fuel FORD MUSTANG 2003 User Guide

Exceptions To Normal Schedule
Yellow Coolant
zChange coolant at 5 years or 160,000 km (100,000 miles) of the vehicle's life, whichever comes
first.
z After the initial change, change coolant every 3 years or 80,000 km (50,000 miles) thereafter.
Natural Gas and Propane Vehicles
zInspect NGV fuel tanks from the date of tank manufacture every 3 years.
z Inspect propane fuel tanks from vehicle build date every 5 years.
z Install new NGV fuel tanks from the date of tank manufacture every 15 years.
Normal Vehicle Axle Maintenance
Rear axles and power take off (PTO) units containing synthetic lubricant and light duty trucks equipped
with Ford- design axles are lubricated for life. These lubricants are not to be checked or changed
unless service is required, or if a leak is suspected, or the axle assembly has been submerged in
water.
The axle and PTO should be changed anytime they have been submerged in water. Non- synthetic
rear axle lubricants should be replaced every 4,800 km (3,000 miles) or three months, whichever
occurs first, during extended trailer tow operation above 21°C (70°F) ambient and wide open throttle
for extended periods above 45 mph.
The 3,000 mile lube change interval may be waived if the axle was filled with 75W140 synthetic gear
lubricant meeting Ford specification WSL- M2C192-A, part number F1TZ-19B546- B or equivalent. Add
four ounces of additive friction modifier C8AZ-19B546- A (EST-M2C118- A) or equivalent for complete
refill of Traction- Lok rear axles.
The axle lubricant should be changed anytime an axle has been submerged in water.
Police and Taxi Vehicle Axle Maintenance
Replace rear axle lubricant every 160,000 km (100,000 miles). Rear axle lubricant change may be
waived if the axle was filled with 75W140 synthetic gear lubricant meeting Ford specification WSL-
M2C192- A, part number FITZ-19580-B or equivalent. Add four ounces of additive friction modifier
C8AZ- 19B546- A (EST-M2C118- A) or equivalent for complete refill of Traction- Lok rear axles.
The axle lubricant should be changed anytime an axle has been submerged in water. Klj . 10 ba
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NOTE:
A serpentine drive belt decreases the usefulness of this test. In these cases, use a
vibration analyzer, such as the VA, to pinpoint accessory vibrations. An electronic listening
device, such as an EngineEAR, will also help to identify noises from specific accessories.
Remove the accessory drive belts.
z Increase the engine rpm to where the concern occurs.
z If the vibration/noise is duplicated when carrying out this test, the belts and accessories are not
sources.
z If the vibration/noise was not duplicated when carrying out this test, install each accessory belt,
one at a time, to locate the source.
Vehicle Cold Soak Procedure
To carry out this procedure, proceed as follows:
zTest preparations include matching customer conditions (if known). If not known, document the
test conditions: gear selection and engine rpm. Monitor the vibration/noise duration with a watch
for up to three minutes.
z Park the vehicle where testing will occur. The vehicle must remain at or below the concern
temperature (if known) for 6- 8 hours.
z Before starting the engine, conduct a visual inspection under the hood.
z Turn the key on, but do not start the engine. Listen for the fuel pump, anti- lock brake system
(ABS) and air suspension system noises.
z Start the engine.
z CAUTION: Never probe moving parts.
Isolate the vibration/noise by carefully listening. Move around the vehicle while listening to find
the general location of the vibration/noise. Then, search for a more precise location by using a
stethoscope or EngineEAR.
z GO to Symptom Chart — Idle Noise/Vibration to assist with the diagnosis.
6: Check OASIS/TSBs/Repair History
After verifying the customer concern, check for OASIS reports, TSBs and the vehicle repair history for
related concerns. If information relating to a diagnosis/repair is found, carry out the procedure(s)
specified in that information.
If no information is available from these sources, carry out the vehicle preliminary inspection to
eliminate any obvious faults.
7: Diagnostic Procedure
Qualifying the concern by the particular sensation present can help narrow down the concern. Always
use the "symptom" to "system" to "component" to "cause" diagnosis technique. This diagnostic method
divides the problem into related areas to correct the customer concern.
zVerify the "symptom".
z Determine which "system(s)" can cause the "symptom".
„If a vibration concern is vehicle speed related, the tire and wheel rpm/frequency or
driveshaft frequency should be calculated.
„ If a vibration concern is engine speed related, the engine, engine accessory or engine
firing frequencies should be calculated. Klj . 9 ba
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CARRY OUT a driveline
vibration test. REFER to
Section 205
- 00 . REPAIR as
necessary.
z Binding or
damaged
splines on the
driveshaft slip-
yoke. z
CLEAN and INSPECT the
splines of the slip- yoke,
driveshaft and coupling
shaft for wear or damage.
INSTALL a new slip- yoke or
driveshaft assembly as
necessary. REFER to
Section 205 - 01 . REPAIR as
necessary.
z Driveshaft
runout. z
CARRY OUT a Runout
Check. REFER to Section 205 - 00 . REPAIR as
necessary.
z Incorrect lateral
and radial
tire/wheel
runout. z
INSPECT the tire and
wheels. MEASURE tire
runouts. REPAIR or
INSTALL new components
as necessary. REFER to
Section 204 - 04 .
z Driveline angles
out of
specification. z
CHECK for correct driveline
angles. REPAIR as
necessary. REFER to
Section 205 - 00 .
z Incorrectly
seated CV joint
in the front
wheel hub. z
CHECK the outer CV joint
for correct seating into the
hub. REPAIR as necessary. Symptom Chart —
Engine Noise/Vibration Condition
Possible Sources Action
z Grinding noise—
occurs during
engine cranking z
Incorrect starter
motor mounting. z
INSPECT the starter motor
for correct mounting.
REPAIR as necessary.
REFER to Section 303 - 06 .
z Starter motor. zCHECK the starter motor.
REPAIR or INSTALL a new
starter motor as necessary.
REFER to Section 303 - 06 .
z Incorrect starter
motor drive
engagement. z
INSPECT the starter motor
drive and flexplate/flywheel
for wear or damage.
INSTALL a new starter
motor drive or flywheel as
necessary. REFER to
Section 303 - 06 .
z Engine ticking
noise z
Fuel injector.
z Fuel line.
z Oil pump.
z Valve lifter.
z Belt tensioner.
z Water pump.
z Obstruction of cooling
fan. z
Go To Pinpoint Test B .
z Engine drumming zPowertrain mount. zCARRY OUT Klj . 23 ba
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noise—
normally
accompanied by
vibration Powertrain/Drivetrain Mount Neutralizing in this
section.
z Damaged or
misaligned exhaust
system. z
INSPECT the exhaust
system for loose or broken
clamps and brackets.
CARRY OUT Exhaust System Neutralizing in this
section.
z Whistling noise—
normally
accompanied
with poor idle
condition z
Air intake system. zCHECK the air intake
ducts, air cleaner, throttle
body and vacuum hoses for
leaks and correct fit.
REPAIR or ADJUST as
necessary. REFER to
Section 303 - 12
z
Clunking noise zWater pump has
excessive end play or
imbalance. z
CHECK the water pump for
excessive end play.
INSPECT the water pump
with the drive belt off for
imbalance. INSTALL a new
water pump as necessary.
REFER to Section 303 -
03A .
z Generator has
excessive end play. z
CHECK the generator for
excessive end play.
REPAIR or INSTALL a new
generator. REFER to
Section 414 - 02 .
z Pinging noise zExhaust system leak. zINSPECT the exhaust
system for leaks. REPAIR
as necessary.
z Gasoline octane too
low. z
VERIFY with customer the
type of gasoline used.
CORRECT as necessary.
z Knock sensor
operation. z
CHECK the knock sensor.
INSTALL a new knock
sensor as necessary.
REFER to Section 303 - 14 .
z Incorrect spark
timing. z
CHECK the spark timing.
REPAIR as necessary.
z High operating
temperature. z
INSPECT cooling system
for leaks. CHECK the
coolant level. REFILL as
necessary. CHECK the
coolant for the correct mix
ratio. DRAIN and REFILL
as needed. CHECK engine
operating temperature is
within specifications.
REPAIR as necessary.
z Foul- out spark plug. zCHECK the spark plugs.
REPAIR or INSTALL new
spark plugs as necessary.
z Catalytic converter. zAcceptable noise.
z Knocking noise—
light knocking
noise, also z
Excessive clearance
between the piston
and the cylinder wall. z
Engine cold and at high
idle. Using an EngineEAR,
pull a spark plug or fuel Klj . 24 ba
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described as
piston slap. Noise
is most
noticeable when
engine is cold
with light to
medium
acceleration.
Noise disappears
as engine warms
injector connector until the
noise goes away. CARRY
OUT a cylinder bore
clearance to piston check.
INSTALL a new piston.
REFER to
Section 303 - 01A
for 3.8L engines or
Section 303 - 01B for 4.6L (2V)
engines.
z Knocking noise—
light double
knock or sharp
rap sound.
Occurs mostly
with warm engine
at idle or low
speeds in DRIVE.
Increases in
relation to engine
load. Associated
with poor
lubrication history z
Excessive clearance
between the piston
and the piston pin. z
INSTALL a new piston or
piston pin. REFER to
Section 303 - 01A for 3.8L
engines or Section 303 - 01B
for 4.6L (2V) engines.
z Knocking noise—
light knocking
noise is most
noticeable when
engine is warm.
Noise tends to
decrease when
vehicle is
coasting or in
neutral z
Excessive clearance
between the
connecting rod
bearings and the
crankshaft. z
Engine warm and at idle.
Using an EngineEAR,
PULL a spark plug or fuel
injector connector until the
noise goes away. INSTALL
new bearings. REFER to
Section 303 - 01A for 3.8L
engines or Section 303 - 01B
for 4.6L (2V) engines.
z Knocking— deep
knocking noise.
Noise is most
noticeable when
engine is warm,
at lower rpm and
under a light load
and then at float z
Worn or damaged
crankshaft main
bearings. z
CARRY OUT DERU test.
CHECK for noise with
vehicle at operating
temperature, during
medium to heavy
acceleration. CHECK at
idle with injector
disconnected, noise does
not change. INSTALL new
main bearings. REFER to
Section 303 - 01A for 3.8L
engines or Section 303 - 01B
for 4.6L (2V) engines.
z Knocking noise—
occurs mostly
with warm engine
at light/medium
acceleration z
Spark plugs. zCHECK the spark plug for
damage or wear. INSTALL
new spark plugs as
necessary.
z Carbon accumulation
in combustion
chamber. z
REMOVE carbon from
combustion chamber.
z Whine or
moaning noise z
Air intake system. zCHECK the air cleaner and
ducts for correct fit.
INSPECT the air intake
system for leaks or
damage. REPAIR as
necessary. Klj . 25 ba
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as necessary.
z Accelerator pedal
vibration— felt
through the pedal
as a buzz z
Throttle cable loose
or misrouted. z
INSPECT the throttle cable.
REPAIR as necessary.
REFER to Section 310 - 02 .
z Engine
vibration— mostly
at coast/neutral
coast. Condition
improves with
vehicle
accelerating z
Combustion
instability. z
CHECK the ignition system.
INSTALL new components
as necessary.
z Engine vibration
or shudder—
occurs with light
to medium
acceleration
above 56 km/h
(35 mph) z
Worn or damaged
spark plugs. z
INSPECT the spark plugs
for cracks, high resistance
or broken insulator.
INSTALL a new spark plug
(s) as necessary.
z Plugged fuel injector. zREPAIR or INSTALL a new
injector as necessary.
REFER to Section 303 - 04A
for 3.8L engines or
Section 303 - 04B for 4.6L (2V)
engines.
z Damaged spark plug
wire. z
INSPECT the spark plug
wires for damage. INSTALL
a new spark plug wire(s) as
necessary.
z Contaminated fuel. zINSPECT the fuel for
contamination. DRAIN the
fuel system and refill.
z Worn or damaged
torque converter. z
CHECK the torque
converter. INSTALL a new
torque converter as
necessary. REFER to
Section 307 - 01 .
Symptom Chart—
Idle Noise/Vibration Condition
Possible Sources Action
z Idle air control (IAC)
valve moan — occurs
on throttle tip- out z
IAC valve is
contaminated
with oil. z
GO to Component Tests in
this section.
z Accessory drive belt
chirp — occurs at idle
or high idle, cold or
hot. Most common
occurrence is during
humid weather z
Accessory drive
belt worn, or
pulley is
misaligned or
loose. z
INSPECT for loose or
misaligned pulleys. CHECK
the drive belt for wear or
damage. INSTALL new
pulley(s)/drive belt, or
accessory drive components
as necessary. REFER to
Section 303 - 05 .
z Accessory drive
bearing hoot —
occurs at idle or high
idle in cold
temperatures of
approximately +4°C z
Accessory drive
idler or
tensioner pulley
bearing is
experiencing
stick/slip z
Go To Pinpoint Test C . Klj . 28 ba
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PINPOINT TEST B: ENGINE TICKING NOISE No
INSPECT the wheel
bearings. ADJUST or
REPAIR as necessary.
TEST the system for
normal operation.
A6 CHECK THE FRONT SUSPENSION
z
Check the front suspension for:
zBroken or loose bolts.
z Damaged springs.
z Worn or damaged upper and lower control arm
bushings.
z Loose or rough front bearings.
z Uneven tire wear.
z Are all the suspension components in satisfactory
condition? Yes
GO to
A7 .
No
REPAIR or INSTALL
new components as
necessary. TEST the
system for normal
operation. A7 RESURFACE THE FRONT BRAKE DISCS
z
CAUTION: Do not use a bench lathe to machine brake
discs.
z NOTE: Follow the manufacturer's instructions to machine the
brake discs. After machining, make sure the brake disc meets
the thickness specification.
z Refer to Brake Disc Machining in this section. Resurface the
front brake discs. Road test the vehicle.
z Is the vibration/shudder present? Yes
GO to
A8 .
No
Vehicle is OK. A8 CHECK THE REAR SUSPENSION
z
Check the rear suspension for:
zBroken or loose bolts.
z Damaged or worn springs or spring bushings.
z Worn or damaged upper and lower control arm
bushings.
z Worn or damaged trailing arms.
z Loose or rough rear bearings.
z Uneven tire wear.
z Are all the suspension components in satisfactory
condition? Yes
GO to
A9 .
No
REPAIR or INSTALL
new components as
necessary. TEST the
system for normal
operation. A9 RESURFACE THE REAR BRAKE DISC OR DRUM
z
CAUTION: Do not use a bench lathe to machine brake
discs.
z NOTE: Follow the manufacturers instructions to machine the
brake discs. After machining, make sure the brake disc meets
the thickness specification.
z Refer to Brake Disc Machining in this section. Resurface the
rear brake discs or drums. Road test the vehicle.
z Is the vibration/shudder present? Yes
CHECK the front
suspension for wear or
damage. RESURFACE
the front brake discs.
TEST the system for
normal operation.
No
Vehicle is OK.
Test Step Result / Action to Take
B1 CHECK FOR TICKING NOISE AT THE FUEL
RAIL z
Disconnect the first fuel line clip. Yes Klj . 49 ba
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z
Is the ticking noise gone? CHECK for TSB for applicable vehicle.
REPAIR as necessary. TEST the system
for normal operation.
No
GO to
B2 .
B2 CHECK FOR TICKING NOISE AT THE FUEL
INJECTOR z
Using an EngineEAR, listen at the fuel
injectors by placing a probe on each injector.
To isolate the faulty injector, disconnect the
injector electrical connector and listen for the
noise.
z Is the fuel injector the source of the ticking
noise? Yes
INSTALL a new fuel injector. REFER to
Section 303
- 04A for 3.8L engines or
Section 303 - 04B for 4.6L (2V) engines.
TEST the system for normal operation.
No
GO to B3 .
B3 CHECK THE BELT TENSIONER FOR TICKING
NOISE z
Inspect the accessory drive. Check for the belt
tensioner bottoming at end of travel or not at
end of stroke.
z Using an EngineEAR, listen at the belt
tensioner.
z Is the belt tensioner the source of the
noise? Yes
INSTALL a new belt tensioner. TEST the
system for normal operation.
No
GO to
B4 .
B4 CHECK THE WATER PUMP FOR TICKING
NOISE z
Using an EngineEAR, listen at the water pump
for ticking noise.
z Is the water pump the source of the noise? Yes
INSTALL a new water pump. REFER to
Section 303
- 03A . TEST the system for
normal operation.
No
GO to B5 .
B5 CHECK FOR AN OBSTRUCTION OF THE
COOLING FAN z
Inspect the cooling fan for obstructions.
z Check the cooling fan and shroud for wear or
damage.
z Was there an obstruction or does the
cooling fan show signs of damage? Yes
REPAIR or INSTALL a new cooling fan.
REFER to
Section 303 - 03A . TEST the
system for normal operation.
No
GO to B6 .
B6 CHECK THE OIL PUMP FOR TICKING NOISE
z
Check the oil pump using EngineEARs and
probe at the oil filter adapter to verify the oil
pump as a source.
z Is the oil pump the source of the noise? Yes
INSTALL a new oil pump. REFER to
Section 303
- 01A for 3.8L engines or
Section 303 - 01B for 4.6L (2V) engines.
TEST the system for normal operation.
No
GO to B7 .
B7 CHECK VALVE LIFTERS OR LASH
ADJUSTERS FOR CORRECT OPERATION z
Check valve lifter/lash adjuster for correct
operation, using EngineEARs.
z Are the valve lifters/lash adjusters Yes
VERIFY customer concern. CONDUCT a
diagnosis of other suspect components. Klj . 50 ba
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PINPOINT TEST G: ENGINE TICKING, KNOCKING OR CONTINUOUS
RATTLE
PINPOINT TEST H: FRONT SUSPENSION NOISE CONDUCT diagnosis of
other suspect components.
Test Step Result / Action to Take
G1 CHECK FOR NOISE AT THE VALVE COVERS
AND THE FRONT COVERS (OHC ENGINES) z
Carry out the Vehicle Cold Soak Procedure in
this section.
z Key in START position.
z NOTE: For a short- duration ticking noise,
multiple engine starts may be necessary.
z Using an EngineEAR, listen closely at the valve
covers and the front covers (OHC engines) by
placing the probe near the surface of the valve
cover and then on the surface front cover.
z Key in OFF position.
z Is the noise source apparent? Yes
REMOVE the appropriate cover and
INSPECT for loose, worn/broken
components. REPAIR as necessary.
TEST the system for normal operation.
No
GO to
G2 .
G2 CHECK FOR NOISE AT THE CYLINDER
BLOCK z
Key in START position.
z Using an EngineEAR, listen closely at the
cylinder block by placing a probe on or near
each freeze plug.
z Key in OFF position.
z Is the noise source apparent? Yes
REPAIR or INSTALL new components
as necessary.
No
GO to
G3 .
G3 CHECK FOR NOISE WHILE DISCONNECTING
EACH FUEL INJECTOR ELECTRICAL
CONNECTOR, ONE AT A TIME z
Key in START position.
z Disconnect each fuel injector electrical
connector, one at a time, to decrease piston
force and listen for the noise.
z Key in OFF position.
z Is the noise reduced or eliminated? Yes
INSTALL a new fuel injector. TEST the
system for normal operation.
No
INSPECT accessory drive system or the
transmission as a possible source.
Test Step Result / Action to Take
H1 ROAD TEST THE VEHICLE
z
Test drive the vehicle.
z NOTE: An assistant will be needed for this road test.
z During the road test, drive the vehicle over a rough road.
Using ChassisEARs, determine from which
area/component the noise is originating.
z Is there a squeak, creak or rattle noise? Yes
GO to
H2 .
No
The suspension system is
OK. CONDUCT a diagnosis
on other suspect systems. H2 INSPECT THE STEERING SYSTEM
Yes Klj . 53 ba
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GENERAL PROCEDURES
System Flushing —
CII Power Steering Pump
WARNING: Do not mix oil types. Any mixture or any unapproved oil can lead to seal
deterioration and leaks. A leak can ultimately cause loss of fluid, which can result in a loss of
power steering assist.
1. Remove the fuel pump fuse from the battery junction box.
2. Disconnect the power steering return hose. Plug the reservoir.
3. Attach an extension hose between the power steering return hose and an empty container.
4. Raise the front wheels off the floor. For additional information, refer to Section 100 - 02 .
5. Check the fluid level. If necessary, fill the reservoir to the correct level. zUse Motorcraft MERCON® Multi-Purpose ATF XT -2-QDX or MERCON® equivalent.
6. CAUTION: Do not crank the engine for more than 15 seconds at a time. Allow the
starter to cool for 1 minute before cranking again. Premature starter failure can occur.
CAUTION: Do not hold the steering wheel against the stops for more than three to
five seconds at a time. Damage to the power steering pump will occur.
Turn the steering wheel from stop- to-stop while cranking the engine until the fluid exiting the
power steering return hose is clear of all contamination and foreign material.
zAdd Motorcraft MERCON® Multi-Purpose ATF XT -2-QDX or MERCON® equivalent as
needed.
7. Lower the vehicle.
8. Disconnect the extension hose from the power steering return hose. Remove the plug. Attach the power steering return hose to the reservoir.
SECTION 211-
00: Steering System — General Information 2003 Mustang Workshop Manual Klj . 1 ba
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