🏷️ Basic Information

Make:

Ford

Model:

Falcon

Generation Code:

AU Series 1, 2, 3

Model Years Covered:

1998, 1999, 2000, 2001, 2002

👋 Introduction

Target Audience:

Owners of 1998-2002 Ford AU Falcon seeking to perform their own maintenance and repairs, or professional workshops requiring factory service information.

Value Proposition:

Provides factory-accurate, comprehensive repair information at a fraction of the cost of official dealership manuals, empowering owners with the knowledge to maintain and repair their vehicles effectively.

Comprehensiveness:

Highly detailed, factory-level information with step-by-step instructions and hundreds of illustrations.

Usability:

Designed for both experienced mechanics and the do-it-yourself enthusiast.

Accessibility:

Digital PDF format compatible with all PC-based Windows operating systems and Mac, easily printable.

📋 Manual Details

Market Focus:

Australia

Regions Supported:

Primarily Australian market, with technical data applicable to vehicles sold in other RHD markets where the Falcon was offered.

Estimated Pages:

Varies by specific edition, but typically extensive, encompassing thousands of pages for full factory documentation. For sales purposes, digital versions are often condensed or specific to repair categories.

Type:

Workshop Service Repair Manual

Language:

English

Format:

PDF Download

📖 Manual Coverage

Powertrain:

Engine mechanical, fuel, ignition, cooling, exhaust, lubrication, emissions control, drivetrain (transmission, driveshaft, differential, axles).

Chassis:

Suspension (front and rear), steering, brakes (front and rear, ABS), wheels and tires.

Electrical:

Wiring diagrams, charging system, starting system, lighting, instrumentation, body control modules, audio systems, climate control electronics, power accessories.

Body And Trim:

Exterior body panels, interior trim, seats, glass, doors, hood, trunk, bumpers, seals.

HVAC:

Air conditioning system, heater core, blower motor, controls, refrigerant handling.

Routine Maintenance:

Oil and filter changes, fluid level checks and top-offs, spark plug replacement, air filter replacement, tire rotation, brake pad inspection.

Troubleshooting:

Diagnostic procedures for engine performance issues, electrical faults, HVAC problems, brake system malfunctions, and transmission operation.

Repair And Rebuild:

Detailed step-by-step instructions for component removal, disassembly, inspection, repair, reassembly, and installation, including engine overhauls, transmission rebuilds, brake caliper replacement, and suspension component replacement.

Specifications And Data:

Torque specifications, clearances, fluid capacities, electrical resistance values, diagnostic trouble codes (DTCs) and their meaning.

Level Of Detail:

Factory-level detail, suitable for both DIY enthusiasts and professional mechanics. Includes detailed illustrations, diagrams, and exploded views.

Scope:

Comprehensive, covering complete disassembly and reassembly of major vehicle systems.

📊 Manual Specifications

Format:

PDF

Searchability:

Text-searchable within the PDF document for quick access to specific information.

Printability:

All pages are printable, allowing users to create hard copies of specific sections or the entire manual.

Binding:

Digital (N/A for PDF download)

Paper Type:

Digital (N/A for PDF download)

⚙️ Engine Specifications

Engine Family:

Ford Barra / Windsor V8

Common Engines Covered:

4.0L I6 (OHC and DOHC variants), 4.9L V8 Windsor, 5.6L V8 Windsor (less common).

4.0L I6 Horsepower:

Approx. 175-200 kW (depending on specific engine variant and tune)

4.9L V8 Horsepower:

Approx. 200-220 kW (depending on specific engine variant)

Induction Type:

Multi-point Fuel Injection (MPI)

Fuel Type:

Unleaded Petrol (RON 91 recommended for standard tune, higher octanes for performance variants)

🔧 Transmission

Transmission Options:

4-speed Automatic (BTR DSY/DSG), 5-speed Manual (Getrag).

Optional Transmissions:

Later AU models and performance variants may have offered different automatic transmission options.

Automatic Features:

Electronically controlled, with torque converter lock-up for improved fuel efficiency.

📐 Dimensions

Body Styles:

Sedan, Station Wagon (also referred to as 'Fairmont/Fairlane' variants for luxury trims).

Wheelbase:

Approx. 2794 mm (Sedan), 2944 mm (Wagon)

Kerb Weight:

Varies significantly by model and engine, typically ranging from 1500 kg to 1800 kg.

🛡️ Safety Features

Ancap Rating:

No official ANCAP rating available for the AU Falcon range. Safety features varied by trim level.

ABS:

Anti-lock Braking System (ABS) was optional or standard on higher trim levels and later models.

Traction Control:

Traction control (TC) was available on select models, particularly those with V8 engines or premium packages.

Airbags:

Driver and front passenger airbags were available, with availability increasing in later AU series.

Seatbelts:

Three-point seatbelts for all occupants.

💡 Technology Features

Audio Systems:

Factory fitted radio/cassette players, with CD players becoming more common in later models and higher trims. Basic speaker systems.

Cruise Control:

Standard on most models, or optional on base trims.

Auxiliary Input:

Not typically equipped with factory auxiliary inputs; aftermarket solutions required for modern device connectivity.

🔧 Maintenance

Oil Change Interval:

Typically every 10,000 km or 6 months, whichever comes first. Consult manual for specific engine types and driving conditions.

Spark Plug Replacement Interval:

Varies by spark plug type (copper, platinum, iridium). Intervals typically range from 30,000 km to 100,000 km.

Coolant Change Interval:

Initial change at 240,000 km or 5 years, subsequent changes every 120,000 km or 5 years, whichever comes first. Use specified coolant.

Engine Oil:

API SG/SH or ACEA A2/A3 rated. Viscosity: 5W-30, 10W-30, or 10W-40 depending on ambient temperature. Check manual for specific recommendations. Capacity approx. 4.5-5.5 Litres.

Transmission Fluid Auto:

Mercon V or equivalent. Capacity approx. 7.5-9.5 Litres (drain and fill).

Transmission Fluid Manual:

API GL-4 or GL-5, SAE 75W-90 or 80W-90. Capacity approx. 2.0-2.5 Litres.

Brake Fluid:

DOT 3 or DOT 4.

Coolant:

Ethylene glycol-based coolant, typically a 50/50 mix with demineralised water. Specify Ford-approved coolant for long-life protection.

Lsd Bushings:

wear in the Limited Slip Differential (LSD) bushings can lead to clunking noises and handling issues.

Ignition Coils:

Failure of ignition coils, particularly on the 4.0L inline-six engines, can cause misfires and rough running.

Window Regulators:

Failure of power window regulators and motors is a common electrical/mechanical issue.

Radiator Leaks:

Cracking and leaks from the plastic end tanks of the radiator can occur over time.

Heater Core:

Leaking heater cores can lead to coolant loss and fogging of the interior windshield.

📚 Vehicle History

Ford Australia:

Ford Australia has a long and significant history of designing and manufacturing vehicles specifically for the Australian market. The Falcon is a cornerstone of this heritage, evolving through numerous generations.

Au Falcon Introduction:

The AU Falcon replaced the AU Falcon in September 1998. It represented a significant departure from previous Falcon generations in terms of styling and engineering, featuring a more international 'global' design language.

Au Series Updates:

The AU Falcon underwent several updates: AU Series I (1998-2000), AU Series II (2000-2001), and AU Series III (2001-2002), each introducing styling revisions, feature upgrades, and mechanical improvements.

Manufacturing Location:

Campbellfield, Victoria, Australia

Production Years:

1998-2002

🏆 Awards & Recognition

Market Reception:

The AU Falcon was a sales success in Australia, continuing the Falcon's dominance in the large Australian sedan market, despite initial mixed reviews on its styling.