run flat FORD MUSTANG 2003 User Guide

to
Section 204 - 00 .
z Incorrect tire rotation
intervals. z
ADVISE customer of
condition. ROTATE
tires.
z Tires show
excess wear in
center of tread z
Tires overinflated. zADJUST air pressure.
z Other excessive
tire wear
problems z
Incorrect tire rotation
intervals. z
ADVISE customer of
condition. ROTATE
tires.
z Incorrect tire pressure. zADJUST pressure.
z Loose or leaking shock
absorbers. z
TIGHTEN or INSTALL
new shock absorbers
as necessary.
z Incorrect wheel alignment. zSET alignment to
specification. REFER
to Section 204 - 00 .
z Loose, worn or damaged
suspension components. z
REFER to Section 204 - 00 .
z Wheel and tire assembly
out of balance. z
BALANCE wheel and
tire assembly.
z Excessive lateral or radial
runout of wheel. z
REFER to Section 100 - 04 .
z Wobble or
shimmy z
Damaged wheel bearings. zREFER to Section 204 - 00 .
z Loose or damaged
suspension components. z
REFER to Section 204 - 00 .
z Bent wheel. zINSTALL a new wheel
as necessary.
z Damaged tire. zINSTALL a new tire as
necessary.
z Loose wheel nuts. zTIGHTEN to
specification.
z High- speed
shake z
Wheel hub face/pilot/bolt
circle runout.
z Tires/wheels.
z Wheel bearings.
z Suspension/steering
linkage.
z Engine.
z Transmission.
z Brake discs/imbalance. z
REFER to Section 100 - 04 .
z Vehicle vibration zDriveline — engine.
z Tires. z
REFER to Section 100 - 04 . Klj . 3 ba
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SPECIFICATIONS
SECTION 303-
01A: Engine — 3.8L 2003 Mustang Workshop Manual General Specifications
Item Specification
Lubricants and Sealants
SAE 5W-
20 Premium Synthetic Blend Motor Oil
XO- 5W20- QSP WSS-
M2C153- H Gasket and Trim Adhesive F3AZ-19B508-
AA ESE-
M2G52- A Pipe Sealant with Teflon® D8AZ-19554-
A WSK-
M2G350- A2 Silicone Gasket and Sealant F7AZ-19554-
EA WSE-
M4G323- A4 Metal Surface Cleaner F4AZ-19A536-
RA WSE-
M5B392- A Engine
Displacement 3.8L
Number of cylinders 6
Bore 96.8325 mm (3.81 in)
Stroke 86.0 mm (3.39 in)
Firing order 1-4-2-5-3-
6 Oil pressure (hot 2,500 rpm) 40-
125 psi Oil capacity 5 quarts w/filter change
Compression ratio —
Cylinder Head and Valve Train
Cylinder head gasket surface flatness 0.18 mm (0.007 in)
Combustion chamber volume 61.5-
64.5 cc Valve arrangement (front to rear) —
Valve guide bore diameter 7.015-
7.044 mm (0.276- 0.277 in) Valve stem diameter —
intake 6.955-
6.988 mm (0.2738- 0.2751 in) Valve stem diameter —
exhaust 6.929-
6.962 mm (0.2728- 0.2741 in) Valve stem diameter —
oversize (intake) 9.075-
9.055 mm (0.3573- 0.3565 in) Valve stem diameter —
oversize (exhaust) 9.063-
9.043 mm (0.3568- 0.3560 in) Valve stem diameter —
oversize (intake) 9.456-
9.436 mm (0.3723- 0.3715 in) Valve stem diameter —
oversize (exhaust) 9.444-
9.424 mm (0.3718- 0.3710 in) Valve stem-
to-guide clearance — intake 0.020-
0.069 mm (0.045- 0.090 in) Valve stem-
to-guide clearance — exhaust 0.038-
0.083 mm (0.0015- 0.0033 in) Valve head diameter —
intake 47.27 mm (1.86 in)
Valve head diameter —
exhaust 37.1 mm (1.46 in)
Valve face runout 0.05 mm (0.002 in)
Valve face angle 45.675 degrees
Valve seat width 1.5-
2.0 mm (0.06- 0.08 in) Valve seat runout (T.I.R.) 0.076 mm (0.003 in) Klj . 1 ba
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Valve seat angle 44.75 degrees
Valve spring free length —
Valve spring squareness —
Valve spring compression pressure —
valve
open (without damper) 1000 N (224 lbs) @ 29.2 mm (1.16 in)
Valve spring compression pressure —
valve
closed (without damper) 350 N (79 lbs) @ 40.7 mm (1.62 in)
Valve spring installed height 40.7 mm (1.62 in)
Valve spring installed pressure —
Rocker arm ratio 1.73
Hydraulic Lash Adjuster
Diameter 22.195-
22.212 mm (0.8738- 0.8745 in) Clearance-
to-bore 0.018-
0.068 mm (0.0007- 0.0027 in) Service limit 0.127 mm (0.005 in)
Hydraulic leakdown rate a
Collapsed lash adjuster gap —
Camshaft
Theoretical valve lift @ 0 lash —
intake 11.30 mm (0.45 in)
Theoretical valve lift @ 0 lash —
exhaust 11.47 mm (0.45 in)
Lobe lift —
intake 6.53 mm (0.257 in)
Lobe lift —
exhaust 6.57 mm (0.259 in)
Allowable lobe lift loss 0.127 mm (0.005 in)
Journal diameter 52.082-
52.108 mm (2.0505- 2.0515 in) Camshaft journal bore inside diameter —
No. 1 55.689-
55.664 mm (2.192- 2.191 in) Camshaft journal bore inside diameter —
No. 2
and No. 3 55.308-
55.283 mm (2.177- 2.176 in) Camshaft journal bore inside diameter —
No. 4 55.684-
55.664 mm (2.192- 2.191 in) Camshaft journal-
to-bearing clearance 0.025-
0.076 mm (0.001- 0.003 in) Runout 0.05 mm (0.002 in) runout of No. 2 or No. 3
relative to No. 1 and No. 4 End play 0.025-
0.150 mm (0.001- 0.006 in) Cylinder Block
Cylinder bore diameter 96.813 mm (3.81 in)
Cylinder bore maximum taper 0.050 mm (0.002 in)
Cylinder bore maximum out-of-
round 0.050 mm (0.002 in)
Main bearing bore inside diameter 68.905 mm (2.713 in)
68.885 mm (2.712 in)
Camshaft bearing bore inside diameter —
intake 47.097 mm (1.8542 in) max. 47.072 mm (1.8532
in) min. Camshaft bearing bore inside diameter —
exhaust 39.739 mm (1.5645 in) max. 39.714 mm (1.5635
in) min. Head gasket surface flatness 0.08 mm (0.003 in) in 152.0 mm (6.00 in)
Crankshaft
Main bearing journal diameter 63.983-
64.003 mm (2.5190- 2.5198 in) Klj . 2 ba
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Bearing Inside Diameter (All) 27.012-
26.987 mm (1.0635- 1.0625 inch) Front Bearing Location e
CYLINDER BLOCK
·
Head Gasket Face Flatness 0.15 mm (0.006 in) MAX overall
·
Head Gasket Surface Finish b Main Bearing Bore Diameter 72.400-
72.424 mm (2.8504- 2.8513 inch) CRANKSHAFT
Main Bearing Journal Diameter 67.481-
67.505 mm (2.6567269- 2.6576718 inch) Connecting Rod Journal
·
Diameter 52.983-
53.003 mm (2.085941- 2.086728 inch) Crankshaft Free End Play 0.130-
0.301 mm (0.005118- 0.011850 inch) Crankshaft Runout to Rear Face of Block 0.050 mm (0.01969 inch) MAX
Connecting Rod Bearings
Clearance to Crankshaft
·
Desired 0.027-
0.069 mm (0.0010629- 0.0027165 inch) ·
Allowable 0.027-
0.069 mm (0.0010629- 0.0027165 inch) Bearing Wall Thickness (Std)
f 1.920-
1.928 mm (0.075591- 0.075905 inch) Main Bearings
Clearance to Crankshaft
·
Desired 0.025-
0.045 mm (0.00098- 0.00177 inch) ·
Allowable 0.025-
0.050 mm (0.00098- 0.00197 inch) Bearing Wall Thickness (Std)
f 2.451 mm (0.0965 inch)
Connecting Rod
·
Pin Bore Diameter 22.012-
22.024 mm (0.86661- 0.86708 inch) ·
Crankshaft Bearing Bore Diameter 56.866-
56.886 mm (2.23881- 2.23960 inch) ·
Length (Center- to-Center) 150.7 mm (5.933 inch)
Alignment (Bore-To-
Bore Max. Diff.) g ·
Twist 0.050 per 25 mm (0.00197 per 0.9843 inch)
·
Bend 0.038 per 25 mm (0.00150 per 0.9843 inch)
Side Clearance (Assembled to Crank)
·
Standard 0.15-
0.45 mm (0.00591- 0.01772 inch) ·
Service Limit 0.50 mm (0.01969 inch) MAX
CYLINDER BORE AND PISTON
Cylinder Bore
Diameter
h ·
Surface Finish (RMS) 0.2-
0.6 Microns ·
Out- of-Round Limit 0.015 mm
·
Out- of-Round Service Limit 0.020 mm
·
Taper Service Limit 0.006 mm
Piston
·
Diameter i .028 mm (.0010 inch) Klj . 3 ba
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PINPOINT TEST E: THE POWER LUMBAR IS INOPERATIVE D4 CHECK THE REARWARD POSITION INPUT
z
Connect: Seat Regulator Control Switch C360.
z Measure the voltage between horizontal motor C362, Circuit 981
(RD/WH), harness side and ground.
z Actuate the seat regulator control switch to the REARWARD
position.
z Is the voltage greater than 10 volts? Yes
GO to
D5 .
No
INSTALL a new
seat regulator
control switch.
REFER to Switch —
Seat Regulator
Control . TEST the
system for normal
operation. D5 CHECK THE FORWARD POSITION INPUT
z
Measure the voltage between horizontal motor C362, Circuit 980
(YE/WH), harness side and ground.
z Actuate the seat regulator control switch to the FORWARD position.
z Is the voltage greater than 10 volts? Yes
INSTALL a new
seat track. REFER
to Seat Track
.
TEST the system
for normal
operation.
No
INSTALL a new
seat regulator
control switch.
REFER to Switch —
Seat Regulator
Control . TEST the
system for normal
operation. Test Step Result / Action to Take
E1 CHECK THE LUMBAR COMPRESSOR OPERATION
z
Actuate the lumbar seat control switch to the inflate position.
z Did the lumbar compressor motor run? Yes
GO to
E6 .
No
GO to E2 .
E2 CHECK CIRCUIT 566 (DG)
z
Disconnect: Lumbar Seat Control Switch C361.
z Measure the voltage between lumbar seat control switch
C361, Circuit 566 (DG), harness side and ground. Yes
GO to
E3 .
No
REPAIR the circuit. TEST
the system for normal
operation. Klj . 8 ba
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PINPOINT TEST F: THE POWER BOLSTER/LUMBAR IS
INOPERATIVE —
DRIVER psi) or more?
E11 CHECK THE SEAT BACKREST LUMBAR ADJUSTING PAD
FOR LEAKS z
Remove the in- line pressure gauge.
z Use a hand pump and inflate the seat backrest lumbar
adjusting pad to 34.47 kPa (5 psi). The seat backrest lumbar
adjusting pad should hold pressure for three hours.
z After three hours, is the pressure reading 32.41 kPa (4.7
psi) or more? Yes
INSTALL a new lumbar
seat control switch.
REFER to
Lumbar Control Switch . TEST the system
for normal operation.
No
INSTALL a new seat
backrest lumbar adjusting
pad. REFER to Lumbar Assembly . TEST the
system for normal
operation. Test Step Result / Action to Take
F1 CHECK THE BOLSTER/LUMBAR COMPRESSOR
OPERATION z
Actuate the bolster/lumbar seat control switches.
z Does the bolster/lumbar compressor motor run? Yes
GO to
F5 .
No
GO to F2 .
F2 CHECK CIRCUIT (BK) FOR VOLTAGE
z
Disconnect: Bolster/lumbar pump and solenoid module.
z Measure the voltage at bolster/lumbar pump and solenoid
module pin 1 (BK), harness side and ground.
z Is the voltage greater than 10 volts? Yes
GO to
F3 .
No
REPAIR the circuit. TEST
the system for normal
operation. F3 CHECK CIRCUIT (LG) FOR AN OPEN
z
Measure the resistance between bolster/lumbar pump and
solenoid module pin 2, (LG), harness side and ground. Yes
GO to
F4 .
No
REPAIR the circuit. TEST
the system for normal
operation. Klj . 11 ba
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Driver Air Bag Module
The driver air bag module:
zis installed as an assembly.
z is mounted in the center of the steering wheel.
Clockspring
The clockspring: zis mounted on the steering column, behind the steering wheel.
z provides a continuous electrical path from the restraints control module (RCM) to the driver air
bag.
Passenger Air Bag Module
The passenger air bag module: zis installed as an assembly.
z is mounted in the RH side of the instrument panel.
Restraints Control Module (RCM)
The restraints control module (RCM) performs the following functions: zsignals the inflators to deploy the air bags in the event of a deployable crash.
z monitors the air bag supplemental restraint system (SRS) for faults.
z illuminates the air bag indicator if a fault is detected.
z flashes the air bag indicator to indicate the lamp fault code (LFC) detected.
z communicates through the data link connector (DLC) the current or historical diagnostic trouble
codes (DTCs).
z signals the generic electronic module (GEM) to activate a chime if the air bag indicator is not
available and another SRS fault exists.
NOTE: The safing sensor is internal to the RCM and is not repaired separately.
The RCM monitors the SRS for possible faults. If a fault is detected while the ignition switch is in the
RUN position, the RCM will illuminate the air bag indicator located in the instrument cluster.
When the ignition is cycled (turned off and then on), the air bag indicator will begin its prove out
sequence. During prove out the air bag indicator will illuminate for six seconds, go off for two seconds
and then, if a system fault exists, flash the two- digit LFC. The air bag indicator will flash the LFC five
times, then it will remain illuminated for the rest of the key cycle. The RCM will also communicate the Klj . 2 ba
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2.
WARNING: Incorrect centralization may result in premature component failure. If in
doubt when centralizing the clockspring, repeat the centralizing procedure. Failure to
follow this instruction may result in personal injury.
CAUTION: Make sure the road wheels are in the straight ahead position.
NOTE: If a clockspring has rotated out of center, follow through with this step.
Centralize the clockspring. 1. Hold the clockspring outer housing stationary.
2. Depress the clockspring locking tab to release the rotor.
3. CAUTION: Overturning will destroy the clockspring. The internal ribbon wire
acts as the stop and can be broken from its internal connection.
While holding the clockspring locking tab in the released position, turn the rotor
counterclockwise, carefully feeling for the ribbon wire to run out of length, and a slight
resistance is felt. Stop turning at this point.
4. While holding the clockspring locking tab in the released position, turn the clockspring
clockwise approximately three turns. This is the center point of the clockspring.
„Release the clockspring locking tab. Do not allow the rotor to turn from this
position.
All vehicles 3. NOTE: Slight turning of the clockspring rotor is allowable for alignment purposes to the steering
column.
With the flats of the clockspring aligned to the flats of the steering column, slide the clockspring
onto the steering column engaging the retaining tabs.
4. Route the clockspring wire harness down the side of the steering column and into the holders. Klj . 6 ba
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