Ford Falcon. Manual — part 172
303-03-15 Engine
Cooling 303-03-15
REMOVAL AND INSTALLATION (Continued)
9. Remove the screws securing the fan shroud and
8 Cylinder
fans to the top of the radiator, lift the shroud from
the clips on the bottom of the radiator and lay it
back.
Item
Description
1
Hose assy. to bleed
10. Remove the radiator upper mounting brackets
2
Hose assy. Upper
and carefully lift the radiator from the vehicle.
3
Hose assy. Radiator overflow
Installation
3. On vehicles equipped with automatic transmission
1. Locate the radiator in the vehicle and install the
disconnect the oil cooler lines at the radiator by
upper support brackets.
unscrewing the AF 17mm fittings and plug to
2. Locate the fan shroud in the brackets on the
guard against contamination entry.
bottom of the radiator and install the two securing
4. Remove the air cleaner intake duct.
screws at the top of the shroud.
5. Remove
the
grille.
3. Connect the upper and lower hoses and the
6. XR6 Turbo vehicles: remove intercooler (see
coolant supply hose. Connect the bleed hose to
303-04b for procedure).
the radiator.
7. Remove the 4 bolts holding the A/C condenser
4. Connect the electrical connections to the fans.
and wire or cable tie the condenser to the top
5. Remove the support cable tie/wire from the top
crossmember.
condensor and install the 4 A/C condensor
mounting bolts
6. Install the air cleaner intake duct.
7. XR6 Turbo vehicles: install intercooler (see
303-04b for procedure).
8. Connect the oil cooler lines (auto only) do not
over tighten the fittings as this will demage the oil
cooler.
9. Install air cleaner intake duct.
10. Install the grille.
11. Fill the cooling system as described in General
Procedures Section.
8. Disconnect the electrical connections to the fans.
G97842 en
303-03-16 Engine
Cooling 303-03-16
REMOVAL AND INSTALLATION (Continued)
3. Insert a new ‘C’ Spring Clip. Do not re-use the old
Fan
clip.
Removal
4. Rotate fan (in the direction of normal operation) to
ensure it rotates freely.
1. Remove fan and shroud from vehicle.
5. Install fan and shroud assembly into vehicle.
Radiator Hose
Removal and Installation
NOTE: Radiator hoses should be replaced whenever
they become cracked, rotted or have a tendency to
collapse, See Draining and Filling the Cooling
System.
1. Drain radiator: then loosen the clamps at each
end of hose to be removed. Slide hose off radiator
connection and the cylinder head water outlet or
water pump connection.
2. Position the clamps and hoses as shown in the
applicable installation in this chapter. Tighten
Item
Description
clamps.
1
Condensor assy.
3. Fill coolant supply tank to the “FULL/MAX” mark.
2
Radiator assy.
4. Fill and bleed the cooling system as described in
3
Motor and Fan assy.
Draining and Filling the Cooling System in this
4
Screw and washer assy.
section.
NOTE: The hose clamps initial factory fit make
2. Lay the assembly flat.
use of a torque limiting cap that’s drive shears off
3. Remove and discard the ‘C’ Spring Clip by gently
once the torque valve is reached.
sliding sideways.
For service remove the cap body by prying off to
4. Gently prise drive plate from cavity.
reveal the hand tool drive feature.
5. Remove
fan.
Install the hose clamps as close as possible to the
bead on the inlet and outlet pipes. Use only Ford
approved hoses and clamps when replacement is
necessary. Clamps with a “ bow spring‘‘ show
improved resistance to compression set of the
rubber hoses
Coolant Supply Tank
Removal
1. Remove supply tank cap and loosen radiator
drain tap and drain cooling system until no coolant
remains in the supply tank.
2. Remove the bleed tubes found on upper surface
of supply tank.
Item
Description
1
Shroud
2
Fan
3
Drive plate
4
‘C’ Spring clip
5
Screw
6
Motor
Installation
1. Place fan on spindle.
2. Install drive plate ensuring locating peg fits into
hole correctly.
G97842 en
303-03-17 Engine
Cooling 303-03-17
REMOVAL AND INSTALLATION (Continued)
3. Remove the two bolts which retain the supply tank
6 Cylinder
to the vehicle and release the leg to the RH
suspension tower.
Item
Description
1
Hose assy. Upper
Item
Description
2
Hose assy. Bleed
1
Supply tank cap
3
Hose to engine vent
2
Screw
8 Cylinder
4. Remove coolant feed hose on side surface of
supply tank.
Installation
1. Remove supply tank cap.
2. Position coolant feed hose onto supply tank.
3. Position supply tank in vehicle and tighten coolant
feed hose.
4. Attach supply tank to vehicle using the locating
leg and two attaching screws.
5. Attach bleed tubes to the top of the supply tank.
6. Fill the supply tank with coolant as described in
General Procedures Section.
Item
Description
1
Hose assy. to bleed
2
Hose assy. Upper
3
Hose assy. Radiator overflow
G97846 en
303-04b-1
Fuel Charging and Controls — Turbocharger
303-04b-1
SECTION : 303-04b Fuel Charging and Controls —
Turbocharger
VEHICLE APPLICATION : 2003.0 BA Falcon
CONTENTS
PAGE
SPECIFICATIONS
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...303-04b-2
DESCRIPTION AND OPERATION
Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303-04b-3
Boost
Control
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .303-04b-3
Charge Air Cooler (Intercooler) . . . . . . . . . . . . . . . . . . . . . . ..303-04b-4
Heatshielding
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .303-04b-5
DIAGNOSIS AND TESTING
Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303-04b-6
Inspection and Verification . . . . . . . . . . . . . . . . . . . . . . . . .303-04b-6
Symptom
Chart
. . . . . . . . . . . . . . . . . . . . . . . . . . . . ..303-04b-6
Pinpoint
Tests
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303-04b-7
REMOVAL AND INSTALLATION
Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..303-04b-16
Boost Pressure Sensor . . . . . . . . . . . . . . . . . . . . . . . . . ..303-04b-20
Wastegate Control Solenoid (WCS) . . . . . . . . . . . . . . . . . . . . .303-04b-21
Charge Air Cooler (Intercooler) . . . . . . . . . . . . . . . . . . . . . . ..303-04b-21
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