coolant FORD MUSTANG 2003 Workshop Manual

18. Disconnect the electrical connector.
19. Disconnect the following generator electrical connectors:
zBattery power supply wire.
z Voltage regulator.
20. Disconnect the camshaft position (CMP) sensor electrical connector.
21. Disconnect the engine coolant temperature (ECT) sensor electrical connector. Klj . 5 ba
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DESCRIPTION AND OPERATION
Accessory Drive
Component Locations—
3.8L
Component Locations— 4.6L
SECTION 303-
05: Accessory Drive 2003 Mustang Workshop Manual Item Part Number Description
1 19D784 A/C clutch pulley
2 8620 Drive belt
3 8509 Coolant pump pulley
4 8678 Belt idler pulley
5 10344 Generator pulley
6 10344 Power steering pump pulley
7 63126 Crankshaft vibration damper
8 6B209 Drive belt tensioner
9 — Drive belt tensioner (part of 6B209)
Item Part Number Description
1 10344 Generator pulley
2 8620 Drive belt
3 8A528 Coolant pump pulley
4 3D673 Power steering pump pulley
5 6316 Crankshaft vibration damper
6 19D784 A/C clutch pulley Klj . 1 ba
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Item Part Number Description
1 8678 Belt idler pulley
2 8678 Belt idler pulley
3 8678 Belt idler pulley
4 3A733 Power steering pulley
5 10344 Coolant pump pulley
6 6C254 Crankshaft pulley
7 6B209 Belt tensioner
8 19D784 A/C clutch pulley
9 8620 Drive belt Klj . 2 ba
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Component Tests
Drive Belt Noise/Flutter
Drive belt chirp occurs due to pulley misalignment or excessive pulley runout. It can be the result of a
damaged pulley or an incorrectly aligned pulley.
To correct, determine the area where the noise comes from. Check each of the pulleys in that area
with a straightedge to the crankshaft pulley, looking for accessory pulleys out of position in the fore/aft
direction or at an angle to the straightedge.
Drive belt squeal is an intermittent noise that occurs when the drive belt slips on a pulley during certain
conditions, such as: engine start up, rapid engine acceleration, or A/C clutch engagement.
Drive belt squeal can occur:
zif any of the accessories are damaged, have a worn or damaged bearing, internal torsional
resistance above normal. All accessories should be rotatable by hand in the unloaded condition.
If not, inspect the accessory.
z if fluid gets on the drive belt. This includes power steering fluid, engine coolant, engine oil or air
conditioning system lubricant. If fluid does get on the drive belt during service, clean the drive
belt with soap and water and thoroughly rinse with clean water.
z NOTE: The drive belt tensioner arm should rotate freely without binding.
if the drive belt is too long. A drive belt that is too long will allow the drive belt tensioner arm to
go all the way to the arm travel stop under certain load conditions, which will release tension to
the drive belt. If the drive belt tensioner indicator is outside the installation wear range window,
install a new drive belt.
z if the drive belt tensioner is worn or damaged.
Belt Tension
NOTE: Drive belt tension is not adjustable.
The drive belt tensioner automatically adjusts drive belt tension. Symptom Chart Condition
Possible Sources Action
z Drive belt
noise, chirping,
flutter z
Defective/worn drive
belt.
z Misaligned pulley.
z Pulley runout.
z Damaged
accessories.
z Fluid contamination
of drive belt. z
GO to Component Tests, Drive
Belt, Noise/Flutter.
z Damaged or worn
drive belt tensioner. z
GO to Component Tests, Belt
Tensioner, Automatic.
z Premature
drive belt wear z
Defective drive belt.
z Misaligned pulley.
z Pulley runout.
z Damaged
accessories.
z Incorrectly installed
drive belt. z
GO to Component Tests, Drive
Belt Noise/Flutter and Drive
Belt Misalignment diagnosis. Klj . 2 ba
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REMOVAL AND INSTALLATION
Accessory Drive Belt —
4.6L (2V) and (4V)
Removal and Installation
Mach I 1. Remove the air intake scoop. For additional information, refer to Section 303 - 12 .
Cobra 2. Remove the supercharger drive belt cover.
3. Rotate the supercharger belt tensioner clockwise and remove the supercharger belt.
4. Remove the coolant hose mounting bolt.
5. Remove the belt idler support bracket assembly.
SECTION 303-
05: Accessory Drive 2003 Mustang Workshop Manual Klj . 1 ba
22003 Mustang Workshop Manual
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REMOVAL AND INSTALLATION
Accessory Drive Belt Idler Pulley —
4.6L (2V) and (4V)
Removal and Installation
Mach I 1. Remove the air intake scoop. For additional information, refer to Section 303 - 12 .
Cobra 2. Remove the supercharger drive belt cover.
3. Rotate the supercharger belt tensioner clockwise and remove the supercharger belt.
4. Remove the coolant hose mounting bolt.
5. Remove the belt idler support bracket assembly.
SECTION 303-
05: Accessory Drive 2003 Mustang Workshop Manual Klj . 1 ba
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SPECIFICATIONS
a
Refer to the procedure
SECTION 303-
12: Intake Air Distribution and Filtering 2003 Mustang Workshop Manual Torque Specifications
Description Nm lb-
ft lb-
in Air cleaner and duct assembly bolt 7 62 —
Coolant supply and return manifold
a — — —
Charge air cooler bolts
a — — —
Supercharger mounting bolts
a — — —
Air intake scoop bolts 25 18 —
Air intake scoop bracket bolt 25 18 —
Air intake scoop bracket nuts 25 18 —
Air intake scoop bracket throttle body nut 9 — 80
Exhaust gas recirculation (EGR) vacuum regulator solenoid bolts 10 — 89 Klj . 1 ba
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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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28. Remove the coolant supply and return manifold.
29. Remove the coolant supply and return tubes and seals.
30. Remove the fuel supply manifold mounting studs.
31. Remove the fuel supply manifold and fuel injectors as an assembly. Klj . 7 ba
102003 Mustang Workshop Manual
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37.
NOTE: Once the torque procedure has been started, final tightening must be finished within five
minutes maximum.
Tighten the CAC bolts in the sequence shown in two stages. 1. Tighten to 2 Nm (18 lb- in).
2. Tighten to 6 Nm (53 lb- in).
38. Tighten the supercharger and CAC cooler assembly- to-lower intake manifold bolts in the
sequence shown in three stages.
1. Tighten to 2 Nm (18 lb- in).
2. Tighten to 25 Nm (18 lb- ft).
3. Tighten an additional 90 degrees.
39. Tighten the coolant supply and return manifold in two stages. 1. Tighten to 10 Nm (89 lb- ft).
2. Tighten an additional 90 degrees. Klj . 9 ba
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