fuel FORD MUSTANG 2003 Owner's Manual

9.
CAUTION: Do not overfill the reservoir.
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.
10. Install the fuel pump fuse.
11. 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.
Start the engine and turn the steering wheel from stop- to-stop.
12. CAUTION: Do not overfill the reservoir.
NOTE: If the power steering system is noisy and is accompanied by evidence of aerated fluid it
will be necessary to purge the power steering system.
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. Klj . 2 ba
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GENERAL PROCEDURES
System Flushing —
CIII 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 could 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-
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9.
CAUTION: Do not overfill the reservoir.
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.
10. Install the fuel pump fuse.
11. 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.
Start the engine and turn the steering wheel from stop- to-stop.
12. CAUTION: Do not overfill the reservoir.
NOTE: If the power steering system is noisy and is accompanied by evidence of aerated fluid it
will be necessary to purge the power steering system.
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. Klj . 2 ba
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GENERAL PROCEDURES
Fill
1. 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.
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.
2. Remove the fuel pump fuse from the battery junction box.
3. Raise the front wheels off the floor. For additional information, refer to Section 100 - 02 .
4. 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.
5. Lower the vehicle.
6. CAUTION: Do not overfill the reservoir.
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.
7. Install the fuel pump fuse.
SECTION 211-
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DESCRIPTION AND OPERATION
Engine
NOTE:
This section contains information, steps and procedures that may not be specific to your
engine.
This section covers general procedures and diagnosis and testing of the engine system, except for
exhaust emission control devices, which are covered in the Powertrain Control/Emissions Diagnosis
Manual.
The engine incorporates the following features:
za closed positive crankcase ventilation (PCV) system. For additional information, refer to
Section 303 - 08 .
z an exhaust emission control system. For additional information, refer to Section 303 - 08 .
z an evaporative emission control system. For additional information, refer to Section 303 - 13 .
Some engines incorporate a fail- safe cooling system. Refer to the appropriate section in Group 303 for
the procedure.
The engine, fuel system, ignition system, emissions system and exhaust system all affect exhaust
emission levels and must be maintained according to the maintenance schedule. Refer to the
scheduled Maintenance Guide.
Correct engine identification is required to order parts. Refer to the appropriate section in Group 303 for the procedure.
For complete vehicle and engine identification codes, refer to
Section 100 - 01 .
SECTION 303-
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Inspection and Verification
1. Verify the customer concern by operating the engine to duplicate the condition.
2. Visually inspect for obvious signs of mechanical damage. Refer to the following chart.
3. If the inspection reveals obvious concerns that can be readily identified, repair as necessary.
4. If the concerns remain after the inspection, determine the symptoms. GO to Symptom Chart .
Symptom Chart Material
Item Specification
Gasoline Engine Oil
Dye
164-
R3705 or
equivalent ESE-
M99C103- B1 Engine Oil Refer to owner
literature
Visual Inspection Chart Mechanical
z
Engine coolant leaks
z Engine oil leaks
z Fuel leaks
z Damaged or severely worn parts
z Loose mounting bolts, studs and nuts
Symptom Chart Condition
Possible Sources Action
z Difficult
starting z
Damaged ignition
system. z
Refer to the appropriate section
in Group 303 for the procedure.
REFER to the Powertrain
Control/Emissions Diagnosis
(PC/ED) manual.
z Damaged fuel
system. z
Refer to the appropriate section
in Group 303 for the procedure.
REFER to the Powertrain
Control/Emissions Diagnosis
(PC/ED) manual.
z Damaged starting
system. z
Refer to the appropriate section
in Group 303 for the procedure. Klj . 2 ba
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REFER to the Powertrain
Control/Emissions Diagnosis
(PC/ED) manual.
z Damaged charging
system/battery. z
REFER to Section 414 - 00 .
z Burnt valve. zINSTALL a new valve.
z Worn piston. zINSTALL a new piston.
z Worn piston rings. zINSTALL new piston rings.
z Worn cylinder. zREPAIR or INSTALL a new
cylinder block.
z Damaged head
gasket. z
INSTALL a new head gasket.
z Damaged cooling
system. z
Refer to the appropriate section
in Group 303 for the procedure.
REFER to the Powertrain
Control/Emissions Diagnosis
(PC/ED) manual.
z Poor idling zVacuum leaks. zRefer to the appropriate section
in Group 303 for the procedure.
REFER to the Powertrain
Control/Emissions Diagnosis
(PC/ED) manual.
z Malfunctioning or
damaged ignition
system. z
Refer to the appropriate section
in Group 303 for the procedure.
REFER to the Powertrain
Control/Emissions Diagnosis
(PC/ED) manual.
z Malfunctioning or
damaged fuel
system. z
Refer to the appropriate section
in Group 303 for the procedure.
REFER to the Powertrain
Control/Emissions Diagnosis
(PC/ED) manual.
z Damaged valve
tappet or lash
adjuster. z
INSTALL a new valve tappet or
lash adjuster.
z Damaged valve
tappet guide or lash
adjuster. z
INSTALL a new valve tappet
guide or valve tappet.
z Incorrect valve-to-
valve seat contact. z
REPAIR or INSTALL a new
valve or valve seat.
z Damaged head
gasket. z
INSTALL a new head gasket.
z Abnormal
combustion z
Malfunctioning or
damaged fuel
system. z
Refer to the appropriate section
in Group 303 for the procedure.
REFER to the Powertrain
Control/Emissions Diagnosis
(PC/ED) manual.
z Malfunctioning or
damaged ignition
system. z
Refer to the appropriate section
in Group 303 for the procedure.
REFER to the Powertrain
Control/Emissions Diagnosis
(PC/ED) manual.
z Malfunctioning or
damaged air intake
system. z
Refer to the appropriate section
in Group 303 for the procedure.
REFER to the Powertrain
Control/Emissions Diagnosis Klj . 3 ba
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(PC/ED) manual.
z Damaged valve
tappet or lash
adjuster. z
INSTALL a new valve tappet or
lash adjuster.
z Damaged valve
tappet guide or
valve tappet. z
INSTALL a new valve tappet
guide or valve tappet.
z Burnt or sticking
valve. z
REPAIR or INSTALL a new
valve.
z Weak or broken
valve spring. z
INSTALL a new valve spring.
z Carbon
accumulation in
combustion
chamber. z
ELIMINATE carbon buildup.
z Excessive oil
consumption z
Leaking oil. zREPAIR oil leakage.
z Malfunctioning PCV
system. z
REPAIR or INSTALL new
necessary components.
z Worn valve stem
seal. z
INSTALL a new valve stem seal.
z Worn valve stem or
valve guide. z
INSTALL a new valve and valve
guide.
z Sticking piston
rings. z
REPAIR or INSTALL new piston
rings.
z Worn piston ring
groove. z
INSTALL a new piston and
piston pin.
z Worn piston or
cylinder. z
REPAIR or INSTALL a new
piston or cylinder block.
z Engine noise zLeaking exhaust
system. z
REPAIR exhaust leakage.
z Incorrect drive belt
tension. z
REFER to Section 303 - 05 .
z Malfunctioning
generator bearing. z
Refer to the appropriate section
in Group 414 for the procedure.
z Malfunctioning
water pump
bearing. z
REFER to Section 303 - 03A .
z Malfunctioning or
damaged cooling
system. z
REFER to Section 303 - 03A .
z Malfunctioning or
damaged fuel
system. z
Refer to the appropriate section
in Group 303 for the procedure.
REFER to the Powertrain
Control/Emissions Diagnosis
(PC/ED) manual.
z Loose timing
chain/belt (6268). z
ADJUST or INSTALL a new
timing chain/belt.
z Damaged timing
chain tensioner
(6L266). z
INSTALL a new timing chain
tensioner.
z Excessive main
bearing clearance. z
ADJUST clearance or INSTALL
a new crankshaft main bearing
(6333). Klj . 4 ba
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z
Seized or heat
damaged
crankshaft main
bearing. z
INSTALL a new crankshaft main
bearing.
z Excessive
crankshaft end
play. z
INSTALL a new thrust bearing or
crankshaft (6303).
z Excessive
connecting rod
bearing clearance. z
INSTALL a new connecting rod
bearing or connecting rod
(6200).
z Heat damaged
connecting rod
bearing (6211). z
INSTALL a new connecting rod
bearing.
z Damaged
connecting rod
bushing (6207). z
INSTALL a new connecting rod
bushing.
z Worn cylinder. zREPAIR or INSTALL a new
cylinder block (6010).
z Worn piston (6108)
or piston pin
(6135). z
INSTALL a new piston or piston
pin.
z Damaged piston
rings. z
INSTALL new piston rings.
z Bent connecting
rod. z
INSTALL a new connecting rod.
z Malfunctioning
valve tappet (6500)
or lash adjuster. z
INSTALL a new valve tappet or
lash adjuster.
z Excessive valve
tappet or lash
adjuster clearance. z
ADJUST clearance or INSTALL
a new valve tappet guide or
valve tappet.
z Broken valve spring
(6513). z
INSTALL a new valve spring.
z Excessive valve
guide clearance. z
ADJUST clearance or INSTALL
a new valve guide (6510) or
valve.
z Insufficient
power z
Malfunctioning or
damaged ignition
system. z
Refer to the appropriate section
in Group 303 for the procedure.
REFER to the Powertrain
Control/Emissions Diagnosis
(PC/ED) manual.
z Malfunctioning or
damaged fuel
system. z
Refer to the appropriate section
in Group 303 for the procedure.
REFER to the Powertrain
Control/Emissions Diagnosis
(PC/ED) manual.
z Malfunctioning or
damaged air intake
system. z
Refer to the appropriate section
in Group 303 for the procedure.
REFER to the Powertrain
Control/Emissions Diagnosis
(PC/ED) manual.
z Damaged or
plugged exhaust
system. z
INSPECT exhaust system.
z Incorrect tire size. zREFER to Section 204 - 04 .
z Dragging brakes. zREFER to Section 206 - 00 . Klj . 5 ba
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4. WORN RINGS OR DILUTED OIL: When the engine is accelerated (dotted needle), the needle
drops to 0 kPa (0 in- Hg). Upon deceleration, the needle runs slightly above 74 kPa (22 in- Hg).
5. STICKING VALVES: When the needle (dotted) remains steady at a normal vacuum but occasionally flicks (sharp, fast movement) down and back about 13 kPa (4 in- Hg), one or more
valves may be sticking.
6. BURNED OR WARPED VALVES: A regular, evenly- spaced, downscale flicking of the needle
indicates one or more burned or warped valves. Insufficient hydraulic lash adjuster or hydraulic
lash adjuster (HLA) clearance will also cause this reaction.
7. POOR VALVE SEATING: A small but regular downscale flicking can mean one or more valves are not seating.
8. WORN VALVE GUIDES: When the needle oscillates over about a 13 kPa (4 in- Hg) range at idle
speed, the valve guides could be worn. As engine speed increases, the needle will become
steady if guides are responsible.
9. WEAK VALVE SPRINGS: When the needle oscillation becomes more violent as engine rpm is increased, weak valve springs are indicated. The reading at idle could be relatively steady.
10. LATE VALVE TIMING: A steady but low reading could be caused by late valve timing.
11. IGNITION TIMING RETARDING: Retarded ignition timing will produce a steady but somewhat low reading.
12. INSUFFICIENT SPARK PLUG GAP: When spark plugs are gapped too close, a regular, small pulsation of the needle can occur.
13. INTAKE LEAK: A low, steady reading can be caused by an intake manifold or throttle body gasket leak.
14. BLOWN HEAD GASKET: A regular drop of fair magnitude can be caused by a blown head gasket or warped cylinder head- to-cylinder block surface.
15. RESTRICTED EXHAUST SYSTEM: When the engine is first started and is idled, the reading may be normal, but as the engine rpm is increased, the back pressure caused by a clogged
muffler (5230), kinked tail pipe or other concerns will cause the needle to slowly drop to 0 kPa
(0 in-Hg). The needle then may slowly rise. Excessive exhaust clogging will cause the needle to
drop to a low point even if the engine is only idling.
16. When vacuum leaks are indicated, search out and correct the cause. Excess air leaking into the system will upset the fuel mixture and cause concerns such as rough idle, missing on
acceleration or burned valves. If the leak exists in an accessory unit such as the power brake
booster (2005), the unit will not function correctly. Always fix vacuum leaks.
Excessive Engine Oil Consumption
The amount of oil an engine uses will vary with the way the vehicle is driven in addition to normal
engine- to-engine variation. This is especially true during the first 16,100 km (10,000 miles) when a new
engine is being broken in or until certain internal engine components become conditioned. Vehicles
used in heavy- duty operation may use more oil. The following are examples of heavy- duty operation:
z trailer towing applications
z severe loading applications
z sustained high speed operation Klj . 12 ba
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