fuel pump FORD MUSTANG 2003 Owner's Manual

DESCRIPTION AND OPERATION
Fuel System
Component Location
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, resulting in possible personal injury. SECTION 310-
00: Fuel System — General Information 2003 Mustang Workshop Manual Item Part Number Description
1 9341 Inertia fuel shutoff switch
2 9F593 Fuel injector
3 9155 Fuel filter
4 9002 Fuel tank
5 9H307 Fuel pump module and flange assembly Klj . 1 ba
22003 Mustang Workshop Manual
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The vehicle:
zuses a returnless fuel system.
z is equipped with a multiport fuel injection (MFI) system.
z uses separately controlled fuel injectors (9F593) for each cylinder. The fuel injectors are
mounted to the intake manifold.
z fuel injectors are supplied with pressurized fuel from the fuel pump (9350) through the fuel
injection supply manifold (9D280).
z fuel injection supply manifold is controlled by the electronic fuel delivery module which is
enabled by the powertrain control module (PCM) (12A650). Klj . 2 ba
22003 Mustang Workshop Manual
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DESCRIPTION AND OPERATION
Fuel Tank And Lines
WARNING: Do not smoke, carry lighted tobacco or an open flame of any type when
working on or near any fuel- related component. Highly flammable mixtures are always present
and may be ignited, possibly resulting in personal injury.
The vehicle utilizes a returnless fuel system consisting of:
zthe fuel tank.
z a fuel tank filler pipe which contains a restrictor plate to permit only unleaded fuel to be pumped
into the fuel tank.
z a 1/8 turn fuel tank filler cap.
z a fuel filter providing filtration to protect the fuel injectors.
z a single fuel line accommodating the returnless fuel system.
z a fuel injection supply manifold which contains a differential pressure sensor and a fuel
temperature sensor.
z a fuel pump and sender assembly which provides pressurized fuel to the engine and contains:
„an inlet filter.
„ a check valve which maintains system pressure after the pump is shut off.
„ a pressure relief valve for overpressure protection in the event of restricted flow.
The fuel pump is controlled by an electronic fuel pump driver module which is enabled by the
powertrain control module (PCM). Electrical power to the fuel pump is provided through the inertia fuel
shutoff (IFS) switch, which is located in the luggage compartment. SECTION 310-
01: Fuel Tank and Lines 2003 Mustang Workshop Manual Klj . 1 ba
12003 Mustang Workshop Manual
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REMOVAL AND INSTALLATION
Fuel Pump Module
Removal and Installation
1. Remove the fuel tank. For additional information, refer to Fuel Tank in this section.
2. NOTE: For installation, tighten the bolts in the sequence shown.
Remove the module assembly flange bolts.
3. Clean the area around the fuel delivery module mounting flange.
4. Lift the fuel pump, carefully detach the fuel float arm and remove the fuel pump from the fuel tank.
5. NOTE: Install a new fuel pump O- ring.
To install, reverse the removal procedure.
SECTION 310-
01: Fuel Tank and Lines 2003 Mustang Workshop Manual Klj . 1 ba
22003 Mustang Workshop Manual
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(20A).
z Battery junction
box (BJB) fuse
12 (40A).
z Circuitry.
z GEM.
z No communication with
the instrument cluster z
Central junction
box (CJB) fuse
(s):
„11
(15A).
„ 21 (5A).
„ 34
(20A).
z Circuitry.
z Standard
corporate
protocol (SCP)
network.
z Instrument
cluster. z
Go To Pinpoint Test A .
z Incorrect fuel gauge
indication z
Circuitry.
z Fuel pump
module.
z Instrument
cluster. z
Go To Pinpoint Test B .
z Incorrect oil pressure
gauge indication z
Circuitry.
z Engine oil
pressure
switch.
z Instrument
cluster. z
Go To Pinpoint Test C .
z Incorrect temperature
gauge indication z
Circuitry.
z Engine coolant
temperature
sensor.
z Powertrain
control module
(PCM).
z Instrument
cluster. z
Go To Pinpoint Test D .
z Incorrect voltage gauge
indication— except
Cobra z
Circuitry.
z Generator.
z Standard
corporate
protocol (SCP)
network.
z Instrument
cluster. z
Go To Pinpoint Test E .
z Incorrect tachometer
indication z
Standard
corporate
protocol (SCP)
network.
z Powertrain
control module
(PCM).
z Instrument
cluster. z
Go To Pinpoint Test F .
z Incorrect boost gauge zPressure line. zGo To Pinpoint Test G . Klj . 10 ba
412003 Mustang Workshop Manual
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PINPOINT TEST B: INCORRECT FUEL GAUGE INDICATION A4 CHECK GROUND CIRCUIT 397 (BK/WH) FOR AN OPEN
z
Key in OFF position.
z Measure the resistance between the instrument cluster C220b pin
20, circuit 397 (BK/WH), harness side and ground.
z Is the resistance less than 5 ohms? Yes
GO to
A5 .
No
REPAIR the circuit.
TEST the system
for normal
operation. A5 CHECK GROUND CIRCUIT 1205 (BK) FOR OPEN
z
Measure the resistance between the instrument cluster C220b pin 1,
circuit 1205 (BK), harness side and ground.
z Is the resistance less than 5 ohms? Yes
REFER to
Section 418 - 00 .
No
REPAIR the circuit.
TEST the system
for normal
operation. Test Step Result / Action to
Take B1 CARRY OUT THE INSTRUMENT CLUSTER FUEL GAUGE
ACTIVE COMMAND CAUTION: Use the correct probe adapter(s) when
making measurements. Failure to use the correct probe
adapter(s) may damage the connector. NOTE: Fuel fills of less
than 9.5 liters (2.5 gallons) require at least 10 minutes to update
the fuel gauge indication.
z Key in ON position.
z Select the instrument cluster FUELLEVEL active command.
Trigger, monitor, and scroll FUELLEVEL at: 0% , 50%, and
100%.
z Does the fuel gauge display: below E at 0%, half at 50%, and
F at 100%? Yes
GO to
B2 .
No
GO to B8 .
B2 CHECK THE FUEL GAUGE OPERATION
z
Key in OFF position.
z Disconnect: Fuel Pump Assembly C463.
z Connect one lead of the Instrument Gauge System Tester to the
fuel pump module C463 pin 5, circuit 29 (YE/WH), harness side
and the other lead of the Instrument Gauge System Tester to the Yes
GO to
B3 .
No
GO to B5 . Klj . 15 ba
412003 Mustang Workshop Manual
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fuel pump module C463 pin 8, circuit 327 (BK/OG), harness side.
z Set the Instrument Gauge System Tester to 160 ohms.
z Key in ON position.
z Turn the ignition switch to RUN for one second.
z Key in OFF position.
z Set Instrument Gauge System Tester to 15 ohms.
z Key in ON position.
z NOTE: The fuel gauge should read E or below when carrying out
this test step.
z Wait one minute and read the fuel gauge.
z Key in OFF position.
z Set Instrument Gauge System Tester to 160 ohms.
z Key in ON position.
z NOTE: The fuel gauge should read F (full) or above when
carrying out this test step.
z Wait one minute and read the fuel gauge.
z Key in OFF position.
z Does the fuel gauge operate correctly? B3 CHECK THE FUEL TANK
z
Check the fuel tank for any damage or deformation.
z Is the fuel tank OK? Yes
GO to
B4 .
No
INSTALL a new fuel
tank; REFER to
Section 310 - 01 . TEST
the system for normal
operation. B4 CHECK THE FUEL PUMP ASSEMBLY
z
Check the fuel pump assembly in- tank mounting, float, float rod,
wiring and connections for damage or obstruction.
z Is the fuel pump assembly and wiring OK? Yes
INSTALL a new fuel
sender. TEST the
system for normal
operation.
No
REPAIR as necessary.
TEST the system for
normal operation.
B5 CHECK CIRCUIT 29 (YE/WH) FOR SHORT TO POWER
z
Disconnect: Instrument Cluster C220b.
z Key in ON position.
z Measure the voltage between the instrument cluster C220b pin
19, circuit 29 (YE/WH), harness side and ground. Yes
REPAIR the circuit.
TEST the system for
normal operation.
No
GO to
B6 . Klj . 16 ba
412003 Mustang Workshop Manual
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z
Is any voltage present? B6 CHECK THE FUEL PUMP ASSEMBLY FEED CIRCUIT 29
(YE/WH) z
Key in OFF position.
z Measure the resistances between the instrument cluster C220b
pin 19, circuit 29 (YE/WH), harness side and the fuel pump
module C463 pin 5, circuit 29 (YE/WH), harness side; and
between the instrument cluster C220b pin 19, circuit 29 (YE/WH),
harness side and ground.
z Is the resistance less than 5 ohms between the instrument
cluster and the fuel pump module and greater than 10,000
ohms between the instrument cluster and ground? Yes
GO to
B7 .
No
REPAIR the circuit.
TEST the system for
normal operation. B7 CHECK FUEL PUMP MODULE GROUND CIRCUIT 327 (BK/OG)
AND CIRCUIT 397 (BK/WH) z
Measure the resistance between the instrument cluster C220b
pin 20, circuit 397 (BK/WH), harness side and the fuel pump
module C463 pin 8, circuit 327 (BK/OG), harness side.
z Is the resistance less than 5 ohms? Yes
GO to
B8 .
No
REPAIR the circuit(s)
in question. TEST the
system for normal
operation. B8 CHECK FOR CORRECT INSTRUMENT CLUSTER OPERATION
z
Disconnect all instrument cluster connectors.
z Check for:
zcorrosion
z pushed- out pins
z Connect all instrument cluster connectors and make sure they
seat correctly. Yes
INSTALL a new
instrument cluster.
REFER to
Instrument Cluster in this section.
TEST the system for Klj . 17 ba
412003 Mustang Workshop Manual
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Camshaft Position (CMP) SensorEngine Performance
Central Control ModuleAnti-Theft System
ClockspringAir Bag Restraint System; Cruise Control
Systems; Steering Column Switches
Clutch Pedal Position SwitchStarters
Clutch Start SwitchStarters
Combination MeterAnalog Instrument Panels
Constant Control Relay Module (CCRM)Engine Performance; Electric Cooling Fans
Convenience CenterPower Distribution; Illu mination/Interior Lights
Convertible Top MotorPower Convertible Top
Convertible Top SwitchPower Convertible Top
Crankshaft Position (CKP) SensorEngine Performance
Cruise Control ModuleCruise Control Systems
Cruise Control SwitchCruise Control Systems
Condenser Fan Relay(s)Electric Cooling Fans
Data Link Connector (DLC)Engine Performance
Daytime Running Lights ModuleDaytime Running Lights; Exterior Lights
Defogger RelayRear Window Defogger
Diagnostic Energy Reserve Module (DERM)Air Bag Restraint System
Discriminating Sensor (Air Bag)Air Bag Restraint System
DistributorEngine Performance
Door Lock ActuatorsPower Door Locks; Remote Keyless Entry
Door Lock Relay(s)Power Door Locks
Electrochromic MirrorPower Mirrors
Electronic Level Control (ELC) Height SensorElectronic Suspension
Electronic Level Control (ELC) ModuleElectronic Suspension
Engine Coolant Temper ature (ECT) Sending UnitAnalog Instrument Panels
Engine Coolant Temperature (ECT) SensorEngine Performance
Engine Control ModuleEngine Performance; Ge nerators & Regulators;
Starters
ETACS ECUWarning Systems; Power Windows; Remote Keyless Entry
Evaporative (EVAP) Emissions CanisterEngine Performance
EVAP Canister Purge SolenoidEngine Performance
EVAP Canister Vent SolenoidEngine Performance
Exhaust Gas Recirculation (EGR) ValveEngine Performance
Fuel Tank Vacuum SensorEngine Performance
Fog LightsHeadlight Systems; Daytime Running Lights
Fog Light RelayHeadlight Systems; Daytime Running Lights
Fuel Door Release SolenoidPower Fuel Door Release
Fuel Gauge Sending UnitAnalog Instrument Panels
Fuel InjectorsEngine Performance
Fuel PumpEngine Performance
Fuel Pump RelayEngine Performance; Power Distribution


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SIR Coil Assembly (Clockspring)Air Bag Restraint System
Slip Ring (Clockspring)Air Bag Restraint System; Steering Column Switches
SRS Control ModuleAir Bag Restraint System
Starter MotorStarters
Starter Interrupt RelayStarters
Starter SolenoidStarters
Starter RelayStarters
Steering Wheel Position SensorAnti-Lock Brakes
StoplightsExterior Lights
Stoplight SwitchEngine Performance; Cruise Control Systems;
Anti-Lock Brakes
Sun Roof ECUPower Sun Roof
Sun Roof MotorPower Sun Roof
Sun Roof Position SensorPower Sun Roof
TaillightsExterior Lights
Throttle Position (TP) SensorEngine Performance
Torque Converter Clutch Solenoid/SwitchEngine Performance
Traction Control SwitchAnti-Lock Brakes
Trailer Tow ConnectorExterior Lights
Trailer Tow RelayExterior Lights
Transmission/TransaxleEngine Performance
Transmission Control Module (TCM)Engine Performance; Starters
Transmission Range SensorStarters; Back-Up Lights; Engine Performance
Transmission Range SwitchBack-Up Lights; Engine Performance; Anti-Theft
System
Turn Signal FlasherExterior Lights
Turn Signal LightsExterior Lights
Twilight Sentinel SwitchHeadlight Systems; Daytime Running Lights
Vapor Canister Le ak Detection PumpEngine Performance
Vehicle Control Module (VCM)Engine Performance
Vehicle Dynamic ModuleElectronic Suspension
Vehicle Speed Control ServoCruise Control Systems
Vehicle Speed SensorData Link Connectors; Analog Instrument Panels;
Cruise Control Systems; Electronic Suspension
Voltage RegulatorGenerators & Regulators
Water-In-Fuel SensorEngine Performance; Analog Instrument Panels
Wheel Speed SensorsAnti-Lock Brakes
Window Timer ModulePower Convertible Top
Windshield Intermittent Wiper RelayWiper/Washer Systems
Windshield Washer MotorWiper/Washer Systems
Wiper MotorWiper/Washer Systems

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