fuel FORD MUSTANG 2003 Workshop Manual

REMOVAL AND INSTALLATION
Evaporative Emission Canister
Removal and Installation
1. WARNING: The evaporative emission system contains fuel vapor and condensed
fuel vapor. Although not in large quantities, it still presents the danger of explosion or
fire. Disconnect the battery ground cable from the battery to minimize the possibility of
an electrical spark occurring, possibly causing a fire or explosion if fuel vapor or liquid
fuel is present in the area. Failure to follow these instructions may result in personal
injury.
Disconnect the battery ground cable. For additional information, refer to Section 414 - 01 .
2. Raise and support the vehicle. For additional information, refer to Section 100 - 02 .
3. Remove the left rear wheel. For additional information, refer to Section 204 - 04 .
4. WARNING: Do not smoke or carry lighted tobacco or open flame of any type when
working on or around any fuel- related component. Highly flammable mixtures are always
present and may be ignited. Failure to follow these instructions may result in personal
injury.
Disconnect the canister vent solenoid hose assembly.
5. Disconnect the connector.
6. Disconnect the evaporative emission (EVAP) canister purge outlet tube.
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REMOVAL AND INSTALLATION
Evaporative Emission Canister Purge Valve
Removal and Installation
1. WARNING: The evaporative emission system contains fuel vapor and condensed
fuel vapor. Although not in large quantities, it still presents the danger of explosion or
fire. Disconnect the battery ground cable from the battery to minimize the possibility of
an electrical spark occurring, possibly causing a fire or explosion if fuel vapor or fuel
liquid is present in the area. Failure to follow these instructions may result in personal
injury.
Disconnect the battery ground cable. For additional information, refer to Section 414 - 01 .
2. Raise and support the vehicle. For additional information, refer to Section 100 - 02 .
3. Remove the RH front wheel. For additional information, refer to Section 204 - 04 .
4. Remove the right front splash shield. 1. Remove the three screws.
2. Remove the five pin- type retainers.
5. Disconnect the connector.
6. Disconnect the main emission vacuum control connector.
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7.
WARNING: Do not smoke or carry lighted tobacco or open flame of any type when
working on or around any fuel- related component. Highly flammable mixtures are always
present and may be ignited. Failure to follow these instructions may result in personal
injury.
Disconnect the evaporative emission (EVAP) canister purge outlet tube.
8. Disconnect the EVAP return tube.
9. Remove the nuts and the EVAP canister purge valve. Klj . 2 ba
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REMOVAL AND INSTALLATION
Fuel Vapor Vent Valve
Removal and Installation
1. NOTE: The fuel vapor vent valve is repaired along with the fuel vapor control valve and the in-
line fuel tank pressure sensor as a fuel vapor control valve tube assembly.
For removal and installation of the fuel vapor vent valve, refer to Fuel Vapor Control Tube Assembly Valve in this section.
SECTION 303-
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REMOVAL AND INSTALLATION
Fuel Vapor Control Tube Assembly Valve
Removal and Installation
1. Remove the fuel tank. For additional information, refer to Section 310 - 01 .
2. Remove the retainers.
3. NOTE: The fuel vapor vent valve, fuel vapor control valve and the in- line fuel tank pressure
sensor are repaired as a fuel vapor control valve tube assembly.
NOTE: It may be necessary to lubricate the fuel vapor control valve tube assembly grommets
with ESE- M00B144- B Merpol® or equivalent to assist in the removal procedure.
Remove the fuel vapor control valve tube assembly. 1. Loosen the fuel vapor vent valve.
2. Loosen the fuel vapor control valve.
3. Remove the fuel vapor control valve tube assembly.
4. NOTE: Lubricate all O- ring seals with MERPOL® O-Ring Seal Lubricant or equivalent meeting
Ford specification ESE-M99B144- B.
NOTE: New grommets are necessary when the fuel vapor control valve tube assembly is
removed.
To install, reverse the removal procedure.
zLeak test the system. For additional information, refer to Evaporative Emission System Leak Test in this section.
z Carry out the evaporative emission repair verification drive cycle. For additional
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REMOVAL AND INSTALLATION
Fuel Tank Pressure Sensor
Removal and Installation
1. NOTE: The in-line fuel tank pressure sensor is repaired along with the fuel vapor vent valve and
the fuel vapor control valve as a fuel vapor control valve tube assembly.
For removal and installation of the fuel vapor control valve, refer to Fuel Vapor Control Tube Assembly Valve in this section.
SECTION 303-
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SPECIFICATIONS
SECTION 303-
14: Electronic Engine Controls 2003 Mustang Workshop Manual General Specifications
Item Specification
Lubricants
Super premium SAE 5W-
20 Engine Oil XO-5W20-DSP WSS-
M2C914- A Penetrating and Lock Lubricant E8AZ-19A501-
B N/A
Pipe Sealant with Teflon D8AZ-19554-
A WSK-
M26350- A2
Torque Specifications Description Nm lb-
ft lb-
in Cylinder head temperature (CHT) sensor —
3.8L 10 — 89
Engine coolant temperature (ECT) sensor —
4.6L (2V) 20 — 15
Engine coolant temperature (ECT) sensor —
4.6L (4V) 24 18 —
Heated oxygen sensors (HO2S) 41 30 —
Catalyst monitor sensors 41 30 —
Crankshaft position (CKP) sensor bolts —
3.8L 6 — 53
Crankshaft position (CKP) sensor bolts —
4.6L 10 — 89
Power steering reservoir bolts 10 — 89
Camshaft position (CMP) sensor bolt —
4.6L 10 — 89
PCM connector to module bolt 6 — 53
Idle air control (IAC) valve bolts 10 — 89
Camshaft synchronizer housing bolt 25 18 —
Throttle position (TP) sensor screws 3 — 27
Fuel pressure sensor bolts 4 — 35
Air intake scoop bolts 25 18 —
Air intake scoop bracket bolt 25 18 —
Air intake scoop bracket nuts 25 18 —
Air intake scoop bracket throttle body nut 9 — 80
Exhaust gas recirculation (EGR) vacuum regulator solenoid bolts 10 — 89 Klj . 1 ba
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The camshaft position sensor:
zsends the powertrain control module a signal indicating camshaft position, used for fuel
synchronization.
The crankshaft position sensor:
zsends the powertrain control module a signal indicating crankshaft position.
z is essential for calculating spark timing.
The mass air flow sensor:
zsends the powertrain control module a signal indicating mass air flow rate of air entering the
engine.
The intake air temperature sensor:
zsends the powertrain control module a signal indicating the temperature of the air entering the
engine.
The heated oxygen sensor:
zhas the ability to create a voltage signal depending on exhaust oxygen content.
z provides feedback information to the powertrain control module used to calculate fuel delivery.
The rear catalyst monitor sensor:
zmonitors oxygen content after the oxygen flows through the catalytic converter.
z provides a voltage to the powertrain control module used to calculate catalytic converter
integrity.
The wheel speed sensor:
zsends a signal to the powertrain control module indicating wheel speed. Klj . 2 ba
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REMOVAL AND INSTALLATION
Intake Manifold Runner Control (IMRC) Actuator —
3.8L
Removal and Installation 1. Disconnect the battery ground cable. For additional information, refer to Section 414 - 01 .
2. Drain the cooling system. For additional information, refer to Section 303 - 03A .
3. Remove the upper intake manifold. For additional information, refer to Section 303 - 01A .
4. Remove the fuel injector supply manifold. For additional information, refer to Section 303 - 04A .
5. Remove the coolant bypass tube. For additional information, refer to Section 303 - 03A .
6. Remove the bolt and heater water inlet tube at the back of the lower intake.
7. Remove the two stud bolts and one bolt. Position the actuator aside.
8. Disconnect the linkage and remove the actuator.
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22003 Mustang Workshop Manual
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REMOVAL AND INSTALLATION
Fuel Pressure Sensor
Removal
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 be ignited. 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.
Mach I
1. Remove the air intake scoop. For additional information, refer to Section 303 - 12 .
All engines 2. Relieve the fuel pressure. For additional information, refer to Section 310 - 00 .
3. NOTE: The 4.6L (4V) Cobra engine is shown, the other engines are similar.
Disconnect the connector and the vacuum line. 4. Remove the bolts and the sensor. SECTION 303-
14: Electronic Engine Controls 2003 Mustang Workshop Manual Material
Item Specification
Super Premium SAE 5W-20
Motor Oil
XO- 5W20- DSP or equivalent WSS-
M2C914-
A Klj . 1 ba
22003 Mustang Workshop Manual
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