charging FORD MUSTANG 2003 User Guide

54. Connect the fuel charging wiring harness.
55. Connect the 16-
pin and the 42-pin connectors.
56. Connect the evaporative emissions return tube. 57. Position the cables, and install the bolts. Klj . 15 ba
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SPECIFICATIONS
SECTION 303-
04A: Fuel Charging and Controls — 3.8L 2003 Mustang Workshop Manual General Specifications
Item Specification
Lubricants and Chemicals
SAE 5W-
20 Premium Synthetic Blend Motor Oil XO-5W20- QSP WSS-
M2C153- H
Torque Specifications Description Nm lb-
in Throttle body nuts and bolts 9 80
Fuel injection supply manifold bolts 10 89
42-
pin engine bulkhead electrical connector bolt 6 53 Klj . 1 ba
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DESCRIPTION AND OPERATION
Fuel Charging And Controls
The fuel injection supply manifold (9F792):
zdelivers fuel to the fuel injector.
z receives fuel from the fuel supply line.
The throttle body (9E926):
zcontrols air supply to the upper intake manifold (9424) by positioning the throttle plate.
z connects the accelerator cable (9A758) and, if equipped, the speed control actuator cable
(9A825) to the throttle lever.
z is not adjustable.
z cannot be cleaned.
The fuel injector (9F593):
zis electrically operated by the powertrain control module (PCM) (12A650).
z has an internal solenoid that opens a needle valve to inject fuel into the lower intake manifold.
z atomizes the fuel as the fuel is delivered.
z is deposit- resistant. Do not clean.
The fuel pressure relief valve (9H321):
zis used to inspect and relieve fuel pressure.
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04A: Fuel Charging and Controls — 3.8L 2003 Mustang Workshop Manual Klj . 1 ba
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DIAGNOSIS AND TESTING
Fuel Charging And Controls
Refer to the Powertrain Control/Emissions Diagnosis (PC/ED) manual.
SECTION 303-
04A: Fuel Charging and Controls — 3.8L 2003 Mustang Workshop Manual Klj . 1 ba
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GENERAL PROCEDURES
Idle Speed Adjustment
Powertrain Control/Emissions Diagnosis (PC/ED) manual
SECTION 303-
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REMOVAL AND INSTALLATION
Throttle Body
Removal and Installation
WARNING: Do not smoke or carry lighted tobacco or open flame of any type when
working on or near any fuel related components. Highly flammable mixtures are always present
and may ignite. Failure to follow these instructions may result in personal injury.
CAUTION: The throttle body bore and plate area have a special coating and cannot be
cleaned.
1. Remove the air cleaner outlet tube (9B659). For additional information, refer to Section 303 - 12 .
2. Disconnect the throttle position (TP) sensor electrical connector.
3. Disconnect the accelerator cable (9A758) and (if equipped) the speed control actuator cable (9A825).
4. NOTE: Discard the throttle body gasket after removing the throttle body.
Remove the throttle body. zRemove the nuts.
z Remove the bolts.
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REMOVAL AND INSTALLATION
Fuel Injectors
Removal and Installation
WARNING: Do not smoke or carry lighted tobacco or open flame of any type when
working on or near any fuel related components. Highly flammable mixtures are always present
and may ignite. Failure to follow these instructions may result in personal injury.
WARNING: Fuel in the fuel system remains under high pressure even when the engine is
not running. Before working on or disconnecting any of the fuel lines or fuel system
components, the fuel pressure must be relieved. Failure to follow these instructions may result
in personal injury
1. Remove the supply manifold. For additional information, refer to Supply Manifold in this section.
2. Remove the six fuel injectors from the supply manifold.
3. CAUTION: The retaining clip must be in the upper groove on the injector or the
injector may become loose.
NOTE: Inspect the two O- rings from each fuel injector. Install new O- rings as needed.
NOTE: Lubricate the new O- rings with clean engine oil to aid installation.
To install, reverse the removal procedure.
SECTION 303-
04A: Fuel Charging and Controls — 3.8L 2003 Mustang Workshop Manual Material
Item Specification
SAE 5W-
20 Premium Synthetic
Blend Motor Oil
XO- 5W20-QSP or equivalent WSS-
M2C153-
H Klj . 1 ba
22003 Mustang Workshop Manual
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REMOVAL AND INSTALLATION
Fuel Charging Wiring Harness
Removal and Installation
WARNING: Do not smoke or carry lighted tobacco or open flame of any type when
working on or near any fuel related components. Highly flammable mixtures are always present
and may ignite. Failure to follow these instructions may result in personal injury.
1. Disconnect the battery ground cable. For additional information, refer to Section 414 - 01 .
2. Remove the upper intake manifold. For additional information, refer to Section 303 - 01A .
3. Disconnect the following electrical connectors. z42- pin engine bulkhead connector
z 16- pin connector
z 8-pin connector
z A/C pressure switch
4. Separate the wiring harness from the dash panel.
5. Disconnect the intake manifold runner control (IMRC) actuator electrical connector.
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REMOVAL AND INSTALLATION
Supply Manifold
Removal and Installation
WARNING: Do not smoke or carry lighted tobacco or open flame of any type when
working on or near any fuel related components. Highly flammable mixtures are always present
and may ignite. Failure to follow these instructions may result in personal injury.
WARNING: Fuel in the fuel system remains under high pressure even when the engine is
not running. Before working on or disconnecting any of the fuel lines or fuel system
components, the fuel system pressure must be relieved. Failure to follow these instructions
may result in personal injury.
1. Disconnect the battery ground cable.
2. Remove the upper intake manifold. For additional information, refer to Section 303 - 01A .
3. Relieve the fuel pressure. For additional information, refer to Section 310 - 00 .
4. Disconnect the fuel line. For additional information, refer to Section 310 - 00 .
5. Separate the wiring harness from the supply manifold.
6. NOTE: Right side shown, left side similar.
Disconnect the six fuel injector electrical connectors. 7. Disconnect the fuel pressure sensor. SECTION 303-
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SPECIFICATIONS
SECTION 303-
04B: Fuel Charging and Controls — 4.6L (2V) 2003 Mustang Workshop Manual General Specifications
Item Specification
Lubricants and Chemicals
Super Premium SAE 10W-30, XO-
10W30-DSP WSS-
M2C153- G
Torque Specifications Description Nm lb-
ft lb-
in Throttle body bolts 10 — 89
Fuel injection supply manifold bolts 10 — 89
Fuel charging wiring 42 pin connector bolt 6 — 53
Battery supply wire nut 8 — 71
EGR pressure transducer bracket bolts 25 18 —
Generator battery supply nut 8 — 71 Klj . 1 ba
12003 Mustang Workshop Manual
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