Ford AU Fairmont 1998-2002 Service & Repair Workshop Manual
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🏷️ Basic Information Identification Make: Ford Model: Fairmont Generation: AU Model Years: 1998-2002 👋 Introduction Market Position Target Audience: Ford AU Fairmont owners, DIY enthusiasts, independent mechanics, and professional technicians. Competitive Analysis Value Proposition: Provides factory-level repair information for lifetime use, eliminating the need for costly dealership services or subscription-based digital manuals. Key Features Content Quality: Authentic factory documentation ensures accuracy and completeness of repair procedures. Accessibility: Instant download and cross-platform compatibility allow for immediate access to critical repair data. 📋 Manual Details Coverage Areas Vehicle Make: Ford Vehicle Model: Fairmont Vehicle Generation: AU Series I, II, III Vehicle Years Covered: 1998, 1999, 2000, 2001, 2002 Page Count Estimated Pages: Hundreds (specific count not provided, but described as 'hundreds of pages') Manual Type Type: Factory Service and Repair Workshop Manual Language Language: English Format Format: Downloadable PDF 📖 Manual Coverage Systems Covered Engine Mechanical: Complete overhaul, diagnosis, and repair of all engine variants Engine Management: Fuel injection, ignition systems, emissions control, ECU diagnostics Transmission Manual: Service, repair, and overhaul of manual gearboxes Transmission Automatic: Service, repair, and overhaul of automatic transmissions, including valve body and torque converter Drivetrain: Front-wheel drive components, driveshafts, CV joints, differentials Suspension: Front and rear suspension systems, shock absorbers, springs, control arms, wheel alignment Steering: Power steering system, steering rack, steering column, wheel alignment Brakes: Disc and drum brake systems, ABS, hydraulic components, brake fluid service Electrical System: Battery, charging system, starting system, lighting, wipers, horns Body And Chassis: Body panel repair, interior trim, doors, windows, sunroof, chassis components HVAC: Air conditioning, heating, ventilation system diagnosis and repair Fuel System: Fuel pump, fuel injectors, fuel tank, fuel lines, evaporative emissions control Cooling System: Radiator, water pump, thermostat, coolant hoses, fan assembly Exhaust System: Exhaust manifold, catalytic converter, mufflers, pipes, hangers Safety Systems: Airbag system diagnosis and replacement, seatbelt mechanisms Procedures Included Routine Maintenance: Oil changes, filter replacements, fluid checks, tire rotation, spark plug replacement Troubleshooting: Diagnostic procedures for common and uncommon faults, symptom-based troubleshooting guides Component Repair: Step-by-step instructions for component removal, repair, and reinstallation Electrical Diagnostics: Wiring diagrams, circuit testing, component testing procedures Engine Rebuild: Detailed instructions for engine disassembly, inspection, and reassembly with specifications Transmission Rebuild: Detailed instructions for transmission disassembly, inspection, and reassembly with specifications Bodywork Repair: Procedures for dent repair, panel replacement, rust treatment, and painting preparation HVAC Service: Refrigerant handling, leak detection, component replacement, and system flushing Software Updates: Information on ECU reprogramming and software updates for relevant modules (if applicable) Technical Depth Depth: Comprehensive: Covers basic maintenance to complete engine and transmission rebuilds, including advanced diagnostics. Detail Level: Highly detailed with step-by-step instructions, hundreds of pages, detailed photos, and diagrams. 📊 Manual Specifications File Format Format: PDF Compatibility: Windows and MAC computers Searchability: Likely searchable text within PDF (implied by comprehensive nature) Print Quality Printable: Yes, single pages or entire manual Binding Type Binding: Not Applicable (Digital PDF Download) Paper Type Paper Type: Not Applicable (Digital PDF Download) Licensing Usage Rights: Lifetime use on multiple devices, no expiry or renewal fees ⚙️ Engine Specifications Primary Engine Engine Options Au: 3.3L & 3.8L naturally aspirated V6 (Vortec-derived architecture), 5.0L V8 (Windsor architecture), 4.0L inline-6 (Barra evolution). Performance V6 Power 3.3L: Approx. 115 kW (154 hp) @ 4800 rpm V6 Torque 3.3L: Approx. 270 Nm (199 lb-ft) @ 3000 rpm V6 Power 3.8L: Approx. 140 kW (188 hp) @ 4800 rpm (Naturally Aspirated), 175 kW (235 hp) @ 4800 rpm (Supercharged) V6 Torque 3.8L: Approx. 330 Nm (243 lb-ft) @ 3200 rpm (Naturally Aspirated), 380 Nm (280 lb-ft) @ 3200 rpm (Supercharged) V8 Power 5.0L: Approx. 175 kW (235 hp) @ 4800 rpm V8 Torque 5.0L: Approx. 375 Nm (277 lb-ft) @ 3200 rpm I6 Power 4.0L: Approx. 157 kW (211 hp) @ 5000 rpm I6 Torque 4.0L: Approx. 360 Nm (266 lb-ft) @ 3000 rpm Fuel System Injection Type: Electronic Fuel Injection (EFI) Fuel Type: Unleaded Petrol (Octane rating as per manufacturer recommendation, typically 91 RON) 🔧 Transmission Standard Standard Transmission: 4-speed Automatic (4HP22/4HP24, ZF sourced for some variants) or 5-speed Manual Optional Optional Transmission: 4-speed Automatic (AX47, AX48, AX4N, 4R55E) Features Auto Modes: Selectable modes (e.g., Economy, Sport) on some automatic transmissions. 📐 Dimensions Exterior Wheelbase: Approx. 2790 mm (109.8 inches) Length: Approx. 4810-4900 mm (189.4-192.9 inches) depending on body style Width: Approx. 1790-1815 mm (70.5-71.5 inches) Height: Approx. 1430-1460 mm (56.3-57.5 inches) Weights Curb Weight: Approx. 1500-1700 kg (3307-3748 lbs), varies by engine and options 🛡️ Safety Features Ratings Australian Ancap Rating: AU Fairmont generally received 3-4 star ANCAP ratings for its era, depending on specific features and testing protocols. (Requires verification for exact model year). Active Features ABS: Anti-lock Braking System standard on most models. Passive Features Airbags: Driver and front passenger airbags standard on most models. Side airbags optional on some later models. Seatbelts: Front and rear...
Unleaded Petrol (Octane rating as per manufacturer recommendation, typically 91 RON)
🔧 Transmission
Standard
Standard Transmission:
4-speed Automatic (4HP22/4HP24, ZF sourced for some variants) or 5-speed Manual
Optional
Optional Transmission:
4-speed Automatic (AX47, AX48, AX4N, 4R55E)
Features
Auto Modes:
Selectable modes (e.g., Economy, Sport) on some automatic transmissions.
📐 Dimensions
Exterior
Wheelbase:
Approx. 2790 mm (109.8 inches)
Length:
Approx. 4810-4900 mm (189.4-192.9 inches) depending on body style
Width:
Approx. 1790-1815 mm (70.5-71.5 inches)
Height:
Approx. 1430-1460 mm (56.3-57.5 inches)
Weights
Curb Weight:
Approx. 1500-1700 kg (3307-3748 lbs), varies by engine and options
🛡️ Safety Features
Ratings
Australian Ancap Rating:
AU Fairmont generally received 3-4 star ANCAP ratings for its era, depending on specific features and testing protocols. (Requires verification for exact model year).
Active Features
ABS:
Anti-lock Braking System standard on most models.
Passive Features
Airbags:
Driver and front passenger airbags standard on most models. Side airbags optional on some later models.
Seatbelts:
Front and rear seatbelts with pre-tensioners for front occupants.
💡 Technology Features
Infotainment
Audio System:
Factory fitted AM/FM radio with CD player and/or cassette player. Optional premium sound systems with amplifier.
Driver Assistance
Cruise Control:
Standard cruise control on most models.
Connectivity
Phone Integration:
No integrated Bluetooth or smartphone connectivity on models from this era. Aftermarket solutions available.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically 10,000 km or 6 months, whichever comes first, depending on engine oil type and driving conditions.
Spark Plug Replacement:
Varies by engine, e.g., 40,000 km for standard plugs, 100,000 km for platinum/iridium plugs (refer to manual for specific engine).
Transmission Fluid Change:
Automatic transmission fluid change typically every 60,000 km or 4 years. Manual transmission fluid inspection/change as per manual recommendations.
Fluid Specifications
Engine Oil Type:
API SG/SH/SJ or higher, SAE 10W-30 or 10W-40 recommended (check manual for specific engine and climate).
Coolant Type:
Ethylene glycol-based coolant, typically a 50/50 mix with deionized water. Ford recommends specific coolant formulations (e.g., Motorcraft® Gold Coolant).
Brake Fluid Type:
DOT 3 or DOT 4 brake fluid.
Power Steering Fluid:
Dexron III ATF or equivalent power steering fluid.
Known Issues
Interior Trim Wear:
Pitting or delamination of interior plastics, wear on steering wheel and shifter boots, particularly on higher mileage vehicles.
Window Regulator Failure:
Common failure of electric window regulators leading to windows not operating.
Tailshaft Vibration:
Vibrations, particularly under acceleration, can be due to worn universal joints or driveshaft imbalance.
Radiator Leaks:
Leaking plastic tanks on the radiator, especially at the top and bottom seams.
Ignition Coil Pack Failure:
Failure of ignition coil packs, leading to misfires and rough running, particularly on V6 engines.
📚 Vehicle History
Brand Heritage
Ford Australia:
Ford Australia has a long history of producing iconic vehicles tailored to Australian conditions, with the Fairmont representing a step up in luxury and refinement from the Falcon.
Model Evolution
Au Fairmont Launch:
The AU Falcon and Fairmont range replaced the AU Falcon, marking a significant departure in styling and engineering with a focus on European influences.
Au Series Updates:
The AU range underwent series updates (Series II, Series III) to address market feedback, improve styling, and introduce new features.
Production
Manufacturing Location:
Broadmeadows, Victoria, Australia
🏆 Awards & Recognition
Recognitions
Local Market Awards:
The AU Falcon/Fairmont range received some criticism for its styling upon release but was recognized for its improved dynamics and technology by Australian automotive journalists.
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