Ford Falcon. Manual — part 189

303-04c-44

Single Fuel LPG

303-04c-44

DISASSEMBLY AND ASSEMBLY (Continued)

10. Back cover, back cover gasket and second stage

1. Second stage lever pin. Lubricate pin with

diaphragm. Discard diaphragm and gasket.

molybdenum grease only .

NOTE: Re-Assembly will be easier if the

2. Reinstall second stage shield.

converter studs remain on the main bracket and

3. Second stage lever spring, button and cap.

the converter body (minus the rear cover) is

Ensure spring is correctly is seated.

gently pulled from the studs.

4. Coolant chamber gasket. Install second stage pin

11. Second stage pin. Discard pin.

guide bush to second stage body section.

12. Front cover, front cover gasket and sensitive

5. Coolant chamber gasket support and second

diaphragm. Discard gasket and sensitive

stage body section onto first stage body section.

diaphragm.

Use eight studs to hold diaphragm in place while

assembling.

13. Sensitive diaphragm support plate and gasket.

Discard gasket.

NOTE: Position longer mounting studs in original

location, ensure gasket is not binding.

14. Two idle body section bolts.

NOTE: Beware of primary spring pressure.

6. Second stage body section bolts.
7. Second stage lever pin. Lubricate pin with

15. Separate idle body section from first stage body

molybdenum grease only .

section.

8. Second stage diaphragm gasket cover and gasket

16. First stage diaphragm assembly primary lever

paper.

assembly at the same time by lifting diaphragm

and removing screws. Separate assembly and

NOTE: Install large disc of second stage

discard first stage diaphragm, washers and first

diaphragm towards body section.

stage lever assembly. Remove and discard

9. Idle jet, O-Ring, and seat in body section use tool

O-Ring and idle transfer tube.

303-689.

17. First stage cover and screw.

NOTE: Use same type of idle jet as removed.

NOTE: Do not remove the first stage nozzle from

Bevelled edge of seat should be towards ejector.

the housing.

Push in until firmly seated.

18. Second stage body section bolts.

NOTE: 0.8mm idle jet has a machined groove in

it.

19. Separate second stage body section from first

stage body section. Retain water chamber gasket 10. Spring idle seat with O-Ring and idle lock off

support. Discard water chamber gasket.

assembly.

20. Cap, spring button and second stage spring.

11. First stage lever assembly and screws.

21. Second stage lever assembly and screws.

12. O-Ring and idle transfer tube. Take care when

Discard second stage lever seat.

assembling body’s that transfer tube does not

22. Bolt and water pipe bracket (not shown on

dislodge.

exploded view).

13. First stage cover with screw.

23. Inlet and outlet coolant connectors (not shown on 14. First stage diaphragm assembly and spring.

explored view). Discard coolant connecters

Install spring with small end towards diaphragm.

O-Rings.

NOTE: Slide retainer over end of first stage lever.

NOTE: Clean coolant connector openings in first

LUBRICATE RETAINER WITH MOLYBDENUM

stage body section with 22mm or 7/8" round wire

GREASE ONLY.

brush. Clean coolant connectors and especially

15. Idle body section to first stage body section and

the grooves for the O-Rings.

two idle body section bolts.

24. Remove and discard filter and O-Rings.

16. Sensitive diaphragm support plate gasket into

25. Remove and discard second stage pin guide

sensitive diaphragm support plate.

bush.

17. Sensitive diaphragm support plate and screw.

NOTE: Use a punch that is smaller than the guide

18. Sensitive diaphragm, gasket, front cover, and

bush.

nuts.

NOTE: Clean all parts with solvent or mineral

NOTE: Prime valve retaining bracket.

spirits. Do not use carburator cleaner or lacquer

thinner.

19. Main solenoid.
20. 0-rings on coolant fittings (not shown).

Assembly

21. Lower and upper coolant fitting into first stage

NOTE: It is advised to use oil (Shell R-10) or acid free

body section. The coolant in connector has two

vaseline on all O-Rings prior to assembly.

alignment K.

G86742 en

303-04c-45

Single Fuel LPG

303-04c-45

DISASSEMBLY AND ASSEMBLY (Continued)

22. Bracket and screw to retain water pipes in place

(not shown).

1. Prime hose from stepper motor to prime

valve.

2. Stepper motor retaining bolts and stepper

motor with new O-Ring.

3. Solenoid coil and plunger from prime valve

with new O-Ring and plunger.

4. Prime valve retaining bracket.

Idle Jet

Disassembly
1. Remove idle solenoid (8mm headed bolt).
2. Remove idle solenoid stem (17mm). Take care

that the idle seat does not eject due to spring

pressure.

3. Remove idle seat carefully as seat can be easily

damaged.

4. Remove idle jet using removing tool (No.

303-689).

5. Clean idle jet with high pressure air in both

directions. Usual precautions should be taken

when using high pressure air.
NOTE: Never blow the idle jet while it is still

installed in the converter.

Assembly
1. Reassemble in the reverse order.

G86743 en

303-05-1 Accessory

Drive 303-05-1

SECTION : 303-05 Accessory Drive

VEHICLE APPLICATION : 2003.0 BA Falcon
CONTENTS

PAGE

SPECIFICATIONS

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303-05-2

DESCRIPTION AND OPERATION

Accessory Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303-05-3

Belt Tensioner - I6 & V8 . . . . . . . . . . . . . . . . . . . . . . . . . . .303-05-3

Water Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..303-05-4

DIAGNOSIS AND TESTING

Accessory Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303-05-5

Inspection and Verification . . . . . . . . . . . . . . . . . . . . . . . . ...303-05-5

Symptom

Chart

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303-05-5

Belt

Tensioner

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..303-05-5

REMOVAL AND INSTALLATION

Accessory Drive Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . .303-05-6

Accessory Drive Belt Tensioner . . . . . . . . . . . . . . . . . . . . . . . 303-05-6

Accessory Drive Belt Idler Pulley . . . . . . . . . . . . . . . . . . . . . . ..303-05-6

303-05-2 Accessory

Drive 303-05-2

SPECIFICATIONS

General Specifications

Description

Specification

Sealer

ESZ - M4G281 - A

Torque Specifications

Description

Nm

Accessory drive belt tensioner bolt -

25

4.0L I6
Accessory drive belt idler pulley bolt

25

- 4.0L I6
Water pump bolts - 4.0L I6

20

G97110 en