1998-2002 Ford AU Falcon (AU Fairmont) Mark I Mark II Mark III Workshop Repair Service Manual Best -130MB
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๐ท๏ธ Basic Information Identification Make: Ford Model: Falcon (AU Series) Alternate Model Designation: Fairmont (AU Series) Model Generations Covered: AU Series (Mark I, Mark II, Mark III) Production Years Covered: 1998, 1999, 2000, 2001, 2002 Codes Vin Decoder Prefix Au Falcon: N/A (VIN structure varies, specific decoder required) ๐ Introduction Market Position Segment: Large Family Sedan / Luxury Sedan (Fairmont variant) Target Audience: Owners, DIY enthusiasts, mechanics, restorers of 1998-2002 Ford AU Falcon and Fairmont models. Competitive Analysis Key Competitors Era: Holden Commodore (VT/VX), Toyota Avalon, Mitsubishi Magna, Nissan Maxima. Key Features Content Richness: Extremely detailed, covering all aspects of repair and maintenance. Visual Aid Quality: High Quality Photos, Illustrations, and Diagrams. Usability: Easy to use, printable for practical workshop application. ๐ Manual Details Coverage Areas Primary Coverage: Workshop Repair and Service Secondary Coverage: Maintenance, Diagnostics, Rebuild, Refurbishment, Restoration Page Count Estimated Page Count: Likely extensive, exceeding 1000 pages (based on typical workshop manuals of this era and scope). Manual Type Type: Digital Workshop Repair Service Manual Language Language: English Format Format: PDF (Portable Document Format) File Size Mb: 130 ๐ Manual Coverage Systems Covered Powertrain: Engine Mechanical, Lubrication System, Cooling System, Engine Control System, Fuel System, Exhaust System, Clutch, Manual Transaxle, Automatic Transaxle Drivetrain Suspension Brakes: Front Axle, Rear Axle, Front Suspension, Rear Suspension, Road Wheels & Tires, Brake System, Parking Brake System, Brake Control System Steering Restraints: Power Steering System, Steering System, Seat Belts, Supplemental Restraint System (SRS) Body Comfort Electrical: Body, Lock & Security System, Glasses, Window System & Mirrors, Roof, Exterior & Interior Trim, Instrumental Panel, Seats, Air Conditioner System, Wiring Diagrams, Starting & Charging System, Lighting System, Driver Information System, Wiper, Washer & Horn, Body Control System, LAN System, Audio Visual, Navigation & Telephone System, Auto Cruise Control System, Power Supply, Ground & Circuit Elements Procedures Included Diagnostics Troubleshooting: Comprehensive diagnostic and repair procedures for all systems. Maintenance Routine: All maintenance procedures. Repair Rebuild: Detailed repair and rebuild procedures for major components. Refurbishment Restoration: Guidance applicable to refurbishing and restoring the vehicle. Technical Depth Depth: Professional Technician and Mechanic Level - covers everything from basic maintenance to in-depth diagnostics and repair. ๐ Manual Specifications File Format Type: PDF Searchability: Likely searchable text within the PDF. Print Quality Printability: Printable pages, allowing for hard copy reference. Binding Type Binding: N/A (Digital Format - No physical binding) Paper Type Paper: N/A (Digital Format - No physical paper) Content Completeness Completeness Statement: 100% complete and intact, no missing/corrupt pages/sections. โ๏ธ Engine Specifications Primary Engine Base Engine Common Au Falcon: 3.3L (3300cc) OHV V6 (Ecotec 'Vortec' derivative from GMH, branded as 'Duratec' by Ford Australia in some contexts, though this is more common on later models. The AU series commonly used the Barra family of inline-6 engines later in its life cycle. Early AU likely uses the Windsor V8 and potentially an earlier Ford inline-6. *Clarification needed based on specific engine code.*) Optional Engines: 4.0L (3984cc) SOHC I6 (Barra 182, Barra 220), 5.0L (302 cu in / 4942cc) OHV V8 (Windsor - particularly early AU), 5.4L (330 cu in / 5408cc) SOHC V8 (Triton - later AU variants). Performance Horsepower Range Estimated: Approximately 160-180kW for 4.0L I6, 175kW for 5.0L V8, 220kW for 4.0L I6 (Barra 220), 240kW for 5.4L V8. Torque Range Estimated: Approximately 300-350 Nm for 4.0L I6, 370-380 Nm for 5.0L V8, 370 Nm for Barra 182, 420 Nm for Barra 220, 470 Nm for 5.4L V8. Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) - Multi-point or Sequential depending on engine. Fuel Type: Unleaded Petrol (ULP) ๐ง Transmission Standard Transmission Options: 4-speed Automatic, 5-speed Manual. Optional Transmission Options Premium: 5-speed automatic (e.g., 5R50W for V8s), 6-speed manual (less common for AU series). Features Automatic Features: Electronic control, often with 'Sport' or 'Economy' modes depending on variant. ๐ Dimensions Exterior Body Styles: Sedan, Station Wagon, Utility (Ute). Length Sedan Approx Mm: 4944 Wheelbase Mm: 2790 Weights Kerb Weight Kg Approx: 1550 - 1750 (depending on body style and engine) ๐ก๏ธ Safety Features Ratings Ancap Rating Era: Pre-ANCAP star rating system for early models. Later models would have undergone testing under evolving standards. Active Features ABS: Available on higher trims or as an option. Passive Features Airbags: Driver airbag standard. Passenger airbag optional or standard on Fairmont/higher trims. Seatbelts: Pre-tensioned front seatbelts. ๐ก Technology Features Infotainment Audio System: Factory fitted AM/FM Radio Cassette Player or CD Player. Optional premium sound systems on Fairmont models. AUX input not standard. Driver Assistance Cruise Control: Available as standard on higher trims or as an option on lower trims. Connectivity Bluetooth: Not available as standard. Aftermarket solutions are common. Navigation: Rarely factory fitted, typically only on top-tier Fairmont Ghia or as a dealer-fitted accessory. ๐ง Maintenance Service Intervals Oil Change Interval Typical: 10,000 km or 6 months (whichever comes first). Major...
Front Axle, Rear Axle, Front Suspension, Rear Suspension, Road Wheels & Tires, Brake System, Parking Brake System, Brake Control System
Steering Restraints:
Power Steering System, Steering System, Seat Belts, Supplemental Restraint System (SRS)
Body Comfort Electrical:
Body, Lock & Security System, Glasses, Window System & Mirrors, Roof, Exterior & Interior Trim, Instrumental Panel, Seats, Air Conditioner System, Wiring Diagrams, Starting & Charging System, Lighting System, Driver Information System, Wiper, Washer & Horn, Body Control System, LAN System, Audio Visual, Navigation & Telephone System, Auto Cruise Control System, Power Supply, Ground & Circuit Elements
Procedures Included
Diagnostics Troubleshooting:
Comprehensive diagnostic and repair procedures for all systems.
Maintenance Routine:
All maintenance procedures.
Repair Rebuild:
Detailed repair and rebuild procedures for major components.
Refurbishment Restoration:
Guidance applicable to refurbishing and restoring the vehicle.
Technical Depth
Depth:
Professional Technician and Mechanic Level - covers everything from basic maintenance to in-depth diagnostics and repair.
๐ Manual Specifications
File Format
Type:
PDF
Searchability:
Likely searchable text within the PDF.
Print Quality
Printability:
Printable pages, allowing for hard copy reference.
Binding Type
Binding:
N/A (Digital Format - No physical binding)
Paper Type
Paper:
N/A (Digital Format - No physical paper)
Content Completeness
Completeness Statement:
100% complete and intact, no missing/corrupt pages/sections.
โ๏ธ Engine Specifications
Primary Engine
Base Engine Common Au Falcon:
3.3L (3300cc) OHV V6 (Ecotec 'Vortec' derivative from GMH, branded as 'Duratec' by Ford Australia in some contexts, though this is more common on later models. The AU series commonly used the Barra family of inline-6 engines later in its life cycle. Early AU likely uses the Windsor V8 and potentially an earlier Ford inline-6. *Clarification needed based on specific engine code.*)
Optional Engines:
4.0L (3984cc) SOHC I6 (Barra 182, Barra 220), 5.0L (302 cu in / 4942cc) OHV V8 (Windsor - particularly early AU), 5.4L (330 cu in / 5408cc) SOHC V8 (Triton - later AU variants).
Performance
Horsepower Range Estimated:
Approximately 160-180kW for 4.0L I6, 175kW for 5.0L V8, 220kW for 4.0L I6 (Barra 220), 240kW for 5.4L V8.
Torque Range Estimated:
Approximately 300-350 Nm for 4.0L I6, 370-380 Nm for 5.0L V8, 370 Nm for Barra 182, 420 Nm for Barra 220, 470 Nm for 5.4L V8.
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI) - Multi-point or Sequential depending on engine.
Fuel Type:
Unleaded Petrol (ULP)
๐ง Transmission
Standard
Transmission Options:
4-speed Automatic, 5-speed Manual.
Optional
Transmission Options Premium:
5-speed automatic (e.g., 5R50W for V8s), 6-speed manual (less common for AU series).
Features
Automatic Features:
Electronic control, often with 'Sport' or 'Economy' modes depending on variant.
๐ Dimensions
Exterior
Body Styles:
Sedan, Station Wagon, Utility (Ute).
Length Sedan Approx Mm:
4944
Wheelbase Mm:
2790
Weights
Kerb Weight Kg Approx:
1550 - 1750 (depending on body style and engine)
๐ก๏ธ Safety Features
Ratings
Ancap Rating Era:
Pre-ANCAP star rating system for early models. Later models would have undergone testing under evolving standards.
Active Features
ABS:
Available on higher trims or as an option.
Passive Features
Airbags:
Driver airbag standard. Passenger airbag optional or standard on Fairmont/higher trims.
Seatbelts:
Pre-tensioned front seatbelts.
๐ก Technology Features
Infotainment
Audio System:
Factory fitted AM/FM Radio Cassette Player or CD Player. Optional premium sound systems on Fairmont models. AUX input not standard.
Driver Assistance
Cruise Control:
Available as standard on higher trims or as an option on lower trims.
Connectivity
Bluetooth:
Not available as standard. Aftermarket solutions are common.
Navigation:
Rarely factory fitted, typically only on top-tier Fairmont Ghia or as a dealer-fitted accessory.
๐ง Maintenance
Service Intervals
Oil Change Interval Typical:
10,000 km or 6 months (whichever comes first).
Major Service Interval Typical:
40,000 km or 24 months (includes spark plugs, filters etc.).
Fluid Specifications
Engine Oil Specification Typical:
API SG/SH or ACEA A1/A2. Viscosity typically 5W-30, 10W-30, or 10W-40 depending on climate and engine. Consult manual for exact specification.
Coolant Specification:
Ethylene Glycol based coolant, typically a 50/50 mix with distilled water. Specific Ford specifications apply (e.g., Ford Premium Coolant).
Transmission Fluid Atf Automatic:
Mercon V or equivalent for later 5-speed autos. Mercon or Mercon II for 4-speed autos. Consult manual for specific type and capacity.
Known Issues
Common Rear Suspension Issue:
Cracking or failure of the Watts Linkage mounting points, particularly on heavy-duty variants or with spirited driving. Requires reinforcing or repair.
Common Body Paint Issue:
Clear coat peeling, especially on plastic bumpers and door handles, due to age and UV exposure.
Common Electrical Issue:
Intermittent issues with body control modules, door locks, or window regulators, especially with high mileage. Check wiring looms for damage.
Common Engine Wear Item:
Timing chain wear on some early Barra engines (though less prevalent than later generations). Spark plug replacement is crucial.
๐ Vehicle History
Brand Heritage
Ford Australia Legacy:
The AU Falcon represented a significant departure from previous Falcon generations, aiming for a more global aesthetic. It was a key model in Ford Australia's product line for a crucial period.
Model Evolution
Mark I Introduction:
Launched in 1998, featuring a distinctive 'flattened egg' design language and significant platform changes for improved ride and handling.
Mark Ii Update:
Released in late 1999/early 2000, with styling revisions, improved interior and updated engine options (e.g., introduction of the more powerful Barra I6 engines).
Mark Iii Update:
Launched in late 2001/early 2002, featuring further styling refinements, updated features, and improved powertrain integration.
Production
Manufacturing Location:
Broadmeadows, Victoria, Australia.
๐ Awards & Recognition
Recognitions
Australian Car Of The Year Contention:
While the AU Falcon itself did not win a major Car of the Year award in its initial release, it was a significant product for Ford Australia and critically reviewed for its chassis dynamics and powertrain offerings (especially the later Barra engines).