AU Falcon FAIRMONT XR6 XR8 Workshop Manual

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🏷️ Basic Information Identification Make: Ford Model: Falcon Generation: AU Series 1-3 Production Years: 1998-2002 Body Styles Covered: Sedan, Ute (Utility), Wagon (Station Wagon) Trim Levels Covered: Fairmont, XR6, XR8, and entire AU range 👋 Introduction Market Position Target Audience: DIY mechanics, independent repair shops, automotive enthusiasts working on Ford AU Falcon vehicles. Value Proposition: Provides in-depth technical knowledge and procedures essential for maintaining, diagnosing, and repairing the Ford AU Falcon across its diverse range and production years. Competitive Analysis Manual Type Comparison: This is a 'Workshop Manual,' akin to factory service information, offering a significantly higher level of detail than a 'Haynes' or 'Chilton' type manual. Key Features Completeness: Covers all major mechanical, electrical, and body systems for a wide range of AU Falcon variants. Engine Transmission Coverage: Specific coverage for the three primary engine options and three main transmission types used in the AU Falcon. Diagnostic Tools: Includes sections on troubleshooting and diagnostic charts, crucial for identifying complex issues. 📋 Manual Details Coverage Areas Manual Type: Workshop Manual / Service Manual / Repair Manual Language: English Format: Download Link (Digital Format) Manual Coverage Scope: Comprehensive coverage for all specified models, engines, and transmissions across Series 1, 2, and 3. 📖 Manual Coverage Systems Covered General Information: Includes vehicle identification, service precautions, general maintenance procedures. Engine Maintenance Tune Up: Routine maintenance, tune-up procedures, ignition timing, idle speed adjustments, emissions checks. Engine Rebuild 6 Cylinder: Detailed procedures for 4.0L OHC and 4.0L OHC VCT 6-cylinder engines: disassembly, inspection, assembly, torque specifications. Engine Rebuild V8: Detailed procedures for 5.0L V8 engine: disassembly, inspection, assembly, torque specifications. Starting System: Diagnosis and repair of starter motor, starter solenoid, battery cables. Charging System: Diagnosis and repair of alternator, voltage regulator, charging circuit. Cooling System: Radiator, water pump, thermostat, coolant hoses, heater core, fan clutch, flushing procedures. Fuel Ignition Systems: Fuel pump, fuel injectors, fuel lines, ignition coils, spark plugs, ignition timing. Engine Management Emission Control: EEC-V (Electronic Engine Control) system, sensors (MAF, TPS, O2, etc.), actuators, emission control devices, diagnostic trouble codes (DTCs). Clutch: Clutch operation, hydraulic system, clutch disc, pressure plate, release bearing for manual transmissions. Automatic Transmission Btr 6 Cyl: BTR 93LE Automatic Transmission: operation, removal, installation, overhaul, hydraulic control, torque converter. Automatic Transmission Btr V8: BTR 97LE Automatic Transmission: operation, removal, installation, overhaul, hydraulic control, torque converter. Manual Transmission M57: M57 5-Speed Manual Transmission: operation, removal, installation, overhaul, internal components. Driveline Tailshaft Ujoints: Tailshaft assembly, universal joints, center bearing (if applicable). Final Drive Beam Axle: Rear beam axle differential: removal, installation, inspection, lubrication, bearings. Final Drive Irs: Independent Rear Suspension (IRS) differential: removal, installation, inspection, lubrication, bearings. Steering: Power steering system, steering rack, steering column, steering linkage, steering wheel. Front Suspension Axle: MacPherson strut, control arms, ball joints, kingpins, wheel bearings, alignment specifications. Rear Suspension Beam Axle: Standard rear beam axle: shock absorbers, springs, trailing arms, Panhard rod, bushings. Rear Suspension Irs: Independent Rear Suspension (IRS): shock absorbers, springs, control arms, bushings, alignment specifications. Brake Systems: Front disc brakes, rear disc brakes (or drum on some variants), brake pads, rotors, calipers, brake lines, master cylinder, ABS system. Exhaust System: Exhaust manifolds, catalytic converter, mufflers, pipes, hangers, oxygen sensors. Fuel Tank Efi Fuel Pump: Fuel tank capacity, fuel pump module, fuel filter, fuel pressure regulator, EVAP system. Wheels Tires: Wheel specifications, tire pressure, rotation, balancing, wheel replacement. Windscreen Wipers Washers: Wiper motor, wiper arms, wiper blades, washer pump, washer fluid reservoir. Body: Body panel removal/installation, door mechanisms, glass, bumpers, trim. Heating Ac Climate Control: HVAC system, heater core, A/C compressor, refrigerant, blower motor, climate control modules. Instruments Switches Stereo Cruise Horn: Dashboard instruments, switches, lighting controls, audio system, cruise control module and actuators, horn system. Body Electrics Smartlock Smartshield Satnav: Body control module (BCM), Smartlock immobilizer, Smartshield alarm system, Satellite Navigation (if fitted), central locking, power windows. Lights Lighting System: Headlights, taillights, indicator lights, interior lighting, fog lights, parking lights, bulb types. Troubleshooting Diagnostic Charts: Systematic troubleshooting guides, symptom-based diagnostics, fault finding procedures. Electric Wiring Fuses: Detailed wiring diagrams for all electrical systems, fuse box locations and ratings, relay assignments. Falcon Update: Potentially includes service bulletins or specific updates relevant to the AU Falcon range. Procedures Included Maintenance Procedures: Oil changes, filter replacements, fluid checks and top-ups, spark plug replacement, belt inspection and replacement. Repair Procedures: Component replacement (e.g., water pump, alternator, starter motor, brake pads, shock absorbers), system diagnosis and repair. Rebuild Procedures: Complete engine and transmission rebuilds with detailed step-by-step instructions, torque specifications, and clearances. Diagnostic Procedures: Using diagnostic tools (e.g., OBD-II scanners), interpreting diagnostic trouble codes, tracing electrical faults. Adjustment Procedures: Engine idle speed, ignition timing, clutch pedal free play, handbrake adjustment. Installation Procedures: Component installation, accessory fitting, body panel replacement. Technical Depth Depth Of Coverage: Extremely high. Covers everything from basic scheduled maintenance to complete engine and transmission...

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Sku: 333176

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Tags: Car Cars Fairmont Falcon Ford XR6 XR8

Product variants

Description

🏷️ Basic Information

Identification

Make:

Model:

Falcon

Generation:

AU Series 1-3

Production Years:

1998-2002

Body Styles Covered:

Sedan, Ute (Utility), Wagon (Station Wagon)

Trim Levels Covered:

Fairmont, XR6, XR8, and entire AU range

👋 Introduction

Market Position

Target Audience:

DIY mechanics, independent repair shops, automotive enthusiasts working on Ford AU Falcon vehicles.

Value Proposition:

Provides in-depth technical knowledge and procedures essential for maintaining, diagnosing, and repairing the Ford AU Falcon across its diverse range and production years.

Competitive Analysis

Manual Type Comparison:

This is a 'Workshop Manual,' akin to factory service information, offering a significantly higher level of detail than a 'Haynes' or 'Chilton' type manual.

Key Features

Completeness:

Covers all major mechanical, electrical, and body systems for a wide range of AU Falcon variants.

Engine Transmission Coverage:

Specific coverage for the three primary engine options and three main transmission types used in the AU Falcon.

Diagnostic Tools:

Includes sections on troubleshooting and diagnostic charts, crucial for identifying complex issues.

📋 Manual Details

Coverage Areas

Manual Type:

Workshop Manual / Service Manual / Repair Manual

Language:

English

Format:

Download Link (Digital Format)

Manual Coverage Scope:

Comprehensive coverage for all specified models, engines, and transmissions across Series 1, 2, and 3.

📖 Manual Coverage

Systems Covered

General Information:

Includes vehicle identification, service precautions, general maintenance procedures.

Engine Maintenance Tune Up:

Routine maintenance, tune-up procedures, ignition timing, idle speed adjustments, emissions checks.

Engine Rebuild 6 Cylinder:

Detailed procedures for 4.0L OHC and 4.0L OHC VCT 6-cylinder engines: disassembly, inspection, assembly, torque specifications.

Engine Rebuild V8:

Detailed procedures for 5.0L V8 engine: disassembly, inspection, assembly, torque specifications.

Starting System:

Diagnosis and repair of starter motor, starter solenoid, battery cables.

Charging System:

Diagnosis and repair of alternator, voltage regulator, charging circuit.

Cooling System:

Radiator, water pump, thermostat, coolant hoses, heater core, fan clutch, flushing procedures.

Fuel Ignition Systems:

Fuel pump, fuel injectors, fuel lines, ignition coils, spark plugs, ignition timing.

Engine Management Emission Control:

EEC-V (Electronic Engine Control) system, sensors (MAF, TPS, O2, etc.), actuators, emission control devices, diagnostic trouble codes (DTCs).

Clutch:

Clutch operation, hydraulic system, clutch disc, pressure plate, release bearing for manual transmissions.

Automatic Transmission Btr 6 Cyl:

BTR 93LE Automatic Transmission: operation, removal, installation, overhaul, hydraulic control, torque converter.

Automatic Transmission Btr V8:

BTR 97LE Automatic Transmission: operation, removal, installation, overhaul, hydraulic control, torque converter.

Manual Transmission M57:

M57 5-Speed Manual Transmission: operation, removal, installation, overhaul, internal components.

Driveline Tailshaft Ujoints:

Tailshaft assembly, universal joints, center bearing (if applicable).

Final Drive Beam Axle:

Rear beam axle differential: removal, installation, inspection, lubrication, bearings.

Final Drive Irs:

Independent Rear Suspension (IRS) differential: removal, installation, inspection, lubrication, bearings.

Steering:

Power steering system, steering rack, steering column, steering linkage, steering wheel.

Front Suspension Axle:

MacPherson strut, control arms, ball joints, kingpins, wheel bearings, alignment specifications.

Rear Suspension Beam Axle:

Standard rear beam axle: shock absorbers, springs, trailing arms, Panhard rod, bushings.

Rear Suspension Irs:

Independent Rear Suspension (IRS): shock absorbers, springs, control arms, bushings, alignment specifications.

Brake Systems:

Front disc brakes, rear disc brakes (or drum on some variants), brake pads, rotors, calipers, brake lines, master cylinder, ABS system.

Exhaust System:

Exhaust manifolds, catalytic converter, mufflers, pipes, hangers, oxygen sensors.

Fuel Tank Efi Fuel Pump:

Fuel tank capacity, fuel pump module, fuel filter, fuel pressure regulator, EVAP system.

Wheels Tires:

Wheel specifications, tire pressure, rotation, balancing, wheel replacement.

Windscreen Wipers Washers:

Wiper motor, wiper arms, wiper blades, washer pump, washer fluid reservoir.

Body:

Body panel removal/installation, door mechanisms, glass, bumpers, trim.

Heating Ac Climate Control:

HVAC system, heater core, A/C compressor, refrigerant, blower motor, climate control modules.

Instruments Switches Stereo Cruise Horn:

Dashboard instruments, switches, lighting controls, audio system, cruise control module and actuators, horn system.

Body Electrics Smartlock Smartshield Satnav:

Body control module (BCM), Smartlock immobilizer, Smartshield alarm system, Satellite Navigation (if fitted), central locking, power windows.

Lights Lighting System:

Headlights, taillights, indicator lights, interior lighting, fog lights, parking lights, bulb types.

Troubleshooting Diagnostic Charts:

Systematic troubleshooting guides, symptom-based diagnostics, fault finding procedures.

Electric Wiring Fuses:

Detailed wiring diagrams for all electrical systems, fuse box locations and ratings, relay assignments.

Falcon Update:

Potentially includes service bulletins or specific updates relevant to the AU Falcon range.

Procedures Included

Maintenance Procedures:

Oil changes, filter replacements, fluid checks and top-ups, spark plug replacement, belt inspection and replacement.

Repair Procedures:

Component replacement (e.g., water pump, alternator, starter motor, brake pads, shock absorbers), system diagnosis and repair.

Rebuild Procedures:

Complete engine and transmission rebuilds with detailed step-by-step instructions, torque specifications, and clearances.

Diagnostic Procedures:

Using diagnostic tools (e.g., OBD-II scanners), interpreting diagnostic trouble codes, tracing electrical faults.

Adjustment Procedures:

Engine idle speed, ignition timing, clutch pedal free play, handbrake adjustment.

Installation Procedures:

Component installation, accessory fitting, body panel replacement.

Technical Depth

Depth Of Coverage:

Extremely high. Covers everything from basic scheduled maintenance to complete engine and transmission overhauls, including complex electrical system diagnostics and body repairs.

Diagnostic Capabilities:

Detailed troubleshooting flowcharts, symptom analysis, and specific diagnostic routines for engine management and electrical systems.

Rebuild Detail Level:

Comprehensive, with step-by-step instructions, critical torque specifications, component clearances, and special tool requirements.

📊 Manual Specifications

File Format

File Format:

Digital (Download Link provided) - typically PDF

Print Quality

Digital Quality:

High resolution for clear diagrams and text, usually searchable text within PDF.

Binding Type

Binding Type:

N/A (Digital Format)

Paper Type

Paper Type:

N/A (Digital Format)

⚙️ Engine Specifications

Primary Engine

Engine 1 Variant:

4.0L OHC (Overhead Camshaft) 6-cylinder

Engine 1 Power Approx:

168 kW (approx.)

Engine 1 Torque Approx:

365 Nm (approx.)

Engine 2 Variant:

4.0L OHC VCT (Variable Camshaft Timing) 6-cylinder (often designated 'Barra' in later AU Series, though 'Barra' naming was more prominent in BA onwards).

Engine 2 Power Approx:

175-185 kW (approx., depending on Series and specific tune)

Engine 2 Torque Approx:

370-380 Nm (approx.)

Engine 3 Variant:

5.0L OHV (Overhead Valve) V8 (Windsor)

Engine 3 Power Approx:

175 kW (approx. in early models), increased in XR8 variants.

Engine 3 Torque Approx:

400+ Nm (approx.)

Fuel System

Fuel System Type:

Electronic Fuel Injection (EFI)

Fuel Type:

Unleaded Petrol (ULP)

🔧 Transmission

Standard

Transmission 1:

BTR M57 5-Speed Manual Transmission

Optional

Transmission 2:

BTR 93LE 4-Speed Automatic Transmission (for 6-Cylinder engines)

Transmission 3:

BTR 97LE 4-Speed Automatic Transmission (for V8 engines)

Features

Automatic Control Systems:

Hydraulic control systems, electronic shift control (in later iterations/models).

📐 Dimensions

Exterior

Wheelbase Sedan Wagon:

2791 mm (approx.)

Wheelbase Ute:

3096 mm (approx.)

Weights

Kerb Weight Range:

1600 - 1800+ kg (varies significantly by body style and engine)

🛡️ Safety Features

Ratings

Ancap Rating:

AU Falcon generally received 3-star ANCAP ratings in its earlier configurations, with improvements in later series.

Active Features

Anti-lock Braking System (ABS) was an option on many models and standard on XR variants.

Passive Features

Airbags:

Driver and passenger airbags were standard on higher trims like Fairmont and XR models, optional on others.

Seatbelts:

Three-point seatbelts with pretensioners in the front.

💡 Technology Features

Infotainment

Audio System:

Factory fitted radio/cassette player or CD player with varying speaker configurations depending on trim level. Later models offered more advanced audio systems.

Driver Assistance

Cruise Control:

Electronic cruise control system available on most models, standard on Fairmont and XR variants.

Connectivity

Optional Features:

Satellite Navigation (SatNav) was an option on higher-end models in later series. Basic mobile phone integration might be present in some later models.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Typically 10,000 km or 6 months, whichever comes first (refer to specific manual chapter for exact recommendations).

Transmission Service Interval:

Automatic transmission fluid and filter change: 40,000 - 60,000 km (depending on driving conditions).

Spark Plug Replacement:

Varies by engine type: 4.0L OHC (approx. 80,000-100,000 km), 5.0L V8 (approx. 60,000-80,000 km), VCT 6-cyl (longer intervals possible).

Fluid Specifications

Engine Oil 6 Cyl:

API SG/SH/SJ or higher, SAE 10W-30 or 10W-40 (check manual for specific climate/viscosity recommendations).

Engine Oil V8:

API SG/SH/SJ or higher, SAE 10W-30 or 10W-40 (often recommended 5W-30 or 10W-30 for Windsor V8s).

Automatic Transmission Fluid:

BTR specified fluid (often DEXRON-III or equivalent, check manual for exact specification like MERCON).

Coolant:

Ethylene glycol based coolant, typically a 50/50 mix with distilled water (e.g., Ford Genuine Coolant or equivalent).

Known Issues

Engine Issues:

Head gasket failures on some 4.0L OHC engines, particularly early series. Oil leaks from rocker cover gaskets. VCT solenoid issues on later 6-cylinders.

Transmission Issues:

BTR transmissions can develop issues with solenoids, torque converter lock-up clutch, and occasional gear selection problems if not maintained.

Suspension Steering:

Wear in front suspension bushes and ball joints. Power steering leaks are not uncommon.

Electrical Issues:

Body Control Module (BCM) issues, minor electrical gremlins, issues with power window motors and central locking actuators.

📚 Vehicle History

Brand Heritage

Ford Australia:

The Ford Falcon is an iconic Australian-made vehicle, representing a significant portion of Ford's local manufacturing history and market presence.

Model Evolution

Au Falcon Introduction:

The AU Falcon was a radical departure from its predecessor (EL Falcon), featuring a significantly restyled exterior and interior, intended to modernize the Falcon line-up and compete more effectively against Holden.

Au Series Progression:

Series 1 (1998-1999), Series 2 (1999-2000), Series 3 (2000-2002), with incremental updates to styling, features, and powertrains, particularly the introduction of the 'Barra' engines in later Series 2 and Series 3.

Production

Manufacturing Location:

Campbellfield, Victoria, Australia.

🏆 Awards & Recognition

Recognitions

Industry Awards:

While specific awards for the AU Falcon are not prominently recalled as major breakthroughs, it was a significant sales volume vehicle for Ford Australia and underwent continuous improvement through its series updates to maintain market competitiveness.