oil FORD MUSTANG 2003 Workshop Manual

3. Remove the pressure cap from the cooling system reservoir and the fill plug from the engine
crossover tube.
4. CAUTION: Do not fill the cooling system through the reservoir only. Coolant will not
enter the engine. Only the reservoir and the radiator will be filled and engine overheating
will occur.
Add coolant into the fill neck on the engine crossover tube until coolant reaches the top of the fill
neck on the cooling system reservoir.
5. Install the cooling system pressure cap on the reservoir.
6. Continue to fill the cooling system at the engine crossover fill neck until full.
7. Install the engine crossover tube fill plug.
8. WARNING: To avoid the possibility of personal injury or damage to the vehicle, do
not operate the engine with the hood open until the fan has been first examined for
possible cracks and separation.
CAUTION: If the engine temperature gauge does not move, coolant level is low in
the engine and must be filled. Stop the engine, allow to cool, and fill the cooling system
as outlined.
Run the engine until the thermostat opens (coolant flowing through the radiator lower hose
becomes hot).
9. Stop the engine and allow to cool.
10. Add coolant to the engine crossover tube fill neck until the cooling system is full.
11. Install the fill plug.
12. Repeat the fill procedure if necessary.
Filling — Mach I
CAUTION: Vehicle cooling systems are filled with Motorcraft Premium Gold Engine
Coolant VC -7-A (in Oregon VC -7-B) or equivalent meeting Ford specification WSS- M97B51-A1
(yellow color). Always fill the cooling system with the same coolant that is present in the
system. Do not mix coolant types.
CAUTION: Engine coolant provides freeze protection, boil protection, cooling efficiency,
and corrosion protection to the engine and cooling components. In order to obtain these
protections, the engine coolant must be maintained at the correct concentration and fluid level
in the degas bottle.
When adding engine coolant, use a 50/50 mixture of engine coolant and deionized water.
To maintain the integrity of the coolant and the cooling system:
zAdd Motorcraft Premium Gold Engine Coolant VC -7-A (in Oregon VC -7-B) or equivalent
meeting Ford specification WSS- M97B51-A1 (yellow color). Use the same coolant that Klj . 5 ba
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6.
NOTE: To avoid disturbing the transmission oil cooler fittings, use a backup wrench.
If equipped, remove the transmission lower cooler tube fitting.
7. NOTE: To avoid disturbing the transmission oil cooler fittings, use a backup wrench.
If equipped, remove the upper transmission cooler tube fitting.
8. Remove the lower radiator hose from the radiator. Klj . 2 ba
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DESCRIPTION AND OPERATION
Supercharger Cooling
CAUTION: Some vehicle cooling systems are filled with Motorcraft Premium Engine
Coolant VC -4-A (in Oregon VC- 5, in Canada CXC- 10) or equivalent meeting Ford specification
ESE- M97B44- A (green color). Others are filled with Motorcraft Premium Gold Engine Coolant
VC -7-A or equivalent meeting Ford specification WSS- M97B51-A1 (yellow color). Always fill the
cooling system with the same coolant that is present in the system. Do not mix coolant types.
NOTE: The addition of Motorcraft Cooling System Stop Leak Pellets, VC- 6, darkens Motorcraft
Premium Gold Engine Coolant from yellow to golden tan.
NOTE: The air that is produced from the supercharger is cooled by the intercooler.
Walter C. Avrea, the owner of patents 3,601,181 and RE 27,965, has granted Ford Motor Company
rights with respect to cooling systems covered by these patents.
The cooling system components include the:
zintercooler
z intercooler radiator (8K226)
z pressure relief cap
z degas bottle
z electric water pump (8501)
The degas bottle:
zprovides a location for system fill.
z contains coolant expansion and system pressurization.
z provides air separation during operation.
z replenishes the intercooler coolant to the system.
The intercooler coolant flows:
zfrom the intercooler to the degas bottle.
z from the degas bottle to the water pump.
z from the water pump to the intercooler radiator.
z from the intercooler radiator to the intercooler.
Engine coolant provides freeze protection, boil protection, cooling efficiency and corrosion protection to
the engine and cooling components. In order to obtain these protections, the engine coolant must be
maintained at the correct concentration and fluid level in the degas bottle.
When adding engine coolant, use a 50/50 mixture of engine coolant and clean, drinkable water.
To maintain the integrity of the coolant and the cooling system: SECTION 303-
03B: Supercharger Cooling 2003 Mustang Workshop Manual Klj . 1 ba
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DIAGNOSIS AND TESTING
Supercharger Cooling
Inspection and Verification
WARNING: Never remove the pressure relief cap while the engine is operating or when the
cooling system is hot. Failure to follow these instructions can result in damage to the cooling
system or engine or personal injury. To avoid having scalding hot coolant or steam blow out of
the degas bottle when removing the pressure relief cap, wait until the engine has cooled, then
wrap a thick cloth around the pressure relief cap and turn it slowly. Step back while the
pressure is released from the cooling system. When you are sure all the pressure has been
released, (still with a cloth) turn and remove the pressure relief cap.
CAUTION: Check the coolant and engine oil levels. Top off the coolant level if needed. If
there is engine coolant in the engine oil, the cause must be corrected and the oil changed or major component damage can occur. SECTION 303-
03B: Supercharger Cooling 2003 Mustang Workshop Manual Special Tool(s)
Pressure Test Kit
014-
R1072 or equivalent Battery/Antifreeze Tester
014-
R1060 or equivalent
Material Item Specification
Motorcraft Premium
Engine Coolant
VC
-4-A (in Oregon
VC- 5, in Canada
CXC- 10) ESE-
M97B44- A Motorcraft Premium
Gold Engine Coolant
VC
-7-A WSS-
M97B51- A1 Motorcraft Cooling
System Stop Leak
Pellets
VC-
6 or equivalent ESE-
M99B37- 5 except as
noted in ES-F65E-19A511- AA Klj . 1 ba
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CAUTION: Some vehicle cooling systems are filled with Motorcraft Premium Engine
Coolant VC -4-A (in Oregon VC- 5, in Canada CXC- 10) or equivalent meeting Ford specification
ESE- M97B44- A (green color). Others are filled with Motorcraft Premium Gold Engine Coolant
VC -7-A or equivalent meeting Ford specification WSS- M97B51-A1 (yellow color). Always fill the
cooling system with the same coolant that is present in the system. Do not mix coolant types.
NOTE: The addition of Motorcraft Cooling System Stop Leak Pellets, VC- 6, darkens Motorcraft
Premium Gold Engine Coolant from yellow to golden tan.
1. Verify the customer's concern by operating the engine to duplicate the condition.
2. Inspect to determine if any of the following mechanical or electrical concerns apply.
3. If the inspection reveals an obvious concern that can be readily identified, repair it as necessary.
4. Inspect the coolant condition. 1. WARNING: Never remove the pressure relief cap while the engine is
operating or when the cooling system is hot. Failure to follow these instructions
can result in damage to the cooling system or engine or personal injury. To avoid
having scalding hot coolant or steam blow out of the degas bottle when removing
the pressure relief cap, wait until the engine has cooled, then wrap a thick cloth
around the pressure relief cap and turn it slowly. Step back while the pressure is
released from the cooling system. When you are sure all the pressure has been
released, (still with a cloth) turn and remove the pressure relief cap.
Allow the engine to cool. Once pressure is released, remove the pressure relief cap.
2. CAUTION: Check the coolant and engine oil level and top off the coolant if
needed. If there is engine coolant in the engine oil the cause must be corrected
and oil/fluid changed or major component damage can occur.
CAUTION: Some vehicle cooling systems are filled with Motorcraft Premium
Engine Coolant VC -4-A (in Oregon VC- 5, in Canada CXC- 10) or equivalent meeting
Ford specification ESE- M97B44-A (green color). Others are filled with Motorcraft
Premium Gold Engine Coolant VC -7-A or equivalent meeting Ford specification
WSS- M97B51- A1 (yellow color). Always fill the cooling system with the same
coolant that is present in the system. Do not mix coolant types.
Inspect the coolant color:
„If Motorcraft Premium Engine Coolant (green color) VC-4- A or equivalent meeting
Ford specification ESE-M97B44- A has a clear, light green or blue color, this Visual Inspection Chart
Mechanical Electrical
z
Radiator brackets
z Leaks
z Damaged hoses
z Hose clamps
z Water pump
z Radiator
z Degas bottle
z Water pump bracket z
Damaged water pump wiring Klj . 2 ba
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indicates higher water content than required.
„ NOTE: The addition of Motorcraft Cooling System Stop Leak Pellets, VC- 6,
darkens Motorcraft Premium Gold Engine Coolant from yellow to golden tan.
If Motorcraft Premium Gold Engine Coolant (yellow color) VC-7- A or equivalent
meeting Ford specification WSS- M97B51-A1 has a clear or pale yellow color, this
indicates higher water content than required.
„ Dark brown can indicate unauthorized stop leak may have been used. Use
Motorcraft Cooling System Stop Leak Pellets VC- 6 or equivalent meeting Ford
specification ESE-M99B37- 5 except as noted in ES-F65E-19A511- AA only.
„ A light or reddish brown color indicates that rust may be present in the cooling
system. Flush the system and refill with the correct mixture of water and engine
coolant.
„ An iridescent sheen on top of the coolant or a milky brown color can indicate a
trace of oil is entering the system. For additional information on engine diagnosis,
refer to Section 303 - 00 .
3. If the engine coolant appearance is acceptable, test the engine coolant freezing point
range with the special tool. The freezing point should be in the range - 50°F to -10°F. If
the vehicle is driven in cold climates less than - 34°F, it may be necessary to increase the
coolant concentration to get adequate freeze protection.
„Maximum coolant concentration is 60/40.
„ Minimum coolant concentration is 40/60.
4. Check the coolant system conditions:
„If the intercooler fluid is low, add the specified coolant mixture only.
„ If the intercooler coolant fluid tests weak, add straight engine coolant until the
readings are within acceptable levels.
„ If the engine coolant tests strong, remove some of the engine coolant and add
water until readings are within acceptable levels.
5. If the concern remains after the inspection, determine the symptom(s). GO to Symptom Chart .
6. Verify the cooling system is correctly filled and bled. Refer to Supercharger Cooling System Draining, Filling and Bleeding in this section.
Symptom Chart
Pinpoint Tests PINPOINT TEST A: LOSS OF COOLANT SYMPTOM CHART
Condition
Possible Sources Action
z Loss of intercooler
coolant z
Intercooler.
z Intercooler
radiator.
z Water pump.
z Coolant hoses.
z Degas bottle. z
Go To Pinpoint Test A . Klj . 3 ba
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GENERAL PROCEDURES
Supercharger Cooling System Draining, Filling and
Bleeding
Draining
WARNING: Never remove the pressure relief cap while the engine is operating or when the
cooling system is hot. Failure to follow these instructions can result in damage to the cooling
system or engine or personal injury. To avoid having scalding hot coolant or steam blow out of
the degas bottle when removing the pressure relief cap, wait until the engine has cooled, then
wrap a thick cloth around the pressure relief cap and turn it slowly. Step back while the
pressure is released from the cooling system. When certain all the pressure has been released,
(still with a cloth) turn and remove the pressure relief cap.
CAUTION: The coolant must be recovered in a suitable, clean container for reuse. If the
coolant is contaminated, it must be recycled or disposed of correctly and replaced.
CAUTION: Some vehicle cooling systems are filled with Motorcraft Premium Engine
Coolant VC -4-A (in Oregon VC- 5, in Canada CXC- 10) or equivalent meeting Ford specification
ESE- M97B44- A (green color). Others are filled with Motorcraft Premium Gold Engine Coolant
VC -7-A or equivalent meeting Ford specification WSS- M97B51-A1 (yellow color). Always fill the
cooling system with the same coolant that is present in the system. Do not mix coolant types.
NOTE: The addition of Motorcraft Cooling System Stop Leak Pellets, VC- 6, darkens Motorcraft
Premium Gold Engine Coolant from yellow to golden tan.
NOTE: Less than 80% of coolant capacity can be recovered with the engine in the vehicle. Dirty, rusty
or contaminated coolant requires replacement.
1. Raise and support the vehicle. For additional information, refer to Section 100 - 02 .
2. Remove the lower hose from the intercooler radiator and allow the coolant to drain.
Filling and Bleeding
CAUTION: Engine coolant provides freeze protection, boil protection, cooling efficiency
and corrosion protection to the engine and cooling components. In order to obtain these
protections, the engine coolant must be maintained at the correct concentration and fluid level
in the degas bottle.
CAUTION: Some vehicle cooling systems are filled with Motorcraft Premium Engine
Coolant VC -4-A (in Oregon VC- 5, in Canada CXC- 10) or equivalent meeting Ford specification
ESE- M97B44- A (green color). Others are filled with Motorcraft Premium Gold Engine Coolant
VC -7-A or equivalent meeting Ford specification WSS- M97B51-A1 (yellow color). Always fill the
cooling system with the same coolant that is present in the system. Do not mix coolant types.
NOTE: The addition of Motorcraft Cooling System Stop Leak Pellets, VC- 6, darkens Motorcraft
Premium Gold Engine Coolant from yellow to golden tan.
NOTE: When adding engine coolant, use a 50/50 mixture of engine coolant and clean, drinkable
water. SECTION 303-
03B: Supercharger Cooling 2003 Mustang Workshop Manual Klj . 1 ba
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SPECIFICATIONS
SECTION 303-
04A: Fuel Charging and Controls — 3.8L 2003 Mustang Workshop Manual General Specifications
Item Specification
Lubricants and Chemicals
SAE 5W-
20 Premium Synthetic Blend Motor Oil XO-5W20- QSP WSS-
M2C153- H
Torque Specifications Description Nm lb-
in Throttle body nuts and bolts 9 80
Fuel injection supply manifold bolts 10 89
42-
pin engine bulkhead electrical connector bolt 6 53 Klj . 1 ba
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REMOVAL AND INSTALLATION
Fuel Injectors
Removal and Installation
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 ignite. 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 pressure must be relieved. Failure to follow these instructions may result
in personal injury
1. Remove the supply manifold. For additional information, refer to Supply Manifold in this section.
2. Remove the six fuel injectors from the supply manifold.
3. CAUTION: The retaining clip must be in the upper groove on the injector or the
injector may become loose.
NOTE: Inspect the two O- rings from each fuel injector. Install new O- rings as needed.
NOTE: Lubricate the new O- rings with clean engine oil to aid installation.
To install, reverse the removal procedure.
SECTION 303-
04A: Fuel Charging and Controls — 3.8L 2003 Mustang Workshop Manual Material
Item Specification
SAE 5W-
20 Premium Synthetic
Blend Motor Oil
XO- 5W20-QSP or equivalent WSS-
M2C153-
H Klj . 1 ba
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10. Disconnect the cylinder head temperature (CHT) sensor electrical connector on the back of the
left cylinder head.
11. Disconnect the engine oil pressure sender electrical connector.
12. Disconnect the fuel pressure sensor electrical connector. 13. Disconnect the LH heated oxygen sensor (HO2S) electrical connector. Klj . 3 ba
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