Valve - Spring Free Length ~ Valve - Spring Squareness ~ Valve - Spring Strength ~ Valve - Seat Inspection ~ Valve - Seat Width ~ Valve - Seat Runout ~ Cylinder Bore - Cleaning ~ Cylinder Block - Core Plug Replacement ~ Exhaust Manifold - Inspection ~ Bearing -Inspection ]
  • SECTION : 303-01a Engine - I6 [ Specifications ~ DESCRIPTION AND OPERATION ~ Engine - I6 ~ DIAGNOSIS AND TESTING ~ Engine ~ Inspection and Verification ~ Symptom Chart ~ Component Tests ~ GENERAL PROCEDURES ~ Cylinder Head Inspection ~ Valve Inspection ~ Valve Measurement ~ Valve Guide Inspection ~ Valve Guide Replacement ~ Valve Seat Inspection/Repair ~ Valve Spring Inspection ~ Camshaft End Play Inspection ~ Camshaft Inspection ~ Camshaft Journal Clearance - Plastigauge Method ~ Roller Follower Inspection ~ Lash Adjuster Bore Inspection ~ Cylinder Block Inspection/Repair ~ Cylinder Bore - Taper ~ Cylinder Bore - Out-of-Round ~ Piston Inspection ~ Piston Clearance Inspection/ Repair ~ Piston Ring Clearance Inspection ~ Piston Pin Clearance Inspection ~ Crankshaft Inspection ~ Crankshaft Main Bearing Clearance ~ Crankshaft End Play Inspection/Repair ~ Connecting Rod Inspection ~ Connecting Rod Big End Bearing Clearance ~ Connecting Rod Side Clearance Inspection ~ Piston and Connecting Rod Inspection ~ Timing Chain Elongation ~ IN-VEHICLE REPAIRS ~ Oil Filter ~ Oil Level Indicator & Tube ~ Cylinder Head Temperature Sensor ~ Cam Position Sensor ~ Crankshaft Position Sensor ~ Oil Pressure & Oil Temperature Sensor ~ Combustion Knock Sensor ~ Exhaust Gas Oxygen Sensor ~ Temperature - Manifold Air Pressure Sensor ~ Crankshaft Vibration Damper ~ Crankshaft Front Oil Seal ~ Crankshaft Rear Oil Seal ~ Flywheel/Drive Plate/Clutch Pilot Bearing ~ Clutch Pilot Bearing ~ Water Pump ~ Electronic Throttle Body and Intake Manifold ~ Broadband Throttle Plate ~ Broadband Throttle Shaft Vacuum Motor ~ Exhaust Manifold Assembly ~ Exhaust Manifold - Front and Rear ~ Oil Control Valve Seal ~ Valve Cover ~ Ignition Coils/Wiring Loom ~ Camshafts, VCT Phaser, Oil Control Valves, & OCV Filters ~ Camshaft Removal ~ Camshaft and VCT Phasers ~ Camshaft Installation ~ Timing Chain Tensioner ~ VCT Phaser ~ Rocker Arm, Lash Adjuster, Valve Spring and Valve Stem Seal ~ Rocker Arm and Lash Adjuster ~ Valve spring and Valve Stem Seal ~ Front Cover ~ Camshaft Drive ~ Timing Chain Tensioner Release ~ Cylinder Head ~ Engine ~ Engine Mounting ~ Engine Oil Pan ~ Oil Pump Pickup Tube ~ Oil pump ~ Piston and Rod Assembly ~ Main bearings/Crankshaft ~ Rear Main Bearing Cap Assembly ~ Piston Ring ~ DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES ~ Key Retainer - Valve Spring ~ Valve Stem Seal ~ Piston and Connecting Rod Assembly ~ Piston and Connecting Rod Disassembly and Assembly ~ ]
  • SECTION : 303-01b Engine - 5.4L (3V) [ Specifications ~ DESCRIPTION AND OPERATION ~ Engine ~ DIAGNOSIS AND TESTING ~ Engine ~ IN-VEHICLE REPAIRS ~ Intake Manifold Upper ~ Valve Cover LH and RH (shown) ~ Crankshaft Pulley ~ Crankshaft Front Oil Seal ~ Engine Front Cover ~ Timing Gears, Chains, Tensioners, VCT Sprocket Assemblies and VCT Housings ~ Camshaft (LH shown, RH opposite hand) ~ Rocker Arm, Lash Adjuster, Valve Spring and Valve Stem Seal ~ Valve Spring and Valve Stem Seal ~ Exhaust Manifold (LH shown, RH opposite hand) ~ Oil Filter Adapter ~ Oil Pressure Sender ~ Oil Level Indicator and Tube ~ Oil Pan ~ Oil Pump Screen and Pickup Tube ~ Flywheel ~ Crankshaft Rear Oil Seal ~ Engine Mounts - RH ~ Engine Mounts - LH ~ ]
  • SECTION : 303-01c Engine - V8 (4V) [ Specifications ~ DESCRIPTION AND OPERATION ~ Engine ~ Identification ~ Code Information ~ Induction System ~ Valve Train ~ Positive Crankcase Ventilation System ~ Lubrication System ~ Oil Pump ~ Cooling System ~ Drive Belt System ~ DIAGNOSIS AND TESTING ~ Engine ~ IN-VEHICLE REPAIRS ~ Intake Manifold Upper ~ Intake Manifold - Lower ~ Valve Cover - RH ~ Valve Cover - LH ~ Crankshaft Pulley ~ Crankshaft Front Oil Seal ~ Engine Front Cover ~ Timing Drive Components ~ Valve - Springs, Retainer and Valve Stem Seal ~ Hydraulic Lash Adjusters ~ Roller Followers ~ Camshaft ~ Exhaust Manifold - LH ~ Oil Filter Adapter ~ Oil Pressure Sender ~ Oil Level Indicator and Tube ~ Oil Pan ~ Oil Pump Screen and Pickup Tube ~ Flexplate ~ Crankshaft Rear Oil Seal ~ Engine Mounts - RH ~ Engine Mounts - LH ~ ]
  • SECTION : 303-03 Engine Cooling [ Specifications ~ DESCRIPTION AND OPERATION ~ Engine Cooling ~ Radiator ~ Electric Fans ~ Water Pump ~ Cooling System ~ Cooling Maintenance ~ DIAGNOSIS AND TESTING ~ Engine Cooling ~ Inspection and Verification ~ Symptom Chart ~ Tests ~ Pressure Test ~ Supply Tank Cap Pressure Test ~ Thermostat Test ~ Coolant System ~ Cooling Fan Self Test - All Models ~ GENERAL PROCEDURES ~ Coolant Level Check ~ Cooling Color Inspection ~ Adjusting Anti - Freeze Protection Level ~ Anti - Freeze Replacement ~ Draining and Filling the Cooling System ~ Radiator Cleaning ~ REMOVAL AND INSTALLATION ~ Thermostat ~ Thermostat Housing - 8 Cylinder ~ Thermostat Housing - 6 Cylinder ~ Water Pump - 6 Cylinder ~ Water Pump - V8 ~ Radiator ~ Fan ~ Radiator Hose ~ Coolant Supply Tank ~ ]
  • SECTION : 303-04b Fuel Charging and Controls Turbocharger [ Specifications ~ DESCRIPTION AND OPERATION ~ Turbocharger ~ Boost Control ~ Charge Air Cooler (Intercooler) ~ Heatshielding ~ DIAGNOSIS AND TESTING ~ Turbocharger ~ Inspection and Verification ~ Symptom Chart ~ Pinpoint Tests ~ REMOVAL AND INSTALLATION ~ Turbocharger ~ Boost Pressure Sensor ~ Wastegate Control Solenoid (WCS) ~ Charge Air Cooler (Intercooler) ~ ]
  • SECTION : 303-04c Single Fuel LPG [ Specifications ~ DESCRIPTION AND OPERATION ~ Single Fuel LPG ~ Introduction ~ Licensing Requirements ~ Important Safety Notice ~ Notes, Cautions and Warnings ~ Vehicle Identification ~ Description ~ LPG System Major Components ~ Converter ~ Engine Servicing Requirements ~ Scheduled Maintenance ~ DIAGNOSIS AND TESTING ~ Single Fuel LPG ~ Inspection and Verification ~ Symptom Charts ~ Connector Circuit Reference ~ REMOVAL AND INSTALLATION ~ Primary Service ~ LPG Filter ~ Tank Assembly ~ Pressure Decanting ~ Tank Decanting ~ Tank - Ute ~ Tank - Wagon ~ Tank - Sedan ~ Fuel Gauge and Float Assembly ~ Automatic Fill Limiter ~ Service Valve (With Relief Valve on Ute and Wagon) ~ Fuel Filler Valve ~ Pressure Relief Valve ~ Fuel Filler Hose ~ LPG Fuel Delivery System Hose ~ Bundy Tube Connection ~ Converter Including Filter Lockoff & Solenoid ~ Filter ~ Main/Idle/Prime Lockoff Solenoids ~ Converter Assembly ~ ]
  • SECTION : 303-05 Accessory Drive [ Specifications ~ DESCRIPTION AND OPERATION ~ Accessory Drive ~ Belt Tensioner - I6 & V8 ~ Water Pump ~ DIAGNOSIS AND TESTING ~ Accessory Drive ~ Inspection and Verification ~ Symptom Chart ~ Belt Tensioner ~ REMOVAL AND INSTALLATION ~ Accessory Drive Belt ~ Accessory Drive Belt Tensioner ~ Accessory Drive Belt Idler Pulley ]
  • SECTION : 303-06 Starting System [ Specifications ~ DESCRIPTION AND OPERATION ~ Starting System - 6 Cylinder (Bosch) ~ General Service ~ Description ~ Operation ~ Roadside Service ~ Jump Starting ~ Connecting and Starting Procedure ~ Engine Starting ~ DIAGNOSIS AND TESTING ~ Starting System ~ Symptom Chart ~ Pinpoint Tests ~ Component Tests ~ GENERAL PROCEDURES ~ Starting System ~ REMOVAL AND INSTALLATION ~ Starter Motor ~ DISASSEMBLY AND ASSEMBLY ~ Starter Motor ~ Starter Drive Assembly ~ Solenoid Switch ~ Drive End Housing ~ Armature ~ ]
  • SECTION : 303-12 Intake Air Distribution and Filtering [ Specifications ~ DESCRIPTION AND OPERATION ~ Intake Air Distribution and Filtering ~ Intake Air Distribution and Filtering ~ The Intake Air System ~ DIAGNOSIS AND TESTING ~ Intake Air Distribution and Filtering ~ GENERAL PROCEDURES ~ Cleaning and Inspection ~ REMOVAL AND INSTALLATION ~ Air Cleaner Body - I6 Engine ~ Air Cleaner Element - I6 and V8 Engines ~ Engine Air Ducting - I6 and V8 Engines ~ ]
  • SECTION : 303-14 Powertrain Control Management [ DESCRIPTION AND OPERATION ~ General Information ~ Precautions ~ Special Notes ~ PCM Systems ~ System Overview ~ Control Systems ~ Fuel System ~ Fuel tank ~ Fuel pump ~ Fuel Supply and Return Lines ~ Fuel Filters ~ Fuel Rail ~ Fuel Injector ~ Fuel Pressure Regulator ~ Intake Air System ~ Air Mass Measurement System ~ Variable Camshaft Timing ~ 5.4L, 3 Valve V8 Engine ~ Intake Manifold Charge Control (IMCC) (I6 only) ~ Ignition System ~ Spark Advance Map ~ Engine Cooling System ~ Evaporative Emission System ~ Positive Crankcase Ventilation ~ Catalyst and Exhaust System ~ Air Conditioning System ~ Traction Control ~ Automatic Transmission Control ~ Control Software ~ Powertrain Control Module Memory ~ Operating Strategies ~ Operating Modes ~ Normal Mode ~ Crank Mode ~ Under-Speed Mode ~ Open Loop ~ Closed Loop ~ Powertrain Control Hardware ~ Powertrain Control Module ~ Module Programming ~ General Procedures ~ General Procedures ~ Power and Ground Signals ~ Inputs ~ Crankshaft Position Sensor (CKP) ~ Temperature and Manifold Absolute Pressure Sensor ~ Trimming Sensors ~ Camshaft Position Sensor ~ Cylinder Head Temperature Sensor ~ Engine Oil Temperature Sensor ~ Engine Oil Pressure Sensor ~ Boost Pressure Sensor, I6 Turbo Engine ~ TAS ~ Failure Mode ~ Feedback Inputs ~ Heated Exhaust Gas Oxygen Sensor ~ Knock Sensor ~ Feed Forward Inputs ~ Transmission Range Sensor (TRS-A1) ~ Transmission Range Sensor (TRS-A2) ~ Power Steering Pressure Switch ~ Vehicle Speed ~ Electronic Throttle Control Inputs ~ Pedal Position Sensor ~ Throttle Position Sensor ~ Clutch Engagement Switch, Manual Transmission ~ Brake Switches ~ Reverse Gear Switch ~ Speed Control Range Switch Assembly ~ Air Conditioner Inputs ~ Air Conditioner Demand ~ Air Conditioner Relay ~ Air Conditioner Pressure Transducer ~ Transmission Inputs ~ Transmission Fluid Temperature Sensor ~ Output Actuators ~ Fuel Pump ~ Fuel Injectors 1-8 ~ Ignition Coils ~ Actuators ~ Intake Manifold Charge Control ~ Electro Drive Fans ~ Variable Camshaft Timing ~ Electronic Throttle Body ~ Evap Canister Purge Solenoid ~ Turbocharger Westgate Control ~ Transmission Outputs ~ Shift Solenoid 1 ~ Shift Solenoid 2 ~ Shift Solenoid 3 ~ Shift Solenoid 4 ~ Variable Pressure Solenoid 5 ~ Power Control Solenoid 6 ~ Lock up Solenoid 7 ~ LPG Fuel System Outputs ~ LPG Prime Solenoid PRIME ~ Gas Cut-out Solenoid GCO ~ LPG Stepper Motor A-D ~ Control Area Network (CAN) ~ Smartshield Security ~ Diagnosis ~ DIAGNOSIS AND TESTING ~ Powertrain Control Management ~ Powertrain Control Management ~ GENERAL PROCEDURES ~ Powertrain Control Module ~ Intake Manifold Charge Control ~ VCT Solenoid Valve ~ REMOVAL AND INSTALLATION ~ Crankshaft Position (CKP) Sensor (I6 Engine) ~ Crankshaft Position (CKP) Sensor (V8 Engine) ~ Camshaft Position Sensor (I6 Engine) ~ Camshaft Position Sensor (V8 Engine) ~ Knock Sensor (I6 Engine) ~ Cylinder Head Temperature (CHT) Sensor (I6 Engine) ~ Cylinder Head Temperature (CHT) Sensor (V8 Engine) ~ Throttle Position (TP) Sensor (I6, LPG & Turbo Engines) ~ Throttle Position (TP) Sensor (V8 Engine) ~ Powertrain Control Module (PCM) (I6 Engine) ~ HEGO Sensor (I6 & V8 Engines) ~ HEGO Sensor (Turbo) ~ Boost Pressure Sensor (Turbo Engine) ~ Turbocharger Wastegate Control Solenoid ~ Reverse Gear Switch ~ Temperature and Manifold Absolute Pressure (T-MAP) Sensor ~ Fuel Rail (I6 Engine) ~ Fuel Rail (V8 Engine) ~ Brake Switches ~ Clutch Engagement Switch, (Manual Transmission) ~ Pedal Position Sensor ~ Air Conditioning Relay ~ Air Conditioner Pressure Transducer ~ Transmission Fluid Temperature Sensor ~ Fuel Pump ~ Transmission Range Sensor (TRSA1) ~ Transmission Range Sensor (TRSA2) ~ Intake Manifold Charge Control ~ Phaser removal ~ OCV removal ~ CID sensor removal ~ VCT oil filter removal ~ EVAP Canister Purge Solenoid ~ Power Steering Pressure Switch ~ ]
  • SECTION : 307-01 Automatic Transmission [ Specifications ~ DESCRIPTION AND OPERATION ~ Automatic Transmission ~ BTR Model 93/97LE Automatic transmission general description ~ The Electronic Control System ~ Adaptive Shift Strategy ~ DIAGNOSIS AND TESTING ~ Automatic Transmission ~ Electronic Control System ~ Symptom Chart ~ Connector Circuit Reference ~ GENERAL PROCEDURES ~ Hydraulic System ~ Fluid Level ~ Fluid leakage checks ~ Fluid Leakage Converter Area ~ Gear shift Cable check ~ Initial Engagement check ~ Transmission operation checks - Test preparation ~ Stall test, Engine speed ~ Green Transmission Strategy (Retraining for new Automatic Transmission) ~ Line Pressure Boost Check ~ Road testing ~ Road Test ~ Air Pressure checks ~ Transmission fluid level adjustment ~ Filling a drained/dry transmission and convertor to determine the correct fluid level ~ Gear shift cable adjustment ~ Band adjustment ~ Oil cooler flushing ~ REMOVAL AND INSTALLATION ~ Inhibitor Switch ~ Radiator Oil Cooler ~ Oil Cooler Tube ~ Gear Shift - Column Shift ~ Gear Shift - Floor Mounted ~ Cross Shaft Seals ~ Mass Damper / Extension Housing ~ Valve Body Assembly ~ Front Servo ~ Rear Servo ~ Transmission ~ DISASSEMBLY ~ Transmission ~ Transmission Case ~ DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES ~ Forward Clutch Cylinder ~ C3 Clutch Cylinder ~ Planet Carrier & Centre Support ~ Pump ~ Valve Body ~ ASSEMBLY ~ Transmission ~ Output Shaft & Gear Assembly ~ Rear Band ~ Rear Servo ~ Planet Carrier and Centre Support ~ Extension Housing ~ Front Servo ~ Front Band ~ C2/C4 Clutch ~ C3 Clutch, Reverse Sun Gear & Forward Sun Gear Assembly ~ C1 Clutch Overdrive Shaft & Input Shaft ~ Clutch ~ Pump Cover & Converter Support ~ Valve Bodies ~ Oil Filter and Pan Assembly ~ Torque Converter & Housing ]
  • SECTION : 307-05 Automatic Transmission External Controls [ DESCRIPTION AND OPERATION ~ Automatic Transmission External Controls ~ Sequential Sport Shift Selector ~ DIAGNOSIS AND TESTING ~ Automatic Transmission External Controls ~ Connector Circuit Reference ~ GENERAL PROCEDURES ~ Selector Cable Adjustment ~ REMOVAL AND INSTALLATION ~ Handle Assembly ~ Torsion Spring ~ Housing Sub Assembly ~ Gear Indicator Globe ~ Cap ~ Loom PCB (Printed Circuit Board) ~ Guide Lever ~ Gearshift Assembly ~ Bucket (Metal Pressing) ~ Base and Lever Assembly ~ Spring Leaf Detent ~ Selector Lever Cable ~ ]
  • SECTION : 308-01 Clutch [ Specifications ~ DESCRIPTION AND OPERATION ~ Clutch ~ Introduction ~ Clutch Function ~ DIAGNOSIS AND TESTING ~ Clutch ~ Symptom Chart ~ GENERAL PROCEDURES ~ Pressure Plate Inspection ~ Clutch Disc Inspection ~ Clutch Pressure Plate Adjustment (XR6 Turbo Variant) ~ REMOVAL AND INSTALLATION ~ Disc and Pressure Plate ~ Flywheel - I6 (all variants including XR6 Turbo) ~ Flywheel - All V8 Vehicles (incl XR8 & GT) ~ Pilot Bearing - All Vehicles ~ DISASSEMBLY AND ASSEMBLY ~ Flywheel Auto Flex-Plate (XR6 Turbo only) ~ Ring Gear - All Vehicles except XR6 Turbo ~ Ring Gear - XR6 Turbo only ~ ]
  • SECTION : 308-03a Manual Transmission - i6 [ Specifications ~ DESCRIPTION AND OPERATION ~ Manual Transmission ~ Manual Transmission ~ DIAGNOSIS AND TESTING ~ Manual Transmission ~ Inspection and Verification ~ Symptom Chart ~ GENERAL PROCEDURES ~ Transmission Cleaning ~ Transmission Inspection ~ Aluminium Transmission Case Service ~ Taper Roller Bearings Inspection ~ Fluid Level Check ~ Drain and Refill Transmission ~ REMOVAL AND INSTALLATION ~ Rear Extension Housing Oil Seal ~ Shift Lever and Boot Assembly ~ Speedometer Transducer and Drive Gear ~ Concentric Slave Cylinder (CSC) ~ Transmission Damper ~ Reversing Light Switch ~ Transmission Cross - Member ~ REMOVAL ~ Special Service Tools ~ Transmission ~ INSTALLATION ~ Transmission ~ ]
  • SECTION : 308-03b Manual Transmission - TR3650 [ Specifications ~ DESCRIPTION AND OPERATION ~ Manual Transmission ~ Transmission Identification ~ DIAGNOSIS AND TESTING ~ Manual Transmission ~ GENERAL PROCEDURES ~ Bearings - Inspection ~ IN-VEHICLE REPAIRS ~ Seal ~ Gearshift Lever and Boot ~ Gearshift Boot and retainer Assembly ~ REMOVAL ~ Transmission ~ DISASSEMBLY ~ Transmission ~ DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES ~ Input Shaft and Bearing ~ Output Shaft ~ Countershaft Bearing ~ Synchronizers ~ Gearshift Rail Bushing ~ Gearshift Rail and Fork ~ ]
  • SECTION : 308-06 Manual Transmission External Controls [ Specifications ~ DIAGNOSIS AND TESTING ~ External Controls ~ Inspection and Verification ~ Symptom Chart ~ Pinpoint Tests ~ REMOVAL AND INSTALLATION ~ Gearshift Lever ~ Gearshift Boot and Retainer Assembly ~ ]
  • SECTION : 309-00 Exhaust System [ Specifications ~ DESCRIPTION AND OPERATION ~ Exhaust System ~ DIAGNOSIS AND TESTING ~ Exhaust System ~ Inspection and Verification ~ Pinpoint Tests ~ GENERAL PROCEDURES ~ Exhaust System Alignment ~ REMOVAL AND INSTALLATION ~ All Rear Muffler Assemblies ~ All Intermediate Muffler Assemblies ~ 6 Cylinder Catalyst Assembly ~ 8 Cylinder Catalyst Assemblies (LHS & RHS) ~ 8 Cylinder Y - Pipe Assemblies ~ System Diagrams ~ ]
  • SECTION : 310-00 Fuel System [ Specifications ~ DESCRIPTION AND OPERATION ~ Fuel System ~ Electrical Fuel Pump ~ Evaporative Emission Control System ~ Fuel Filters ~ Fuel system shut off switch ~ Fuel pressure regulator ~ DIAGNOSIS AND TESTING ~ Fuel System ~ Inspection and Verification ~ Symptom Chart ~ Pinpoint Tests ~ GENERAL PROCEDURES ~ Pump Operation Check ~ Pressure Test ~ Fuel Flow (Volume) Test ~ Draining Fuel ~ Purge Control Valve Testing ~ REMOVAL AND INSTALLATION ~ Fuel Tank (Sedan) ~ Fuel Tank (Wagon) ~ Fuel Tank (Ute) ~ In - Line Filter ~ Fuel Supply and Fuel Return Lines ~ Vapour Lines ~ Carbon Canister ~ Fuel Module - Fuel Pump ~ Sender Assembly ~ Fuel Shut Off Switch ~ ]
  • SECTION : 310-02 Acceleration Control [ Specifications ~ DESCRIPTION AND OPERATION ~ Acceleration Control ~ Acronyms and Abbreviations ~ DIAGNOSIS AND TESTING ~ Acceleration Control ~ Inspection and Verification ~ Symptom Chart ~ Connector Circuit Reference ~ Pinpoint Tests ~ REMOVAL AND INSTALLATION ~ Accelerator Pedal and APM unit - Adjustable Pedals ~ Accelerator Pedal and APM unit - Fixed Pedals ~ Adjustable Pedal Indexing ]

and more!

Download free [CAUTION OVER 100 MB FILE!] 2003 Ford BA Falcon Service Manual.pdf (2089 pages pdf file, 148 MB).

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