Ford Falcon. Manual — part 4

100-00-13 General

Information 100-00-13

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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100-00-14 General

Information 100-00-14

DESCRIPTION AND OPERATION (Continued)

the battery is disconnected if working on the

do not work on the fuel lines or system

engine.

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

CAUTION: A discharged battery condition

may have been caused by an electrical short

do not vent off LPG fuel

circuit. If this condition exists there will be an

do not use shop air pressure to force LPG fuel

apparently live circuit on the vehicle even when all

from the fuel tank

normal circuits are switched off. This can cause

do not use paint drying ovens above 40

°C for any arcing when the jumper cables are connected.

alternative fuel vehicles. LPG and CNG fuel tanks

should be removed from the vehicles prior to

CAUTION: While it is not recommended that

being put into paint drying ovens above 40

°C

the vehicle is jump started, it is recognized that

do not modify the system or install new

this may occasionally be the only practical way to

components with parts not designed for gas

mobilize a vehicle. In such an instance the

vehicles

discharged battery must be recharged

immediately after jump starting to avoid

do not evacuate fuel tanks unless there is repair

permanent damage.

that requires removed of the fuel tank

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100-00-15 General

Information 100-00-15

DESCRIPTION AND OPERATION (Continued)

Always make sure that the jumper cables are

Component Cleaning

adequate for the task. Heavy duty cables must be

To prevent ingress of dirt, accumulations of loose dirt

used.

and greasy deposits should be removed before

Always make sure that the slave battery is of the

disconnecting or dismantling components or

same voltage as the vehicle battery. The batteries assemblies.

must be connected in parallel.

Components should be thoroughly cleaned before

Always make sure that switchable electric circuits inspection prior to reassembly.

are switched off before connecting jumper cables.

This reduces the risk of arcing occurring when the

Cleaning Methods:

final connection is made.

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

WARNING: Most solvents require careful

jumper cables do not touch each other or ground

handling and some are harmful. Refer to Health

against the vehicle body at any time while the

and Safety Precautions and to the manufacturers

cables are attached to the battery. A fully charged

literature for safety precautions. Failure to follow

battery, if shorted through jumper cables, can

these instructions may result in personal injury.

discharge at a rate well above 1000 amps causing

Various solvents are available which are suitable for

violent arcing and very rapid heating of the

component cleaning. Some components such as

jumper cables and terminals, and can even cause

brake hydraulic parts and electrical assemblies should

the battery to explode. Failure to follow these

be cleaned only with recommended solvents — refer

instructions may result in personal injury.

to Solvents, Sealers and Adhesives or to the section

Always connect the jumper cables in the following

of the manual relevant to the component.

sequence:

slave battery positive first then vehicle battery

Calibration of Essential Measuring

positive

Equipment

slave battery negative next and then vehicle

ground at least 12 inches (300 mm) from the

WARNING: Failure to follow these

battery terminal, for example engine lifting eye

instructions may result in personal injury or

Always reduce the engine speed to idle before

damage to components.

disconnecting the jumper cables.

It is of fundamental importance that certain essential

Before removing the jumper cables from the vehicle

equipment, for example torque wrenches,

that had the discharged battery, switch on the heater

multimeters, exhaust gas analysers or rolling roads,

blower (high) or the heated rear window, to reduce the are regularly calibrated in accordance with the

voltage peak when the cables are removed.

manufacturers instructions.

Always disconnect the jumper cables in the reverse

Solvents, Sealers and Adhesives

order to the connecting sequence and do not short

the ends of the cables.

Introduction

Do not rely on the generator to restore a discharged

battery. For a generator to recharge a battery, it would

WARNING: Always handle all solvents,

take in excess of eight hours continuous driving with

sealers and adhesives with extreme care. Some

no additional loads placed on the battery.

contain chemicals or give off fumes which can be

dangerous to health. Always follow the

manufacturers instructions. If in doubt about any

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100-00-16 General

Information 100-00-16

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.

General

SAM-1C-9107A
SAM-1C-9107A

Spark plug threads

ESE-M1244-A

Sealers

Application

Ford Spec.

Manufacturer and Identification

For camshaft bearing caps

ESK-M4G260-A

Loctite 518

For cylinder block

WSK-M4G320-A

Hylosil 502

For fitting rear lamp assembly

WSK-M4G329-ABC

For transmission housing (80 gram can)

Finis Code 6 160 443

Adhesives

Application

Ford Spec.

PU for windscreen, side and rear glass

Finis Code 6 997 259

Engine oil level

Road/Roller Testing

Engine coolant level

Road or roller testing may be carried out for various

Tires, for correct pressure, compatible types and

reasons and a procedure detailing pre-test checks,

tread patterns, and wear within limits.

through engine starting and stopping, pre-driving

There is sufficient fuel in the tank to complete the

checks, on-test checks to final checks on completion

test.

of the test is given overleaf.

All around the engine, transmission and under the

Unless complete vehicle performance is being

vehicle for oil, coolant, hydraulic and fuel leaks.

checked, the full road test procedure need not be

Make a note of any apparent leaks and wipe off

carried out. Instead, those items particularly relevant

the surrounding areas to make it easier to identify

to the system/s being checked can be extracted.

the extent of the leak on completion of the test.

Pre-Test Checks

Starting the Engine

NOTE: On initial drive away from cold and within the

WARNING: If the brake system hydraulic fluid

first 1.5 km (1 mile), do not depress accelerator pedal

level is low, pedal travel is excessive or a

beyond half travel until the vehicle has attained a

hydraulic leak is found, do not attempt to road

minimum speed of 25 km/h (15 miles/h). Never

test the vehicle until the reason for the low fluid

operate at high engine speed or with the accelerator

level, excessive pedal travel or hydraulic leak is

pedal at full travel whilst the engine is cold.

found and rectified.
It is suggested that pre-test checks, and functional

With the ignition switched off, check:

tests of those systems/circuits which affect the safe

The handbrake is applied.

and legal operations of the vehicle, such as brakes,

The gear lever is in neutral.

lights and steering, should always be carried out

before the road or roller test.

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