engine FORD MUSTANG 2003 Workshop Manual

17. Install the degas bottle support bracket.
18. Connect the engine ground strap to the frame.
19. Using the special tool, install a new seal ring.
20. Install the high pressure power steering hose to the pump. Klj . 6 ba
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65. Install the hood-
to-body ground strap.
66. Connect the fuel spring lock coupling. For additional information, refer to Section 310 - 00 .
67. Install the air intake scoop bracket. For additional information, refer to Section 303 - 12 .
68. Connect the battery ground cable. For additional information, refer to Section 414 - 01 .
69. Fill the crankcase with clean engine oil and check that all other fluids are at the correct levels.
70. Fill and bleed the engine cooling system. For additional information, refer to Section 303 - 03A .
71. Fill and purge the power steering system. For additional information, refer to Section 211 - 00 .
72. Start the engine and check for leaks. Stop the engine and recheck the fluid levels.
73. Charge the A/C system. For additional information, refer to Section 412 - 00 . Klj . 18 ba
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SPECIFICATIONS
SECTION 303-
03A: Engine Cooling 2003 Mustang Workshop Manual General Specifications
Item Specification
Cooling System Capacity 15.2 L (4.0 gal)
Coolant Type
Motorcraft Premium Gold Engine Coolant VC-7-
A in
(Oregon VC -7-B) (yellow color) WSS-
M97B51- A1 Other Chemicals
Motorcraft Premium Cooling System Flush VC-
1 ESR-
M14P7-A Premium Long Life Grease XG-1-
C ESA-
M1C75- B Cooling System Stop Leak Pellets
VC-
6 ESE-
M99B37- B5 except as noted in ES-
F65E-19A511- AA Gasket Adhesive TA-
6 WSS-
M2G408- A Cooling System Pressure Test Specifications 138 kPa (20 psi)
Radiator Cap Pressure Test Specifications 110 kPa (16 psi)
Thermostat Opening Temperatures
Starts to open (4.6L 2V) 87-
93°C (192- 199°F) Starts to open (3.8L) 86.7-
90.6°C (189- 196°F) Starts to open (Cobra) 80-
83°C (175- 182°F) Fully open 104°C (219°F)
Torque Specifications Description Nm lb-
ft lb-
in Accelerator cable bracket bolts 10 — 89
Cylinder block drain plug 20 15 —
Exhaust manifold to EGR valve tube nut 35 26 —
Fan shroud bolts 10 — 89
Fan motor bolts 10 — 89
Degas bottle nuts 10 — 89
Coolant expansion tank bracket bolts 10 — 89
Radiator support bracket bolts 30 22 —
Transmission fluid cooler fittings 30 22 —
Coolant outlet connection bolts (3.8L) 10 — 89
Bypass tube bracket bolts (3.8L) 10 — 89
Bypass tube bolts (4.6L) 10 — 89
Bypass tube nuts (Supercharged engine) 25 18 —
Coolant hose mounting bolt 25 18 — Klj . 1 ba
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DESCRIPTION AND OPERATION
Engine Cooling
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.
NOTE: The addition of Motorcraft Cooling System Stop Leak Pellets, VC- 6, darkens Motorcraft
Premium Gold Engine Coolant from yellow to golden tan.
The 4.6L cooling system components include the:
zblock heater
z engine coolant temperature (ECT) sensor
z fan blade, fan motor and fan shroud assembly
z radiator
z pressure relief cap
z radiator draincock
z coolant pump
z coolant thermostat
z oil filter adapter
z radiator overflow hose
z upper radiator hose
z lower radiator hose
The radiator overflow hose circulates the coolant.
The coolant thermostat:
zcontrols the engine coolant temperature.
z allows for quicker engine warm- up.
The degas bottle/coolant expansion tank:
zprovides a location for service fill.
z contains coolant expansion and system pressurization.
z provides air separation during operation.
z replenishes the engine coolant to the system.
The engine coolant flows:
zfrom the lower radiator hose to the coolant pump.
z from the coolant pump to the engine block and the cylinder heads.
SECTION 303-
03A: Engine Cooling 2003 Mustang Workshop Manual Klj . 1 ba
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The 3.8L cooling system components include the:
zblock heater
z engine coolant temperature (ECT) sensor
z fan blade, fan motor and fan shroud assembly
z radiator
z radiator cap
z radiator draincock
z coolant pump
z coolant thermostat
z oil filter adapter
z radiator overflow hose
z coolant expansion tank
z upper radiator hose
z lower radiator hose
The fan blade draws air through the radiator to help cool the engine coolant.
The fan motor:
zoperates only when the ignition switch is in the RUN position.
z will not operate with the switch in the OFF position.
The engine coolant:
zflows through the radiator tubes and is cooled by passing air over the cooling fins.
z is then circulated from the radiator outlet tank through the coolant pump and into the cylinder
block to complete the circuit.
A closed coolant thermostat returns the engine coolant to the coolant pump. An open coolant
thermostat allows the engine coolant to flow to the radiator.
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 (4.6L) or coolant expansion tank (3.8L).
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:
zNOTE: The addition of Motorcraft Cooling System Stop Leak Pellets, VC-6, darkens Motorcraft
Premium Gold Engine Coolant from yellow to golden tan.
Add 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 is
present in the cooling system. Do not mix coolant types.
z Do not add/mix orange-colored Motorcraft Speciality Orange Engine Coolant VC- 2 or equivalent Klj . 2 ba
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meeting Ford specification WSS-
M97B44-D. Mixing coolants may degrade the coolant's
corrosion protection.
z Do not add alcohol, methanol, or brine, or any engine coolants mixed with alcohol or methanol
antifreeze. These can cause engine damage from overheating or freezing.
z Do not mix with recycled coolant unless it meets the requirements of Ford specification WSS-
M97B51- A1. Not all coolant recycling processes meet these Ford specifications. Use of such
coolants can harm the engine and cooling system components.
The coolant temperature sensor (4.6L) or cylinder head temperature sensor (3.8L) provides a signal to
the temperature gauge.
The optional block heater:
zelectrical heating element is installed in the core plug opening.
„uses a standard 110V electrical supply
z keeps the engine coolant warm during cold weather. Klj . 3 ba
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DIAGNOSIS AND TESTING
Engine 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 is 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, turn and remove the pressure relief cap (still with a cloth).
CAUTION: Check the coolant level, engine oil and transmission fluid, top off the coolant if
needed. If there is engine coolant in the engine oil or transmission fluid, the cause must be
corrected and oil/fluid changed or major component damage may occur.
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.
SECTION 303-
03A: Engine Cooling 2003 Mustang Workshop Manual Special Tool(s)
Pressure Tester
014-
R1072 or equivalent 73III Automotive Meter
105-
R0057 or equivalent Worldwide Diagnostic System
(WDS)
418-
F224,
New Generation STAR (NGS)
Tester
418- F052, or equivalent scan
tool Battery/Anti-Freeze Tester
014- R1060 or equivalent Klj . 1 ba
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3. If the inspection reveals an obvious concern that can be readily identified, repair as necessary.
4.
CAUTION: Some 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.
NOTE: The addition of Motorcraft Cooling System Stop Leak Pellets, VC-6, darkens Motorcraft
Premium Gold Engine Coolant from yellow to golden tan.
Inspect the coolant condition. 1. Inspect the coolant color.
„If Motorcraft Premium Gold Engine Coolant (yellow color) VC-7- A (in Oregon VC-
7- B) 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-F6SE-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 can indicate a trace of oil is entering the
system. For additional information on engine diagnosis, refer to Section 303 - 00 .
„ A milky brown color may indicate that either engine oil or transmission fluid is
entering the cooling system. If transmission fluid is suspected, the cause may be a
leaky radiator. Pressure test the cooling system. For additional information, refer
to component tests in this section. If engine oil is suspected the cause of the leak
may be internal to the engine. For additional information, refer to Section 303 - 00 .
2. If the engine coolant appearance is acceptable, test the engine coolant freezing point
range with the battery and anti- freeze tester. The freezing point should be in the range -
40°C to - 20°C (-50°F to - 10°F). If the vehicle is driven in cold climates less than - 32°C (-
34°F), it may be necessary to increase the coolant concentration to get adequate freeze
protection.
„Maximum coolant concentration is 60% coolant/40% water.
„ Minimum coolant concentration is 40% coolant/60% water. 3. Adjust coolant range and level, if necessary: Visual Inspection Chart
Mechanical
z
Leaks
z Hoses
z Hose clamps
z Water gasket
z Head gaskets
z Intake manifold gasket
z Coolant pump
z Radiator
z Degas bottle/coolant expansion tank
z Heater core
z Fan/fan clutch
z Engine coolant temperature sensor (4.6L)
z Cylinder head temperature sensor (3.8L)
z Circuitry Klj . 2 ba
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„
If coolant is low, add specified coolant mixture only.
„ If the engine coolant tests too 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 the readings are within acceptable levels.
5. If the concern remains after the inspection, determine the symptom(s) and GO to Symptom Chart
Symptom Chart
Pinpoint Tests
PINPOINT TEST A: LOSS OF COOLANT
Symptom Chart Condition
Possible Sources Action
z Loss of coolant zRadiator.
z Coolant pump seal.
z Radiator hoses.
z Heater hoses.
z Heater core.
z Engine gaskets.
z Degas bottle or
coolant expansion
tank. z
Go To Pinpoint Test
A .
z The engine overheats zThermostat.
z Coolant pump.
z Internal engine coolant
leak.
z Radiator.
z Cooling fan.
z Pressure relief cap or
radiator cap. z
Go To Pinpoint Test
B .
z The engine does not reach
normal operating temperature z
Thermostat. zGo To Pinpoint Test
C .
Test Step Result / Action to Take
A1 CHECK THE ENGINE COOLANT LEVEL
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 is cooled, then wrap a thick cloth
around the pressure relief cap and turn it slowly. Step back Yes
GO to
A2 .
No
REFILL the engine
coolant as necessary.
GO to A2 . Klj . 3 ba
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while the pressure is released from the cooling system.
When you are sure all the pressure has been released, turn
and remove the pressure relief cap (still with a cloth).
NOTE:
Allow the engine to cool before checking the engine
coolant level.
z Key in OFF position.
z Visually check the engine coolant level at the degas bottle or
coolant expansion tank.
z Is the engine coolant level within specification? A2 CHECK THE PRESSURE RELIEF CAP
z
Carry out the Cap— 3.8L or Cap—4.6L test. Go to Component
Tests in this section.
z Is pressure relief cap/radiator cap OK? Yes
GO to
A3 .
No
INSTALL a new
pressure relief
cap/radiator cap. TEST
the system for normal
operation. A3 CHECK THE ENGINE COOLANT FOR INTERNAL LEAK
z
Key in OFF position.
z Inspect the engine coolant in degas bottle/coolant expansion
tank for signs of transmission fluid or engine oil.
z Is oil or transmission fluid evident in the coolant? Yes
If engine oil is evident,
REFER to
Section 303 -
00 . If transmission fluid
is evident, REPAIR or
INSTALL a new radiator
as necessary.
No
GO to A4 .
A4 CHECK THE ENGINE AND THE TRANSMISSION FOR
COOLANT z
Remove the oil level dipstick from the engine and the
transmission.
z Is coolant evident in the oil or transmission fluid? Yes
If coolant is in engine,
REFER to
Section 303 -
00 . If coolant is in
transmission, REPAIR
or INSTALL a new
radiator as necessary.
To repair the automatic
transmission, REFER to
Section 307 - 01 .
No
GO to A5 .
A5 PRESSURE TEST THE ENGINE COOLING SYSTEM
z
Pressure test the engine cooling system. Go to Component
Tests in this section.
z Does the engine cooling system leak? Yes
REPAIR or install new
components. TEST the
system for normal
operation.
No
The cooling system is
operational. GO to
Symptom Chart
. Klj . 4 ba
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