battery FORD MUSTANG 2003 Workshop Manual

PINPOINT TEST I: NO OPERATION IN HIGH BLOWER SETTING z
Is the resistance less than 5 ohms? Low None
Medium/low 2 and 3 only
Medium/high 2, 3 and 4 only
High 1, 2 and 4 only INSTALL a new heater blower
motor switch. REFER to
Section 412 - 04 . TEST the system for
normal operation. H4 CHECK THE FUNCTION SELECT SWITCH FOR A
SHORT TO BATTERY z
Key in OFF position.
z Disconnect: Function Selector Switch C294c.
z Key in ON position.
z Did the blower motor stop operating? Yes
INSTALL a new function selector
switch. REFER to
Section 412 -
04 . TEST the system for normal
operation.
No
REPAIR circuit 249 (DB/LG) for a
short to battery. TEST the system
for normal operation. Test Step Result / Action to Take
I1 CHECK CIRCUIT 261 (OG/BK) FOR AN OPEN CIRCUIT
z
Key in OFF position.
z Disconnect: Blower Motor Switch C294a.
z Key in ON position.
z Turn the function selector switch to the FLOOR position.
z Measure the voltage between blower motor switch C294a,
circuit 261 (OG/BK), harness side and ground.
z Is the voltage greater than 10 volts? Yes
GO to
I2 .
No
REPAIR circuit 261 (OG/BK)
for an open circuit. TEST the
system for normal operation. I2 CHECK CIRCUIT 1205 (BK) FOR AN OPEN Klj . 35 ba
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GENERAL PROCEDURES
Electronic Leak Detection
CAUTION: Good ventilation is necessary in the area where electronic A/C leak testing is to
be carried out. If the surrounding air is contaminated with refrigerant gas, the leak detector will
indicate this gas all the time. Odors from other chemicals such as anti- freeze, diesel fuel, disc
brake cleaner, or other cleaning solvents can cause the same problem. A fan, even in a well-
ventilated area, is very helpful in removing small traces of contamination from the air that
might affect the leak detector.
1. NOTE: The system pressure should be between 413- 551 kPa (60-80 psi) at 24°C (75°F) with
the engine off.
Leak test the refrigerant system using the Refrigerant Leak Detector. Follow the instructions
included with the leak detector for handling and operation techniques.
2. If a leak is found, discharge and recover the refrigerant. For additional information, refer to Air Conditioning (A/C) System Recovery, Evacuation and Charging in this section.
z Repair the system.
z Test the system for normal operation.
SECTION 412-
00: Climate Control System - General Information 2003 Mustang Workshop Manual Special Tool(s)
H10PM Refrigerant Leak
Detector With Battery
216-
00001 or equivalent Klj . 1 ba
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REMOVAL AND INSTALLATION
Evaporator Core Housing
Removal
NOTE:
The evaporator core is not separately serviceable, it is serviced only with the evaporator core
housing assembly.
1. Disconnect the battery ground cable.
2. Recover the refrigerant. For additional information, refer to Section 412 - 00 .
3. Drain the cooling system. For additional information, refer to Section 303 - 03A or
Section 303 -
03B .
4. Remove the instrument panel. For additional information, refer to Section 501 - 12 .
5. Disconnect the heater hose couplings from the heater core. For additional information, refer to Section 412 - 00 .
6. Disconnect the vacuum connector. SECTION 412-
02: Heating and Ventilation 2003 Mustang Workshop Manual Material
Item Specification
PAG Compressor Oil (R-134a
Systems)
F7AZ- 19589- DA (Motorcraft
YN- 12-C) WSH-
M1C231-
B MERPOL®
NA ESE-
M99B144-
B Klj . 1 ba
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z
A one- piece lip- type seal (installed from the front of the A/C compressor) is used to seal it at the
shaft opening in the assembly.
z Five double- acting pistons operate within the cylinder assembly. The pistons are actuated by a
swashplate that converts the rotating action of the shaft to a reciprocating force.
z Reed- type discharge valves are located between the cylinder assembly and the head at each
end of the A/C compressor.
z The A/C compressor uses PAG oil, or equivalent. This oil contains special additives required for
the A/C compressor.
z The A/C compressor oil from vehicles equipped with an FS- 10 A/C compressor may have some
dark colored streaking while maintaining a normal oil viscosity. This is normal for the A/C
compressor and is caused by break- in wear of the piston rings.
The magnetic A/C clutch has the following characteristics: zIt drives the compressor shaft.
z When the battery positive voltage (B+) is applied to the A/C clutch field coil, the clutch plate and
hub assembly is drawn toward the A/C clutch pulley.
z The magnetic force locks the clutch plate and hub assembly and the A/C clutch pulley together
as one unit, causing the compressor shaft to rotate.
z When (B+) is removed from the A/C clutch field coil, springs in the clutch plate and hub
assembly move the clutch plate away from the A/C clutch pulley. A/C Compressor Pressure Relief Valve Item Part Number Description
1 19D798 A/C clutch field coil
2 19D784 A/C clutch pulley
3 N805338-S2 Pulley snap ring
4 19D648 A/C clutch hub spacer
5 19D786 Disk and hub assembly
6 N805332-S2 A/C clutch bolt Klj . 3 ba
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REMOVAL AND INSTALLATION
Air Conditioning (A/C) Compressor —
3.8L
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. Disconnect the battery. For additional information, refer to Section 414 - 01
3. Unlatch the air breather.
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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The boost pressure gauge on the instrument cluster receives and measures the boost pressure
directly from the intake manifold. The boost pressure gauge will display between 0.0-
0.48 kpa (0.0-10
psi) boost pressure dependent upon accelerator position, engine load, and engine rpm.
LOW FUEL Level Indicator
The low fuel level indicator is hardwired from the fuel sender to the instrument cluster. The instrument
cluster will illuminate the low fuel indicator when the usable fuel quantity is less than 1/8 tank (15%) of
fuel tank capacity.
Oil Pressure Gauge
The oil pressure gauge is hardwired from the oil pressure switch to the instrument cluster. The oil
pressure gauge will indicate either normal or no oil pressure.
CHECK FUEL CAP
The CHECK FUEL CAP indicator is used to indicate significant leaks in the fuel tank evaporative
system due to a loose fuel cap. Fuel tank pressure is monitored by the PCM. If a leak is detected the
PCM signals a fault to the instrument cluster via the SCP network. Once the PCM has detected a
loose fuel cap and the CHECK FUEL CAP indicator is illuminated, the indicator will remain illuminated
until the fuel cap is secured and the vehicle has been running for several minutes. For additional
information, refer to the Powertrain Control/Emissions Diagnosis (PC/ED) manual.
BRAKE Warning Indicator
The BRAKE warning indicator activates when the generic electronic module (GEM) detects the ignition
switch circuits are in the RUN state, when the GEM detects low brake fluid level, or that the parking
brake is applied. The BRAKE warning indicator will prove out starting when the GEM detects that the
ignition circuits have made a transition to RUN or START from OFF, ACC, or keyout and ending when
either three seconds have elapsed or when the GEM detects the ignition circuits have made a
transition to OFF, ACC, or keyout.
Safety Belt Warning Indicator
The safety belt switch is hardwired to the GEM. The safety belt warning indicator will be illuminated
when the GEM sends a ground signal to the instrument cluster.
ABS Warning Indicator
The ABS warning indicator will be illuminated when the anti- lock brake control module sends a ground
signal to the instrument cluster. The prove- out of the ABS indicator is controlled by the anti- lock brake
control module.
SERVICE ENGINE SOON Indicator
The SERVICE ENGINE SOON indicator receives its signal from the PCM over the SCP network. If the
instrument cluster does not receive a message from the PCM within five seconds, the instrument
cluster will illuminate the SERVICE ENGINE SOON indicator and log a diagnostic trouble code (DTC).
High Beam Indicator
The high beam indicator will illuminate when the steering column multifunction switch is in the high
beam position by sending a battery signal to the instrument cluster. Right and Left Turn Indicator Klj . 3 ba
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The right and left turn indicators will illuminate when the steering column multifunction switch is in
either turn signal position or hazard lamps position by sending a battery signal to the instrument
cluster.
AIR BAG Warning Indicator
The AIR BAG warning indicator will be illuminated when the restraint control module (RCM) sends a
ground signal to the instrument cluster. The prove-
out of the AIR BAG warning indicator is controlled
by the RCM.
THEFT Indicator
The THEFT indicator provides a passive anti- theft system (PATS) prove-out. The THEFT indicator will
prove out for three seconds following the ignition switch cycle and will flash following an ignition switch
OFF transition to indicate that PATS is active.
Charging System Indicator
The charging system indicator will be illuminated when the generator provides a ground signal to the
instrument cluster. The instrument cluster provides a prove- out when the ignition switch is in the RUN
position with the engine off. When the engine is started, the generator removes the ground to the
instrument cluster and extinguishes the charging system indicator.
Overdrive Off (O/D OFF) Indicator
The O/D OFF indicator is controlled by the off/on message sent from the PCM over the SCP network.
The instrument cluster does not provide a prove- out for the O/D OFF indicator, but will remain
illuminated if the overdrive has been commanded off following the instrument cluster prove- out.
Traction Control Indicator
During initialization, the instrument cluster will receive the traction control system state status message
from the traction control module to determine if the vehicle is equipped with traction control. If the
vehicle is equipped with traction control, this information will be stored in random access memory
(RAM) and the indicator will prove out for three seconds during each ignition cycle. If this message is
not received, the instrument cluster will assume that the vehicle is not traction control equipped and
the indicator will remain off. When the traction control is active, the traction control module sends the
instrument cluster a traction control active signal and the instrument cluster illuminates the traction
control indicator. When the traction control is inactive, the traction control module removes the traction
control active signal and the instrument cluster turns off the indicator.
In the event of a traction control failure, the traction control indicator will remain off and the ABS
indicator will illuminate.
Inspection and Verification 1. Verify the customer concern.
2. Visually inspect for obvious signs of mechanical and electrical damage.
Visual Inspection Chart Mechanical Electrical
z
Fuel tank z
Central junction box (CJB) fuse(s): Klj . 4 ba
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Odometer
Display Description
GAGE Activates gauge sweep of all gauges, then displays present gauge values. Also
carries out the checksum tests on ROM and EE. All segments
illuminated Illuminates all odometer segments.
bulb Illuminates all micro-controlled indicators and LEDs. Install a new indicator or LED as
necessary. r Returns to normal operation of all micro-
controlled indicators and LEDs and displays
hexadecimal value for ROM level (used when requesting assistance from the hotline). EE Displays hexadecimal value for EE level (used when requesting assistance from the
hotline). dt Displays hexadecimal coding of final manufacturing test date (used when requesting
assistance from the hotline). dtc Displays continuous DTCs in hexadecimal format. Pressing the SELECT/RESET
button will display any DTCs stored before proceeding to the next step. enG Displays the English speed in mph. Speedometer will indicate present speed within
tolerances. Display will show 0 if input is not received, if input received is invalid for one second or more, or if speed is 0. m Displays the metric speed data (km/h). Speedometer will indicate present speed
within tolerances. Display will show 0 if input is not received, if input received is invalid for one second or more, or if speed is 0. tAc Displays the tachometer data received from the PCM via the SCP network within
tolerances. Tachometer will indicate present rpm. Display will show 0 if input is not received, if input received is invalid for one second or more, or if engine rpm is 0. FUEL Displays the code (0-255) for the fuel sender input to the instrument cluster. The fuel
gauge will display a filtered fuel level value. This filter will keep the pointer from moving suddenly or erratically.
z255 = open send +/- 0
z 232 = full stop +/- 0
z 215 = full mark +/- 10
z 178 = 3/4 mark +/- 8
z 138 = 1/2 mark +/- 7
z 93 = 1/4 mark +/- 5
z 41 = E mark +/- 4
z 54=LOW FUEL (0- 59)
z 0-18=short (0- 20 max) OIL Displays the code (0-
250) for the oil pressure switch input to the instrument cluster.
Oil pressure gauge will indicate present oil pressure. Normal oil pressure (greater
than 6 psi) will display a value between 000 and 176. A low oil pressure or an
inoperative engine oil pressure switch (less than 6 psi) will display a value greater
than 176. dEGC Display of engine temperature in degrees C input from cylinder head temperature
sensor.
z 49 C = "C" mark
z 60 C = normal band start
z 120 C = normal band end
z -40 C = no SCP message for 5 seconds bAtt Displays the code (0-255) for the battery voltage input to the instrument cluster.
Battery voltage gauge will indicate present battery voltage. Klj . 6 ba
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To exit the instrument cluster self-
diagnostic mode, turn the ignition switch to the OFF position or press
and hold the SELECT/RESET button for three or more seconds and release. z
93- 102 = 6.9- 9.1 volts (low voltage)
z 115- 124 = 8.5- 10.7 volts (norm band start)
z 215- 225 = 15.8- 18 volts (norm band end)
z 230- 241 = 16.9- 19.1 volts (high voltage) rhEo Displays the present decimal rheostat dimming input, 0-
255 (used when requesting
assistance from the hotline). rhi
rhS rho Not used.
Cr Displays the present RUN/START sense input. Display will show -
h for high input with
the ignition switch in the START position and - L for low input with the ignition switch in
the RUN position. PA-
PE7 Not used.
GAGE Repeats test display cycle.
Instrument Cluster Diagnostic Trouble Code (DTC) Index Diagnostic
Tool
Displayed DTC Self-
Diagnostic
Mode Displayed DTC Description Source Action
B1202 9202 Fuel Sender
Open Circuit Instrument
Cluster Go To Pinpoint Test B .
B1204 9204 Fuel Sender
Short to Ground Instrument
Cluster Go To Pinpoint Test B .
B1317 9317 Battery Voltage
High Instrument
Cluster Section 414 - 00 .
B1318 9318 Battery Voltage
Low Instrument
Cluster Section 414 - 00 .
B1342 9342 ECU is Defective Instrument
Cluster INSTALL a new instrument
cluster; REFER to Instrument Cluster in this section. TEST the
system for normal operation. B1343 9343 Heated Backlight
Input Circuit Failure Instrument
Cluster Section 501 - 11 .
B1356 9356 Ignition Run
Circuit Open Instrument
Cluster Go To Pinpoint Test A .
B1364 9364 Ignition Start
Circuit Open Instrument
Cluster Go To Pinpoint Test A .
B2143 A143 Odometer NVM
Mmory Failure Instrument
Cluster Go To Pinpoint Test J .
C1284 5284 Oil Pressure
Switch Failure Instrument
Cluster Go To Pinpoint Test C .
P1197 1197 Mileage Switch
Circuit Failure Instrument
Cluster Go To Pinpoint Test J . Klj . 7 ba
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GEM Diagnostic Trouble Code (DTC) Index
DTC Description Source Action
B1218 Horn Relay Coil Circuit Short to
VBatt GEM REFER to
Section 501 - 14B .
B1312 Lamp Headlamp Input Circuit
Short to Battery GEM REFER to
Section 413 - 09 .
B1317 Battery Voltage High GEM REFER to
Section 414 - 00 .
B1318 Battery Voltage Low GEM REFER to
Section 414 - 00 .
B1322 Driver Door Ajar Circuit Short to
Ground GEM REFER to
Section 417 - 02 .
B1330 Passenger Door Ajar Circuit
Short to Ground GEM REFER to
Section 417 - 02 .
B1334 Decklid Ajar Rear Door Circuit
Short to Ground GEM REFER to
Section 417 - 02 .
B1339 Chime Input Request Circuit
Short to Battery GEM REFER to
Section 413 - 09 .
B1340 Chime Input Request Circuit
Short to Ground GEM REFER to
Section 413 - 09 .
B1342 ECU is Defective GEM Clear the DTCs. Retrieve the DTCs. If DTC B1342
is retrieved, INSTALL a new GEM. REFER to Section 419 - 10 .
B1353 Ignition Key-
In Circuit Open GEM REFER to
Section 413 - 09 .
B1359 Ignition Run/Acc Circuit Failure GEM REFER to
Section 211 - 05 .
B1396 Power Door Lock Circuit Short
to Battery GEM REFER to
Section 501 - 14B .
B1397 Power Door Unlock Circuit
Short to Battery GEM REFER to
Section 501 - 14B .
B1405 Driver Power Window Down
Circuit Short to Battery GEM REFER to
Section 501 - 11 .
B1408 Driver Power Window Up
Circuit Short to Battery GEM REFER to
Section 501 - 11 .
B1426 Lamp Safety Belt Circuit Short
to Battery GEM Go To Pinpoint Test K .
B1428 Lamp Safety Belt Circuit Failure GEM Go To Pinpoint Test K .
B1431 Wiper Brake/Run Relay Circuit
Failure GEM REFER to
Section 501 - 16 .
B1432 Wiper Brake/Run Relay Circuit
Short to Battery GEM REFER to
Section 501 - 16 .
B1434 Wiper Hi/Low Speed Relay Coil
Circuit Failure GEM REFER to
Section 501 - 16 .
B1436 Wiper Hi/Low Speed Relay Coil
Circuit Short to Battery GEM REFER to
Section 501 - 16 .
B1438 Wiper Mode Select Switch
Circuit Failure GEM REFER to
Section 501 - 16 .
B1441 Wiper Mode Select Switch
Circuit Short to Ground GEM REFER to
Section 501 - 16 . Klj . 8 ba
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