belt FORD MUSTANG 2003 Workshop Manual

REMOVAL AND INSTALLATION
Charge Air Cooler
Removal and Installation
1. Drain the supercharger coolant. For additional information, refer to Section 303 - 03B .
2. Release the fuel pressure. For additional information, refer to Section 310 - 00 .
3. Disconnect the supercharger degas hose.
4. Disconnect the coolant hose.
5. Remove the supercharger belt. For additional information, refer to Section 303 - 05 .
6. Remove the air cleaner outlet tube. For additional information, refer to Section 303 - 12 .
7. Disconnect the throttle position (TP) sensor and the idle air control (IAC) valve electrical connectors.
SECTION 303-
12: Intake Air Distribution and Filtering 2003 Mustang Workshop Manual Material
Item Specification
Silicone Gasket and Sealant
F7AZ-
19554- EA or equivalent WSE-
M4G323- EA Klj . 1 ba
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or excessive
runout.
z Clutch disc
facing surface
hardened or
damaged.
z Flywheel
surface glazed
or damaged.
z Transmission
input shaft
eccentric or not
perpendicular.
z Clutch drag zClutch drag.
z Cable release
linkage outside
the flywheel
housing worn,
cracked, bent.
z Excessive
runout or
damaged clutch
disc.
z Clutch disc
splines rusted or
worn.
z Loose pressure
plate to flywheel
bolts. z
Go To Pinpoint Test C .
z Clutch pedal pulsation zClutch disc
damaged or
worn.
z Excessive
flywheel runout.
z Loose pressure
plate to flywheel
bolts.
z Improperly
assembled
release lever to
pivot stud. z
Go To Pinpoint Test D .
z Clutch related vibrations zEngine
component
grounding
against frame.
z Loose flywheel
bolts.
z Excessive
flywheel runout.
z Imbalanced
clutch pressure
plate.
z Accessory drive
belt loose or
damaged. z
Go To Pinpoint Test E .
z Hard shifting zManual
transmission
concern.
z Loose pressure
plate to flywheel
bolts. z
Go To Pinpoint Test F . Klj . 2 ba
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PINPOINT TEST E: CLUTCH RELATED VIBRATIONS z
Inspect the flywheel for damage and
runout. Refer to Flywheel Runout Check .
z Is flywheel OK? Yes
GO to
D6 .
No
TIGHTEN, RESURFACE or INSTALL a new
flywheel as necessary. REFER to Section 308 -
01 . TEST the system for normal operation.
D6 INSPECT RELEASE LEVER
INTERFACE TO PIVOT STUD z
Inspect the release lever and the pivot
stud for damage or misalignment.
z Are there any signs of damage
present or misalignment between the
release lever and pivot stud? Yes
INSTALL a new pivot stud and release lever.
REFER to
Section 308 - 01 . TEST the system
for normal operation.
No
VERIFY customer concern. GO to Symptom Chart if necessary.
Test Step Result / Action to Take
E1 CHECK FOR ENGINE COMPONENT
GROUNDING z
Raise the vehicle on a hoist. Refer to
Section 100 - 02 .
z Check the engine and transmission
mounts for grounding.
z Check for exhaust manifolds or other
engine component grounding on the
body or frame.
z Is there evidence of grounding on
the body or frame? Yes
REPAIR the components as necessary. TEST the
system for normal operation.
No
GO to
E2 .
E2 CHECK FOR ACCESSORY DRIVE
VIBRATIONS z
Key in START position.
z Remove the accessory drive belt.
z Does the vibration stop when the
accessory drive belt is removed
from the engine? Yes
REFER to
Section 303 - 05 to diagnose the
accessory drive belt components.
No
STOP the engine and INSTALL the drive belt. GO
to E3 .
E3 CHECK FOR RELEASE BEARING
NOISE z
Key in START position.
z Depress and hold the clutch pedal.
z Is a whirring, grating, or grinding
noise present only when pedal is
pushed? Yes
INSTALL a new clutch release hub and bearing.
REFER to
Section 308 - 01 .
No
GO to E4 .
E4 INSPECT THE FLYWHEEL
z
Key in OFF position.
z Remove the transmission. Refer to
Section 308 - 03A or
Section 308 - 03B .
z Carry out a flywheel check. Refer to
Flywheel Runout Check . Yes
VERIFY customer concern. GO to
Symptom Chart if necessary.
No Klj . 10 ba
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2. Inspect to determine if one of the following mechanical or electrical concerns apply:
a A leak in the vacuum control circuit may occur during acceleration (slow leak), at all times
(large leak), or only when specific functions are selected (indicating a leak in that portion of the
circuit). The vacuum hoses used in the passenger compartment control circuit are constructed
from PVC plastic material. The vacuum hoses used in the engine compartment are constructed
of Hytrel® . Because of the materials used, never pinch the vacuum hoses off during diagnosis
to locate a leak. A wood golf tee can be used as a plug when it is necessary to plug one end of
a vacuum hose for leak test purposes.
3. If the inspection reveals obvious concerns that can be readily identified, repair as required.
4. If the concern remains after the inspection, connect the scan tool to the data link connector (DLC) located beneath the instrument panel and select the vehicle to be tested from the scan
tool menu. If the vehicle selection cannot be entered:
zcheck that the program card is correctly installed.
z check the connections to the vehicle.
z check the ignition switch position.
If the scan tool still does not allow the vehicle selection to be entered, refer to the scan tool manual. 5. Carry out the DATA LINK DIAGNOSTIC TEST using the scan tool. If the scan tool responds with:
zCKT 914, CKT 915 or CKT 70 = ALL MODULE NO RESPONSE/NOT EQUIPPED, go to
Communication System Diagnostics in Section 418 - 00 to diagnose network concern.
z If the powertrain control module (PCM) is not listed for a communication concern, turn
the A/C function selector switch to OFF and execute self- test diagnostics for the PCM.
6. If any PCM DTCs are retrieved, and are related to the concern, go to the Powertrain Control Module Diagnostic Trouble Code (DTC) Index to continue diagnostics.
7. If no DTCs related to the concern are retrieved, go to the Symptom Chart to continue diagnostics.
Symptom Chart Visual Inspection Chart Mechanical Electrical
z
Loose, missing or damaged A/C compressor
drive belt.
z Loose or disconnected A/C clutch.
z Loose, misrouted or damaged vacuum lines. a
z Broken or leaking refrigerant lines.
z Broken or leaking vacuum control motor. z
Open fuses.
z Blower motor inoperative.
z A/C compressor inoperative.
z Circuitry open/shorted.
z Disconnected electrical
connectors.
Powertrain Control Module Diagnostic Trouble Code (DTC) Index DTC Description Action
P1460 WOT A/C cutout circuit
malfunction Refer to the Powertrain Control/Emissions Diagnosis
(PC/ED) manual.
P1464 A/C demand out of self-
test
range GO to DTC P1464. Klj . 5 ba
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GENERAL PROCEDURES
Air Conditioning (A/C) System Check —
Retail Procedure
NOTE: This Retail Procedure is not eligible for claiming on Ford paid repairs (warranty and ESP).
NOTE: The engine should be run at idle for 10 minutes with the air conditioning on and set to MAX A/C
before carrying out this retail procedure.
NOTE: Read and follow all of the Warnings, Cautions and Notes at the beginning of this section before
continuing.
1. Visual inspection
Open the hood and visually inspect the heating and air conditioning systems for the following:
zCoolant reservoir for correct coolant level
z Heater hoses for deterioration or loose connections
z Radiator and condenser for debris or damaged fins restricting airflow, loose mounting or
connections
z Accessory drive belt(s) and cooling fan(s) for wear or physical damage
z Refrigerant lines and connections for physical damage or loose connections
z Compressor for physical damage or loose connections
z Suction accumulator/drier for physical damage or loose connections
z Wiring and connectors for excessive wear, loose or damaged connections, or incorrect
routing
2. A/C refrigerant analysis
zCarry out air conditioning refrigerant analysis. For additional information, refer to
Refrigerant Identification Testing in this section.
z If the refrigerant fails the analysis, discontinue diagnosis and make recommendations for
repairs.
z If the refrigerant passes the analysis, carry out the air conditioning system check.
3. Air conditioning system check
zConnect manifold gauge set or charging station with gauges to refrigerant system.
z With the vehicle in park, parking brake set, thermometer installed in center panel vent,
and air conditioning system on and set to MAX A/C, start the engine.
z Record air refrigerant system pressures while running the engine at 1,500 rpm and allow
engine to return to idle.
z Operate the blower motor in all control positions and check for correct blower speed
changes.
z With the blower motor on HI, operate air discharge mode selector in all positions and
check for correct airflow in each position.
z Operate the temperature blend selector in all positions and check for correct change in
discharge temperature. Check the air discharge temperature with the selector in the
coolest position and the air conditioning on and set to MAX A/C to determine if the air
discharge temperature is acceptable for the current ambient air temperature.
z Carry out the EATC self- test (if applicable).
If the refrigerant system pressures were low, carry out the refrigerant system leak test.
SECTION 412-
00: Climate Control System - General Information 2003 Mustang Workshop Manual Klj . 1 ba
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4. Disconnect the mass airflow (MAF) sensor electrical connector.
5. Remove the air cleaner outlet tube (9B659).
1. Loosen the clamp.
2. Disconnect the crankcase ventilation tube (6758).
3. Remove the air cleaner outlet tube assembly.
6. Remove the drive belt (8620) from the A/C compressor pulley.
7. Disconnect the electrical compressor clutch connector.
8. Remove the bolt and disconnect the A/C manifold and tube (19D734). zDiscard the O- ring seals. Klj . 2 ba
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REMOVAL AND INSTALLATION
Air Conditioning (A/C) Compressor —
4.6L
Removal and Installation CAUTION: If installing a new air conditioning compressor due to an internal failure of the
old unit, you must carry out the following procedures to remove contamination from the air
conditioning system.
zIf A/C flushing equipment is available, carry out the flushing of the air conditioning
system prior to installing a new air conditioning compressor. For additional information,
refer to Section 412 - 00 .
z If A/C flushing equipment is not available, carry out filtering of the air conditioning
system after a new air conditioning compressor has been installed. For additional
information, refer to Section 412 - 00 .
z Install a new evaporator core orifice (19D990), as directed by the A/C flushing or filtering
procedure.
z Install a new suction accumulator (19C836), as directed by the A/C flushing or filtering
procedure.
NOTE: Installation of a new suction accumulator is not required when repairing the air conditioning
system except when there is physical evidence of system contamination from a failed A/C compressor
or damage to the suction accumulator.
1. If flushing of the air conditioning system has not been performed, recover the refrigerant. For additional information, refer to Section 412 - 00 .
2. Remove the drive belt from the A/C compressor pulley.
3. Raise the vehicle. For additional information, refer to Section 100 - 02 .
4. Disconnect the A/C compressor electrical connector. SECTION 412-
03: Air Conditioning 2003 Mustang Workshop Manual Material
Item Specification
PAG Refrigerant Compressor
Oil (R-
134a Systems)
F7AZ- 19589- DA (Motorcraft YN-
12- C) WSH-
M1C231-
B Klj . 1 ba
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Instrument Cluster—
Base 4.6L Engine transmission)
16 — LOW FUEL level indicator
17 — SERVICE ENGINE SOON indicator
18 — THEFT indicator
19 — AIR BAG warning indicator
20 — Charging system indicator
21 — Safety belt warning indicator
Item Part
Number Description
1 — Fuel gauge
2 — Engine coolant temperature gauge
3 — Speedometer
4 — Turn signal/hazard indicator
5 — High beam indicator
6 — Tachometer
7 — Odometer
8 — Trip odometer reset button
9 — Voltmeter gauge
10 — Oil pressure gauge
11 — CHECK FUEL CAP indicator
12 — BRAKE warning indicator
13 — ABS warning indicator Klj . 2 ba
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Instrument Cluster—
Cobra 14 — Traction control indicator
15 — Overdrive off (O/D OFF) indicator (automatic
transmission)
16 — LOW FUEL level indicator
17 — SERVICE ENGINE SOON indicator
18 — THEFT indicator
19 — AIR BAG warning indicator
20 — Charging system indicator
21 — Safety belt warning indicator
Item Part
Number Description
1 — Fuel gauge
2 — Engine coolant temperature gauge
3 — Speedometer
4 — Turn signal/hazard indicator
5 — High beam indicator
6 — Tachometer
7 — Odometer
8 — Trip odometer reset button
9 — Boost gauge
10 — Oil pressure gauge
11 — CHECK FUEL CAP indicator
12 — BRAKE warning indicator Klj . 3 ba
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13 — ABS warning indicator
14 — Traction control indicator
15 — Overdrive off (O/D OFF) indicator (automatic
transmission)
16 — LOW FUEL level indicator
17 — SERVICE ENGINE SOON indicator
18 — THEFT indicator
19 — AIR BAG warning indicator
20 — Charging system indicator
21 — Safety belt warning indicator Klj . 4 ba
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