AC system FORD MUSTANG 2003 Workshop Manual

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
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REMOVAL AND INSTALLATION
Fuel Tank
Removal
WARNING: Do not smoke, carry lighted tobacco or an open flame of any type when
working on or near any fuel- related components. Highly flammable mixtures are always present
and may be ignited, possibly resulting in personal injury.
WARNING: Fuel supply lines on all vehicles equipped with fuel injected engines will
remain pressurized for long periods of time after engine shutdown. Fuel system pressure must
be relieved prior to fuel system service to prevent possible personal injury or a fire hazard.
1. Disconnect the battery. For additional information, refer to Section 414 - 01 .
2. Relieve the fuel system pressure. For additional information, refer to Section 310 - 00 .
3. Drain the fuel tank. For additional information, refer to Section 310 - 00 .
4. Raise the vehicle. For additional information, refer to Section 100 - 02 .
5. Remove the filler pipe bolt and disconnect the filler pipe hose connections to the fuel tank.
6. Disconnect the fuel tank electrical connector.
SECTION 310-
01: Fuel Tank and Lines 2003 Mustang Workshop Manual Material
Item Specification
Serfactant
(Merpol)
ESE-
M99B144- B Klj . 1 ba
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REMOVAL AND INSTALLATION
Support Straps
Removal
WARNING: Do not smoke, carry lighted tobacco or an open flame of any type when
working on or near any fuel- related components. Highly flammable mixtures are always present
and may be ignited, possibly resulting in personal injury.
WARNING: Fuel supply lines on all vehicles equipped with fuel injected engines will
remain pressurized for long periods of time after engine shutdown. Fuel system pressure must
be relieved prior to fuel system service to prevent possible personal injury or a fire hazard.
1. Remove the fuel tank. For additional information, refer to Fuel Tank in this section.
2. Slide the strap and the retaining pin into the recess and remove the strap retaining pin.
3. Remove the strap.
Installation 1. To install, reverse the removal procedure.
SECTION 310-
01: Fuel Tank and Lines 2003 Mustang Workshop Manual Klj . 1 ba
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REMOVAL AND INSTALLATION
Fuel Filter
Removal
WARNING: Fuel supply lines on all vehicles equipped with fuel injected engines will
remain pressurized for long periods of time after engine shutdown. Fuel system pressure must
be relieved prior to fuel system service to prevent possible personal injury or a fire hazard.
1. Disconnect the battery. For additional information, refer to Section 414 - 01 .
2. Relieve the fuel system pressure. For additional information, refer to Section 310 - 00 .
3. Raise the vehicle. For additional information, refer to Section 100 - 02 .
4. Disconnect the filter push connect fittings. For additional information, refer to Section 310 - 00 .
5. Unsnap the filter from the bracket and remove.
Installation 1. To install, reverse the removal procedure.
SECTION 310-
01: Fuel Tank and Lines 2003 Mustang Workshop Manual Klj . 1 ba
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DIAGNOSIS AND TESTING
Acceleration Control
Inspection and Verification
1. Verify the customer's concern by operating the acceleration control system to duplicate the condition.
2. Inspect to determine if any of the following mechanical concerns apply:
3. If the inspection reveals an obvious concern that can be readily identified, repair as required.
4. If the concern remains after the inspection, determine the symptom(s) and GO to Symptom Chart .
Symptom Chart SECTION 310-
02: Acceleration Control 2003 Mustang Workshop Manual Visual Inspection Chart
Mechanical
z
damaged accelerator pedal and shaft
z damaged linkage
z damaged accelerator cable
z high engine idle speed
z damaged throttle body
Symptom Chart Condition
Possible Sources Action
z Excessive effort
needed to
depress
accelerator pedal
and shaft z
Worn
accelerator lever
pivot bushing. z
INSTALL a new accelerator
pedal and shaft.
z Accelerator
cable binding. z
INSTALL a new accelerator
cable.
z Worn or
damaged
throttle body. z
INSTALL a new throttle body.
REFER to Section 303 - 04A or
Section 303 - 04B .
z Accelerator pedal
and shaft feels
rough or raspy z
Frayed or
binding
accelerator
cable. z
INSTALL a new accelerator
cable.
z Worn or
damaged
throttle body. z
INSTALL a new throttle body.
REFER to Section 303 - 04A or
Section 303 - 04B .
z Accelerator pedal
and shaft binds or
sticks z
Kinked
accelerator
cable. z
INSTALL a new accelerator
cable. Klj . 1 ba
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z
Foreign object
caught in
accelerator
pedal linkage. z
CHECK the accelerator pedal
linkage.
z Worn or
damaged
throttle body. z
INSTALL a new throttle body.
REFER to Section 303 - 04A or
Section 303 - 04B .
z High engine idle
speed z
Kinked
accelerator
cable. z
INSTALL a new accelerator
cable.
z Foreign object
caught in
accelerator
pedal linkage. z
CHECK the accelerator pedal
linkage.
z Incorrect engine
idle speed. z
REFER to the Powertrain
Control/Emissions Diagnosis
(PC/ED) manual for diagnosis
and testing of the idle control
system. Klj . 2 ba
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DESCRIPTION AND OPERATION
Speed Control
The speed control system consists of the following components:
zspeed control actuator cable (9A825)
z deactivator switch
z output shaft sensor (OSS)
z speed control actuator switches (9C888)
z brake pedal position (BPP) switch (13480)
z speed control servo (9C735)
z clutch pedal position switch (manual transmission only)
SECTION 310-
03: Speed Control 2003 Mustang Workshop Manual Klj . 1 ba
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DIAGNOSIS AND TESTING
Speed Control
Refer to Wiring Diagrams Cell
31 , Speed Control for schematic and connector information.
Principles of Operation
The speed control system is designed to maintain vehicle speed above 48 km/h (30 mph). After the
ON switch is depressed, depressing the SET/ACCEL switch will activate the speed control servo. To
increase a set speed, either depress and hold for continuous acceleration, or momentarily tap the
SET/ACCEL switch for 1.6 km/h (1 mph) acceleration increments. To decrease a set speed, depress
and hold the COAST switch until the target speed is reached, or momentarily tap the COAST switch
for 1.6 km/h (1 mph) deceleration increments. When the speed control system has been disabled by
tapping the brake pedal, the RESUME switch can be depressed and the vehicle will return to the
original set speed if the vehicle is traveling over 48 km/h (30 mph) and the OFF switch has not been
depressed.
NOTE: The deactivator switch is provided as an additional safety feature. Normally, when the brake
pedal is depressed, an electrical signal from the brake lamp circuit to the speed control servo will
deactivate the system. Under increased brake pedal effort, the deactivator switch will open and
remove power to the speed control servo, releasing the throttle independent of the speed control
servo.
NOTE: The air bag sliding contract provides the electrical interface between the steering column wiring
and the speed control actuator switches in the steering wheel.
The inputs to the speed control servo are the:
zvehicle speed signal.
SECTION 310-
03: Speed Control 2003 Mustang Workshop Manual Special Tool(s)
Worldwide Diagnostic System
(WDS)
418-
F224,
New Generation STAR (NGS)
Tester
418- F052, or equivalent
diagnostic tool 73 Digital Multimeter or
equivalent
105-
R0051 Breakout Box, EEC-V Control
System 418-049, or equivalent
014- 00950 Klj . 1 ba
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z
speed control actuator switches.
z brake pedal position (BPP) switch.
z clutch pedal position (CPP) switch.
z deactivator switch.
The output of the speed control servo is the:
zspeed control actuator cable controlling the throttle position.
Inspection and Verification
NOTE: If any concerns are noted with the speedometer, stoplamps, or horn, address those concerns
by referring to their associated sections before continuing speed control diagnosis.
1. Verify the customer concern by operating the speed control system.
2. Visually inspect for obvious signs of mechanical and electrical damage.
3. If the fault is not visually evident, verify the symptom and GO to the Symptom chart.
Symptom Chart
NOTE: New speed control diagnostic software is available in Version 12 or higher for the diagnostic
tool. When using this software, it is necessary to use Next Generation Speed Control Adapter 007-
00586 with the diagnostic tool.
NOTE: Refer to the Wiring Diagrams for connector numbers stated in the Pinpoint Test.
Visual Inspection Chart Mechanical Electrical
z
Deactivator switch
z Speed control actuator cable not attached to throttle
z Speed control actuator cable not fully seated to the
engine bracket z
Central junction box (CJB)
Fuse:
„15 (15A)
„ 33 (15A)
„ 35 (15A)
z Battery junction box (BJB)
fuse:
„HORN (20A)
z Wiring harness
z Loose or corroded
connections
z Speed control actuator
switches
Symptom Chart Condition
Possible Sources Action
z The speed control is zCentral junction zGo To Pinpoint Test A . Klj . 2 ba
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Pinpoint Tests
PINPOINT TEST A: THE SPEED CONTROL IS INOPERATIVE
Test Step Result / Action to Take
A1 CHECK THE SPEED CONTROL SERVO VOLTAGE AND
GROUND z
Key in OFF position.
z Disconnect: Speed Control Servo C122.
z Key in ON position.
z Measure the voltage between speed control servo C122 Pin 7,
Circuit 294 (WH/LB), harness side and speed control servo
C122 Pin 10, Circuit 1205 (BK), harness side.
z Is voltage greater than 10 volts? Yes
GO to
A3 .
No
GO to A2 .
A2 CHECK THE CIRCUIT 1205 (BK) FOR AN OPEN
z
Key in OFF position.
z Measure the resistance between speed control servo C122 Pin
10, Circuit 1205 (BK), harness side and ground.
z Is the resistance less than 5 ohms? Yes
REPAIR Circuit 294
(WH/LB). TEST the
system for normal
operation.
No
REPAIR Circuit 1205
(BK). TEST the system
for normal operation.
A3 CHECK DEACTIVATOR SWITCH CIRCUITRY
z
Measure the voltage between speed control servo C122 Pin 9,
Circuit 636 (OG), harness side and speed control servo C122
Pin 10, Circuit 1205 (BK), harness side. Yes
GO to
A6 .
No
GO to A4 . Klj . 4 ba
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