air condition FORD MUSTANG 2003 Workshop Manual

z
Excessive noise zPilot bearing
worn or
damaged.
z Excessive
crankshaft end
play. z
Go To Pinpoint Test G .
z Transmission difficult to
shift z
Lubricant. zADD or DRAIN AND
FILL with specified
lubricant.
z Internal shift
mechanism. z
CHECK the internal shift
mechanism for smooth
operation. REPAIR or
INSTALL a new
mechanism as
necessary.
z Sliding gears,
synchronizers. z
CHECK for free
movement of gears and
synchronizers. REPAIR
or INSTALL new
components as
necessary.
z Housings, shaft. zCHECK for binding
condition between the
input shaft and the
engine crankshaft pilot
bearing or bushing.
REPAIR or INSTALL
new components as
necessary. REFER to
Section 308 - 03A or
Section 308 - 03B .
z Loose pressure
plate to flywheel
bolts. z
CHECK for loose bolts
at the pressure plate.
INSTALL new
components as
necessary. REFER to
Section 308 - 01 .
z NOTE: While verifying
the condition, determine
whether the noise is gear
rollover noise, release
bearing rub or some
other transmission-
related noise. Gear
rollover noise, inherent in
manual transmissions, is
caused by the constant
mesh gears turning at the
engine idle speed while
the clutch is engaged and
the transmission is in
NEUTRAL. Release
bearing rub is sometimes
mistaken for mainshaft
bearing noise. Gear
rollover noise will
disappear when the
clutch is disengaged or
when the transmission is
engaged in gear. z
Lubricant. zADD or DRAIN AND
FILL with specified
lubricant. Klj . 3 ba
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Release bearing rub will
disappear when the
clutch is engaged. In the
event that a bearing is
damaged, the noise is
more pronounced while
engaged in gear under
load or coast than in
NEUTRAL.
Noisy in forward gears
zComponents
grounding out
on the
transmission. z
CHECK for screws,
bolts, etc., of body or
other components
grounding out.
CORRECT as
necessary.
z Components
housing bolts. z
CHECK the torque on
the transmission-to-
flywheel housing bolts
and the flywheel
housing- to-engine block
bolts. TIGHTEN the
bolts to specification.
REFER to Section 308 -
01 .
z Bearings or
gears. z
INSPECT the bearings.
INSPECT the gears and
gear teeth for wear or
damage. INSTALL new
components as
necessary. REFER to
Section 308 - 01 .
z Gears clash when
shifting from one forward
gear to another z
Pilot bearing. zCHECK for a binding
condition between the
input shaft and the
engine crankshaft pilot
bearing. INSTALL new
components as
necessary. REFER to
Section 308 - 01 .
z Gear teeth
and/or
synchronizer. z
REPAIR or INSTALL
new components as
necessary. REFER to
Section 308 - 03A or
Section 308 - 03B .
z Engine idle
speed too high. z
REFER to the
Powertrain
Control/Emissions
Diagnosis (PC/ED)
manual.
z Transmission jumps out
of gear z
Transmission
range selector
lever boot. z
INSTALL a new boot if
exceptionally stiff.
REFER to Section 308 -
03A or
Section 308 -
03B .
z Transmission-to-
engine mounting
bolts. z
TIGHTEN the bolts to
specification. Klj . 4 ba
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DIAGNOSIS AND TESTING
Exhaust System
Symptom Chart
SECTION 309-
00: Exhaust System 2003 Mustang Workshop Manual Symptom Chart
Condition
Possible Sources Action
z Noisy or
leaking
exhaust z
Broken or loose
clamps, hangers or
isolators.
z Punctures in the muffler
(5230).
z Broken, loose or
missing exhaust
manifold fasteners or
gaskets.
z Loose heated oxygen
or catalyst monitor
sensor. z
REPAIR as necessary.
z Exhaust system
misalignment. z
ALIGN exhaust system.
z Broken or loose
catalyst internal
components. z
LOOSEN all fasteners joining
the exhaust system and SHAKE
the system to isolate the
concern. REPAIR as necessary.
z Loss of
power z
Kinked or damaged
exhaust pipe.
z Clogged three- way
catalytic converter
(5F250).
z Foreign object in the
exhaust system. z
REPAIR as necessary. Klj . 1 ba
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DIAGNOSIS AND TESTING
Acceleration Control
Inspection and Verification
1. Verify the customer's concern by operating the acceleration control system to duplicate the condition.
2. Inspect to determine if any of the following mechanical concerns apply:
3. If the inspection reveals an obvious concern that can be readily identified, repair as required.
4. If the concern remains after the inspection, determine the symptom(s) and GO to Symptom Chart .
Symptom Chart SECTION 310-
02: Acceleration Control 2003 Mustang Workshop Manual Visual Inspection Chart
Mechanical
z
damaged accelerator pedal and shaft
z damaged linkage
z damaged accelerator cable
z high engine idle speed
z damaged throttle body
Symptom Chart Condition
Possible Sources Action
z Excessive effort
needed to
depress
accelerator pedal
and shaft z
Worn
accelerator lever
pivot bushing. z
INSTALL a new accelerator
pedal and shaft.
z Accelerator
cable binding. z
INSTALL a new accelerator
cable.
z Worn or
damaged
throttle body. z
INSTALL a new throttle body.
REFER to Section 303 - 04A or
Section 303 - 04B .
z Accelerator pedal
and shaft feels
rough or raspy z
Frayed or
binding
accelerator
cable. z
INSTALL a new accelerator
cable.
z Worn or
damaged
throttle body. z
INSTALL a new throttle body.
REFER to Section 303 - 04A or
Section 303 - 04B .
z Accelerator pedal
and shaft binds or
sticks z
Kinked
accelerator
cable. z
INSTALL a new accelerator
cable. Klj . 1 ba
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PINPOINT TEST B: THE SET SPEED FLUCTUATES z
Is the resistance less than 5 ohms? A16 CHECK CIRCUIT 239 (WH/OG) FOR AN OPEN
z
Disconnect: PCM C175.
z Connect EEC- V 104-Pin Breakout Box.
z Measure the resistance between speed control servo C122 pin
3, circuit 239 (WH/OG), harness side and Breakout Box, EEC- V
Control System pin 68, circuit 239 (WH/OG), harness side.
z Is the resistance less than 5 ohms? Yes
GO to
A17 .
No
REPAIR the circuit.
TEST the system for
normal operation. A17 CHECK THE SPEED CONTROL SERVO
z
INSTALL a known good speed control servo.
z Test drive the vehicle for correct operation.
z Does the speed control operate correctly? Yes
INSTALL a new speed
control servo; REFER to
Actuator
— Speed
Control Servo . TEST
the system for normal
operation.
No
INSTALL a new PCM;
REFER to Section 303 -
14 . TEST the system
for normal operation. Test Step Result / Action to Take
B1 CHECK THAT CONDITION OCCURS
ONLY WHILE USING SPEED CONTROL z
Check that the condition does not occur
when driving without speed control.
z Does the condition occur without
speed control? Yes
REPAIR engine as necessary. TEST the
system for normal operation.
No
GO to
B2 . Klj . 9 ba
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DESCRIPTION AND OPERATION
Climate Control System
WARNING: To avoid accidental deployment and possible injury, the air bag system
backup power supply must be depleted before repairing any climate control components. To
deplete the backup power supply, disconnect the battery ground cable and wait one minute.
Failure to follow these instructions may result in personal injury.
WARNING: Carbon monoxide is colorless, odorless and dangerous. If it is necessary to
operate the engine with the vehicle in a closed area such as a garage, always use an exhaust
collector to vent the exhaust gases outside the closed area.
WARNING: R- 134a is classified as a safe refrigerant, but misuse can make it dangerous.
The following precautions must be observed:
zAlways wear safety goggles when repairing an air conditioning system.
z Avoid contact with liquid refrigerant R- 134a. R-134a vaporizes at approximately - 25°C (-
13°F) under atmospheric pressure and it will freeze skin tissue.
z Never allow refrigerant R- 134a gas to escape in quantity in an occupied space. R- 134a is
non- toxic, but it will displace the oxygen needed to support life.
z Never use a torch in an atmosphere containing R- 134a gas. R-134a is non-toxic at all
normal conditions, but when it is exposed to high temperatures, such as a torch flame, it
decomposes. During decomposition it releases irritation and toxic gases (as described in
the MSDS sheet from the manufacturer). Decomposition products are hydrofluoric acid,
carbon dioxide and water.
z Do not allow any portion of the charged air conditioning system to become too hot. The
pressure in an air conditioning system rises as the temperature rises and temperatures
of approximately 85°C (185°F) can be dangerous.
z Allow the engine to cool sufficiently prior to carrying out maintenance or serious burns
and injury can occur.
CAUTION: To avoid damaging the vehicle or A/C components, the following precautions
must be observed:
zThe A/C refrigerant of all vehicles must be identified and analyzed prior to refrigerant
charging. Failure to due so can contaminate the shop bulk refrigerant and other vehicles.
z Do not add R- 12 refrigerant to an A/C system that requires the use of R- 134a refrigerant.
These two types of refrigerant must never be mixed. Doing so can damage the A/C
system.
z Charge the A/C system with the engine running only at the low- pressure side to prevent
refrigerant slugging from damaging the A/C compressor.
z Use only R- 134a refrigerant. Due to environmental concerns, when the air conditioning
system is drained, the refrigerant must be collected using refrigerant recovery/recycling
equipment. Federal law REQUIRES that R- 134a be recovered into appropriate recovery
equipment and the process be conducted by qualified technicians who have been
certified by an approved organization, such as MACS, ASI etc. Use of a recovery machine
dedicated to R- 134a is necessary to reduce the possibility of oil and refrigerant
incompatibility concerns. Refer to the instructions provided by the equipment manufacturer when removing refrigerant from or charging the air conditioning system. SECTION 412-
00: Climate Control System - General Information 2003 Mustang Workshop Manual Klj . 1 ba
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If two substances of different temperature are placed near each other, the heat in the warmer
substance will transfer to the colder substance.
Latent Heat of Vaporization
When a liquid boils (converts to a gas), it absorbs heat without raising the temperature of the resulting
gas. When the gas condenses (reverts back to a liquid), it gives off heat without lowering the
temperature of the resulting liquid.
Relative Humidity
The amount of moisture (water vapor content) that the air can hold is directly related to the air
temperature. The more heat there is in the air, the more moisture the air can hold. The lower the
moisture content in the air, the more comfortable you feel. Removing moisture from the air lowers its
relative humidity and improves personal comfort.
Effects of Pressure on Boiling or Condensation
As the pressure is increased on a liquid, the temperature at which the liquid boils (converts to a gas)
also increases. Conversely, when the pressure on a liquid is reduced, its boiling point is also reduced.
When in the gas state, an increase in pressure causes an increase in temperature, while a decrease in
pressure will decrease the temperature of the gas.
Compressor Anti-
Slugging Strategy
Liquid refrigerant may accumulate in the A/C compressor under certain conditions. To alleviate
damage to the A/C compressor, compressor anti- slugging strategy (CASS) is utilized.
CASS is initiated only under specific conditions:
zthe ignition is off for more than 8 hours
z the ambient temperature is above -4º C (25ºF)
z battery voltage is above 8.5 volts during engine cranking
When these conditions are present, the powertrain control module (PCM) will activate the A/C control
relay prior to cranking of the engine. The A/C control relay engages the A/C compressor for
approximately 4- 15 A/C compressor revolutions or a maximum of 2 seconds (depending upon vehicle
application), allowing the liquid refrigerant to be pushed from the A/C compressor. CASS is initiated by
the PCM regardless of the function selector switch position or the EATC system settings.
The Refrigerant Cycle
During stabilized conditions (air conditioning system shut down), the refrigerant is in a vaporized state
and pressures are equal throughout the system. When the A/C compressor (19703) is in operation, it
increases pressure on the refrigerant vapor, raising its temperature. The high- pressure and high-
temperature vapor is then released into the top of the A/C condenser core (19712).
The A/C condenser core, being close to ambient temperature, causes the refrigerant vapor to
condense into a liquid when heat is removed from the refrigerant by ambient air passing over the fins
and tubing. The now liquid refrigerant, still at high pressure, exits from the bottom of the A/C
condenser core and enters the inlet side of the A/C evaporator core orifice (19D990).
The A/C evaporator core orifice is the restriction in the refrigerant system that creates the high
pressure buildup upstream of the A/C evaporator core (19860) and separates the high and low
pressure sides of the A/C system. As the liquid refrigerant leaves this restriction, its pressure and
boiling point are reduced.
The liquid refrigerant is now at its lowest pressure and temperature. As it passes through the A/C Klj . 3 ba
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DIAGNOSIS AND TESTING
Climate Control System
Refer to Wiring Diagrams Cell
54 , Air Conditioner/Heater for schematic and connector information.
SECTION 412-
00: Climate Control System - General Information 2003 Mustang Workshop Manual Special Tool(s)
Connector, Refrigerant
Pressure Line
412-
093 (T94P-19623- E) Set, A/C Fittings
412-
DS028 (014- 00333, D93L-
19703- B) or equivalent Vacuum Pump Kit
416-
D002 (D95L-7559- A) or
equivalent Breakout Box, EEC-V Control
System
418- 049 (014-00950, T94L-50-
EEC- V) Worldwide Diagnostic System
(WDS)
418-
F224,
New Generation STAR (NGS)
Tester
418- F052, or equivalent
diagnostic tool Pressure Test Kit
014-
R1072 or equivalent 77 III Automotive Meter
105-
R0056 or equivalent Klj . 1 ba
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Function Selector Switch Vacuum Connector
V=Vacuum
NV=No Vacuum
Inspection and Verification
1. Verify the customer's concern by operating the climate control system to duplicate the condition. 16 18476 Heater core
17 18A559 Panel/floor door (full vacuum position)
18 — Floor airflow
19 18A318 Vacuum control motor—
floor/panel door 20 — Panel vent airflow
Port No. Hose Color Function
1 White Air inlet door
2 Red Panel/floor door
3 Blue Panel/floor door
4 Yellow Panel/defrost door
5 Black Vacuum source
6 — Not used
Function Selector Switch Vacuum Application Chart Switch Port Color Function Function Selector Switch Position
MAX A/C A/C Vent OFF Floor FLR/ DEF Defrost
1 White Recirc/Fresh V NV NV V NV NV NV
2 Red Floor NV NV NV V V NV NV
3 Blue Panel/floor NV NV NV V V V NV
4 Yellow Panel/defrost V V V NV NV NV NV
5 Black Vacuum source V V V V V V V Klj . 4 ba
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Symptom Chart
Condition
Possible Sources Action
z Incorrect/erratic direction
of airflow from outlet(s) z
No vacuum to A/C heater
function switch selector.
z A/C heater function selector
switch leaks vacuum.
z Kinked/pinched vacuum hose.
z Leaking vacuum control
motor.
z Leaking A/C vacuum check
valve.
z Leaking A/C vacuum reservoir
tank and bracket.
z Vacuum actuator arm not
connected to door crank. z
Go To Pinpoint
Test A .
z Insufficient, erratic, or no
heat z
Low engine coolant level.
z Thermostat stuck open.
z Disengaged/damaged
temperature cable. z
Go To Pinpoint
Test B .
z The A/C does not
operate/does not operate
correctly z
CASS strategy failure.
z Open fuses.
z A/C clutch relay.
z Shorted blend door actuator.
z Powertrain control module.
z Circuitry short/open.
z A/C cycling switch damaged.
z A/C system discharged/low
charge.
z Function selector switch
damaged.
z A/C pressure cut-off switch
damaged.
z A/C compressor clutch
damaged. z
Go To Pinpoint
Test C .
z The A/C is always on zCircuitry short/open.
z A/C cycling switch.
z A/C heater function selector
switch.
z Constant control relay
module.
z Incorrect A/C clutch air gap. z
Go To Pinpoint
Test D .
z Insufficient A/C cooling zRestricted A/C evaporator
core orifice.
z Low refrigerant level. z
Go To Pinpoint
Test E .
z No operation in all the
temperature settings z
Damaged blend door actuator
cable.
z Damaged air temperature
control door. z
Go To Pinpoint
Test F .
z The blower motor does
not operate z
Open fuse.
z Circuitry open/shorted.
z Damaged heater blower
motor switch (18578).
z Damaged heater blower
motor switch resistor (18591).
z Damaged blower motor relay.
z Damaged blower motor. z
Go To Pinpoint
Test G .
z The blower motor
operates continuously in z
Circuitry short/open.
z Damaged heater blower z
Go To Pinpoint Klj . 6 ba
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