check engine FORD MUSTANG 2003 Workshop Manual

PINPOINT TEST F: HARD SHIFTING z
Is the flywheel OK? TIGHTEN, RESURFACE or INSTALL a new
flywheel. REFER to
Section 308 - 01 . TEST the
system for normal operation. Test Step Result / Action to Take
F1 CHECK THE CLUTCH RELEASE CABLE
z
NOTE: Check the upper shift boot for twisting.
z NOTE: Check the engine idle speed.
z Inspect the clutch release cable for wear or damage. Make
sure the clutch release cable is correctly routed and that all
the fasteners are installed.
z Are there any fasteners missing or is the cable worn,
damaged or incorrectly routed? Yes
REPAIR or INSTALL a new
clutch release cable as
necessary. TEST the
system for normal
operation.
No
GO to
F2 .
F2 CHECK THE CLUTCH PEDAL
z
Loosen the clutch pedal shaft nut.
z Lift the clutch pedal to the most upward position.
z While holding the clutch pedal in the most upward position,
tighten the nut.
z Was the clutch pedal incorrectly adjusted? Yes
VERIFY customer concern.
TEST the system for
normal operation.
No
GO to
F3 .
F3 CHECK THE CLUTCH PEDAL QUADRANT
z
Pull up on the clutch pedal to the upstop. Pulling up on the
pedal ensures that the quadrant is free to rotate through it's
complete range of motion against the spring load of the
quadrant.
z Is the clutch pedal quadrant binding? Yes
INSTALL a new quadrant.
TEST the system for
normal operation.
No
GO to
F4 .
F4 MEASURE THE CLUTCH RESERVE
NOTE:
Do not check the clutch system after the road test.
Allow the vehicle to cool down before carrying out the clutch
reserve check. NOTE: Remove the floor mat, if equipped, to
allow the clutch pedal to travel to the downstop.
z Install a cable tie to the lower clutch pedal, than attach a
tape measure to the cable tie. Yes
INSTALL a new pressure
plate and clutch disc.
REINSTALL the
transmission. RECHECK
the clutch reserve. TEST
the system of normal
operation.
No
GO to
F5 . Klj . 11 ba
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PINPOINT TEST G: EXCESSIVE NOISE contamination, REPAIR as
necessary. TEST the
system for normal
operation. If the
transmission is still hard to
shift, GO to
F9 .
No
TIGHTEN the bolts to 80
Nm (59 lb- ft). TEST the
system for normal
operation. If the
transmission is still hard to
shift, GO to F9 .
F9 INSPECT THE TRANSMISSION
z
Remove the transmission.
z Disassemble the transmission. Refer to Section 308 - 03B .
z Carry out the following:
zinspect all the shift rails for excessive scuffing or
wear.
z check the interlock pins on the shift rail.
z make sure the interlock bolts are tighten to 31 Nm (23
lb-ft).
z inspect the shift pads for wear or cracking.
z inspect the shift forks for wear or damage.
z check the synchronizer rings (of the affected gear[s])
for wear or damage.
z check the synchronizer hubs (of the affected gear[s])
for wear or damage.
z inspect the clutching teeth of the affected gear.
z Are there any internal components worn or damaged? Yes
INSTALL new components
or REPAIR as necessary.
TEST the system for
normal operation.
No
ASSEMBLE and INSTALL
the transmission. TEST the
system for normal
operation.
Test Step Result / Action to Take
G1 TRANSMISSION NEUTRAL GEAR ROLLOVER TEST
z
Start the engine and let it idle with the transmission in
neutral and the clutch engaged (pedal up). If noise is
excessive, depress the clutch pedal to stop the
transmission input shaft from rotating.
z Does the noise stop when the clutch pedal is
depressed? Yes
INSPECT the clutch component
for damage. REFER to General
Procedures in this section.
No
GO to
G2 .
G2 CHECK THE PILOT BEARING
z
Inspect the pilot bearing for damage. Refer to Bearing .
z Is the pilot bearing OK? Yes
GO to
G3 .
No
INSTALL a new pilot bearing.
REFER to Section 308 - 01 .
G3 CHECK TORSION SPRINGS
z
Inspect the torsion springs for fatigue or breakage.
z Are there any signs of fatigue or breakage? Yes
INSTALL a new clutch disc.
REFER to
Section 308 - 01 .
TEST the system for normal
operation. Klj . 14 ba
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DESCRIPTION AND OPERATION
Fuel Tank And Lines
WARNING: Do not smoke, carry lighted tobacco or an open flame of any type when
working on or near any fuel- related component. Highly flammable mixtures are always present
and may be ignited, possibly resulting in personal injury.
The vehicle utilizes a returnless fuel system consisting of:
zthe fuel tank.
z a fuel tank filler pipe which contains a restrictor plate to permit only unleaded fuel to be pumped
into the fuel tank.
z a 1/8 turn fuel tank filler cap.
z a fuel filter providing filtration to protect the fuel injectors.
z a single fuel line accommodating the returnless fuel system.
z a fuel injection supply manifold which contains a differential pressure sensor and a fuel
temperature sensor.
z a fuel pump and sender assembly which provides pressurized fuel to the engine and contains:
„an inlet filter.
„ a check valve which maintains system pressure after the pump is shut off.
„ a pressure relief valve for overpressure protection in the event of restricted flow.
The fuel pump is controlled by an electronic fuel pump driver module which is enabled by the
powertrain control module (PCM). Electrical power to the fuel pump is provided through the inertia fuel
shutoff (IFS) switch, which is located in the luggage compartment. SECTION 310-
01: Fuel Tank and Lines 2003 Mustang Workshop Manual Klj . 1 ba
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z
Foreign object
caught in
accelerator
pedal linkage. z
CHECK the accelerator pedal
linkage.
z Worn or
damaged
throttle body. z
INSTALL a new throttle body.
REFER to Section 303 - 04A or
Section 303 - 04B .
z High engine idle
speed z
Kinked
accelerator
cable. z
INSTALL a new accelerator
cable.
z Foreign object
caught in
accelerator
pedal linkage. z
CHECK the accelerator pedal
linkage.
z Incorrect engine
idle speed. z
REFER to the Powertrain
Control/Emissions Diagnosis
(PC/ED) manual for diagnosis
and testing of the idle control
system. Klj . 2 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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Item Part Number Description
1 18A318 Vacuum control motor, panel/defrost door
2 18A478 Panel/defrost door (full vacuum position)
3 — Defrost airflow
4 — Side window demister airflow
5 18B545 Temperature blend door (full heat position)
6 19860 A/C evaporator core
7 19A813 Air inlet door (full vacuum position)
8 — Outside air inlet
9 18A318 Vacuum control motor—
air inlet door 10 — Recirculated air inlet
11 19805 Blower motor
12 — Vacuum from the engine intake manifold
13 19A563 A/C vacuum check valve
14 19A566 A/C vacuum reservoir tank and bracket
15 19B888 A/C-
heater function selector switch Klj . 3 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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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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PINPOINT TEST A: INCORRECT/ERRATIC DIRECTION OF AIRFLOW
FROM OUTLET z
Is there voltage present? Test Step Result / Action to
Take A1 CHECK AIRFLOW FROM DEFROSTER OUTLETS
z
Key in START position.
z Place the heater blower motor switch in the HI position and
rotate the function selector switch to each position.
z Check for correct airflow from each function selector switch
position at engine idle and during engine speed acceleration.
z Is there airflow from defroster outlets under all conditions? Yes
GO to
A2 .
No
If the airflow is from
defroster outlets in all
switch positions only
under engine speed
acceleration, GO to
A19 .
If the airflow is
incorrect under one or
more conditions, GO to
A13 .
If the airflow is correct
under all conditions,
RETURN to the
Symptom Chart. A2 CHECK THE VACUUM SUPPLY HOSE
z
Key in OFF position.
z Verify the vacuum supply hose is connected between the engine
manifold and the A/C vacuum check valve.
z Is the hose connected? Yes
GO to
A3 .
No
RECONNECT the
hose. TEST the system
for normal operation. A3 LEAK CHECK THE VACUUM SUPPLY HOSE Klj . 8 ba
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z
Disconnect: Vacuum Supply Hose.
z Connect one end of the vacuum supply hose to a vacuum pump
and test for leaks.
z Does the hose leak? Yes
REPAIR or INSTALL a
new vacuum hose.
TEST the system for
normal operation.
No
GO to
A4 .
A4 CHECK THE VACUUM CHECK VALVE
z
Key in START position.
z Check the A/C vacuum check valve for correct installation by
removing (one at a time) the reservoir hose and the control
assembly source hose from the A/C vacuum check valve. Check
for vacuum.
z Is vacuum available at both check valve ports? Yes
GO to
A6 .
No
GO to A5 .
A5 INSPECT THE VACUUM CHECK VALVE
z
Key in OFF position.
z Disconnect: A/C Vacuum Check Valve.
z Inspect the A/C vacuum check valve for an obstruction and
correct operation. Airflow through the A/C vacuum check valve
should be in the direction toward the engine (engine connection
site is marked "VAC").
z Is the A/C vacuum check valve plugged or obstructed? Yes
INSTALL a new A/C
vacuum check valve.
TEST the system for
normal operation.
No
GO to
A6 .
A6 LEAK TEST THE VACUUM CHECK VALVE
z
Key in OFF position.
z Disconnect: Vacuum Check Valve.
z Connect the A/C vacuum check valve to a vacuum pump with
two hoses and a tee fitting. Yes
INSTALL a new A/C
vacuum check valve.
TEST the system for
normal operation.
No
RECONNECT the A/C
vacuum check valve.
GO to
A7 . Klj . 9 ba
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