relay FORD MUSTANG 2003 User Guide

z
Is the voltage greater than 12.5 volts? for an open. TEST the
system for normal operation.
A2 CHECK THE VOLTAGE TO THE STARTER MOTOR
SOLENOID z
Measure the voltage between the starter motor solenoid
positive terminal and ground.
z Is the voltage 12.5 volts or greater? Yes
GO to
A3 .
No
REPAIR circuit 2037 (RD) for
an open. TEST the system
for normal operation. A3 MANUALLY JUMP THE STARTER MOTOR
z
Connect one end of a fused (15A) jumper wire to the
positive terminal of the battery and touch the other end to
the starter solenoid S- terminal.
z Does the starter solenoid engage? Yes
GO to
A4 .
No
INSTALL a new starter
motor. REFER to Starter Motor — 3.8L or
Starter Motor — 4.6L . TEST the
system for normal operation. A4 TEST THE STARTER MOTOR RELAY
z
Carry out the relay component test on the starter motor
relay. Refer to the relay component test in this section.
z Does the starter motor relay test good? Yes
REPAIR circuit 33
(WH/PK)/262 (BN/PK) for an
open. TEST the system for
normal operation.
No
INSTALL a new starter motor
relay. TEST the system for
normal operation. Klj . 3 ba
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PINPOINT TEST B: THE ENGINE DOES NOT CRANK AND THE
RELAY DOES NOT CLICK
Test Step Result / Action to Take
B1 CHECK CIRCUIT 33 (WH/PK) FOR VOLTAGE
z
Disconnect: Starter Motor Relay.
z Key in START position.
z Measure the voltage between the starter motor relay pin 85,
circuit 33 (WH/PK) and ground while holding the key in the
START position.
z Is the voltage greater than 10 volts? Yes
GO to
B10 .
No
For automatic
transmissions, GO to
B2 . For manual
transmissions, GO to
B5 .
B2 CHECK CIRCUIT 32 (RD/LB) FOR VOLTAGE AT THE DIGITAL
TR SENSOR z
Key in OFF position.
z Disconnect: Digital TR Sensor C110.
z Key in START position.
z Measure the voltage between the digital TR sensor C110 pin
10, circuit 32 (RD/LB) and ground while holding the key in the
START position.
z Is the voltage greater than 10 volts? Yes
GO to
B3 .
No
GO to B7 .
B3 CHECK CIRCUIT 33 (WH/PK) FOR OPEN
z
Key in OFF position.
z Measure the resistance between the digital TR sensor C110 pin Yes
GO to
B4 .
No
REPAIR circuit 33
(WH/PK). TEST the
system for normal
operation. Klj . 4 ba
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12, circuit 33 (WH/PK) and the starter motor relay pin 86, circuit
33 (WH/PK).
z Is the resistance less than 5 ohms? B4 CHECK DIGITAL TRANSMISSION RANGE (TR) SENSOR
ADJUSTMENT z
Carry out the digital TR sensor adjustment. Refer to Section 307 - 01 .
z Is the digital TR sensor adjusted correctly? Yes
INSTALL a new digital
TR sensor. TEST the
system for normal
operation.
No
ADJUST the digital TR
as necessary. TEST the
system for normal
operation.
B5 CHECK CIRCUIT 32 (RD/LB) FOR VOLTAGE AT THE CLUTCH
SWITCH OR JUMPER z
Key in OFF position.
z Disconnect: Clutch Pedal Switch C255.
z Key in START position.
z Measure the voltage between the clutch pedal switch C255 pin
2, circuit 32 (RD/LB) and ground while holding the key in the
START position.
z Is the voltage greater than 10 volts? Yes
GO to
B6 .
No
GO to B7 .
B6 CHECK CIRCUIT 33 (WH/PK)/32 (RD/LB) FOR OPEN
z
Key in OFF position.
z Measure the resistance between the clutch pedal switch C255
pin 1, circuit 33 (WH/PK)/32 (RD/LB) and the starter motor relay
pin 86, circuit 33 (WH/PK)/32 (RD/LB).
z Is the resistance less than 5 ohms? Yes
INSTALL a new clutch
pedal switch. TEST the
system for normal
operation.
No
REPAIR circuit 33
(WH/PK)/32 (RD/LB).
TEST the system for
normal operation.
B7 CHECK FOR VOLTAGE AT FUSE 6
z
Key in OFF position.
z Disconnect: Fuse #6.
z Key in START position. Yes
REPAIR circuit 32
(RD/LB). TEST the Klj . 5 ba
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z
Measure the voltage between the central junction box fuse 6,
circuit 33 (WH/PK) and ground while holding the key in the
START position.
z Is the voltage greater than 10 volts? system for normal
operation.
No
GO to
B8 .
B8 CHECK CIRCUIT 1050 (LG/VT) FOR VOLTAGE
z
Key in OFF position.
z Disconnect: Ignition Switch C209.
z Key in ON position.
z Measure the voltage between the ignition switch connector
C209 pin B4, circuit 1050 (LG/VT) and ground.
z Is the voltage greater than 10 volts? Yes
GO to
B9 .
No
REPAIR circuit 1050
(LG/VT). TEST the
system for normal
operation. B9 CHECK THE IGNITION SWITCH
z
Carry out the ignition switch component test. Refer to
Refer to Wiring Diagrams Cell 149 for schematic and connector
information.
.
z Does the ignition switch test good? Yes
REPAIR circuit 33
(WH/PK). TEST the
system for normal
operation.
No
INSTALL a new ignition
switch. TEST the
system for normal
operation.
B10 CHECK CIRCUIT 1205 (BK) FOR OPEN
z
Key in OFF position. Yes
INSTALL a new starter
motor relay. TEST the
system for normal
operation.
No
REPAIR circuit 1205
(BK). TEST the system
for normal operation. Klj . 6 ba
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PINPOINT TEST C: THE ENGINE CRANKS SLOWLY
PINPOINT TEST D: UNUSUAL STARTER NOISE z
Measure the resistance between the starter motor relay pin 86,
circuit 1205 (BK) and ground.
z Is the resistance less than 5 ohms? Test Step Result / Action to Take
NOTE:
Before beginning this test, be sure that the battery is tested and fully charged. C1 CHECK THE VOLTAGE TO THE STARTER
z
Key in OFF position.
z Measure the voltage between the starter motor
solenoid positive terminal and ground.
z Is the voltage 12.5 volts or greater? Yes
GO to
C2 .
No
REPAIR the circuit between the
battery and the starter solenoid.
CLEAN and TIGHTEN the
connections at the battery terminals.
TEST the system for normal
operation. C2 CHECK MOTOR GROUND CIRCUIT
z
Carry out the Motor Ground Circuit test; refer to
Component Tests in this section.
z Is the ground OK? Yes
INSTALL a new starter motor.
REFER to
Starter Motor — 3.8L or
Starter Motor — 4.6L . TEST the
system for normal operation.
No
REPAIR the ground circuit as
necessary. TEST the system for
normal operation. Test Step Result / Action to Take
D1 CHECK THE STARTER MOTOR
MOUNTING z
Inspect the starter motor mounting Yes Klj . 7 ba
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REMOVAL AND INSTALLATION
Relay Switch
1. Disconnect the battery ground cable. For additional information, refer to Section 414 - 01 .
2. Remove the power distribution box cover.
3. Remove the starter relay from the power distribution box.
Installation 1. To install, reverse the removal procedure.
SECTION 303-
06: Starting System 2003 Mustang Workshop Manual Klj . 1 ba
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Output Shaft Speed (OSS) Sensor Harness Connector 1 — NOT USED
2 — Signal Return
3 — TR3A
4 — TR1
5 — TR2
6 — TR4
7 — NOT USED
8 — NOT USED
9 — Fused Power Feed
10 — Starter Control
11 — Reverse
12 — Starter to Starter Interrupt Relay
Pin Number Circuit Circuit Function
1 — Output Shaft Speed (OSS) Sensor
2 — Signal Return
Digital Transmission Range (TR) Sensor Diagnosis Chart Selector Position PID: TR PID: TR_D PID: TR_V (volts)
TR4 TR3A TR2 TR1 TR3A (PCM Pin 64 to sigrtn)
PARK P/N 0 0 0 0 0.0 Volts
In Between REV 0 1 0 0 1.3 -
1.8 Volts REVERSE REV 1 1 0 0 1.3 -
1.8 Volts In Between REV 0 1 0 0 1.3 -
1.8 Volts NEUTRAL NTRL 0 1 1 0 1.3 -
1.8 Volts In Between
O/D
a 1 1 1 0 1.3 -
1.8 Volts OVERDRIVE
O/D
a 1 1 1 1 1.3 -
1.8 Volts In Between Man 2 1 0 1 1 0.0 Volts Klj . 3 ba
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The clutch control system engages and disengages the clutch. The clutch control system disengages
the clutch when the clutch pedal is depressed and engages the clutch when the clutch pedal is
released. Clutch pedal motion is transmitted by the clutch release lever cable to the clutch release
lever. The clutch release hub and bearing engages the clutch pressure plate diaphragm spring,
releasing the pressure on the clutch disc which in turn disengages the transmission from the engine.
The clutch adjusts automatically to compensate for clutch disc wear. The clutch linkage is self-
adjusting.
The clutch pedal position (CPP) switch prevents the starter motor from engaging unless the clutch
pedal is depressed all the way to the floor. The switch plunger is contacted by the clutch pedal and
extends as the clutch pedal is pressed. The clutch pedal position switch is electrically connected in line
with the ignition switch and the starter motor relay coil. The CPP also turns off the speed control when
the clutch pedal is depressed. 4 7L583 Clutch pedal quadrant and pawl assembly Klj . 2 ba
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If two substances of different temperature are placed near each other, the heat in the warmer
substance will transfer to the colder substance.
Latent Heat of Vaporization
When a liquid boils (converts to a gas), it absorbs heat without raising the temperature of the resulting
gas. When the gas condenses (reverts back to a liquid), it gives off heat without lowering the
temperature of the resulting liquid.
Relative Humidity
The amount of moisture (water vapor content) that the air can hold is directly related to the air
temperature. The more heat there is in the air, the more moisture the air can hold. The lower the
moisture content in the air, the more comfortable you feel. Removing moisture from the air lowers its
relative humidity and improves personal comfort.
Effects of Pressure on Boiling or Condensation
As the pressure is increased on a liquid, the temperature at which the liquid boils (converts to a gas)
also increases. Conversely, when the pressure on a liquid is reduced, its boiling point is also reduced.
When in the gas state, an increase in pressure causes an increase in temperature, while a decrease in
pressure will decrease the temperature of the gas.
Compressor Anti-
Slugging Strategy
Liquid refrigerant may accumulate in the A/C compressor under certain conditions. To alleviate
damage to the A/C compressor, compressor anti- slugging strategy (CASS) is utilized.
CASS is initiated only under specific conditions:
zthe ignition is off for more than 8 hours
z the ambient temperature is above -4º C (25ºF)
z battery voltage is above 8.5 volts during engine cranking
When these conditions are present, the powertrain control module (PCM) will activate the A/C control
relay prior to cranking of the engine. The A/C control relay engages the A/C compressor for
approximately 4- 15 A/C compressor revolutions or a maximum of 2 seconds (depending upon vehicle
application), allowing the liquid refrigerant to be pushed from the A/C compressor. CASS is initiated by
the PCM regardless of the function selector switch position or the EATC system settings.
The Refrigerant Cycle
During stabilized conditions (air conditioning system shut down), the refrigerant is in a vaporized state
and pressures are equal throughout the system. When the A/C compressor (19703) is in operation, it
increases pressure on the refrigerant vapor, raising its temperature. The high- pressure and high-
temperature vapor is then released into the top of the A/C condenser core (19712).
The A/C condenser core, being close to ambient temperature, causes the refrigerant vapor to
condense into a liquid when heat is removed from the refrigerant by ambient air passing over the fins
and tubing. The now liquid refrigerant, still at high pressure, exits from the bottom of the A/C
condenser core and enters the inlet side of the A/C evaporator core orifice (19D990).
The A/C evaporator core orifice is the restriction in the refrigerant system that creates the high
pressure buildup upstream of the A/C evaporator core (19860) and separates the high and low
pressure sides of the A/C system. As the liquid refrigerant leaves this restriction, its pressure and
boiling point are reduced.
The liquid refrigerant is now at its lowest pressure and temperature. As it passes through the A/C Klj . 3 ba
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Item Part Number Description
1 19980 Manual A/C control assembly
2 19E561 A/C cycling switch
3 19D594 A/C pressure cutoff switch (V6)
4 19D594 A/C pressure cutoff switch (V8)
5 12A650 Powertrain control module
6 12B581 Constant control relay module
7 19703 A/C compressor
8 19805 Blower motor Klj . 10 ba
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