check oil FORD MUSTANG 2003 Repair Manual

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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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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1. Turn the engine OFF.
2.
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).
Check the engine coolant level; refer to Cooling System Draining, Filling and Bleeding in this
section.
3. Connect Radiator Heater Core Pressure Tester to the degas bottle nipple and vent hose. Install a pressure test pump to the quick- connect fitting of the test adapter.
4. CAUTION: Do not pressurize the cooling system beyond 152 kPa (22 psi).
NOTE: If the plunger of the pump is depressed too quickly, an erroneous pressure reading will
result.
Slowly depress the plunger of the pressure test pump until the pressure gauge reading stops
increasing and note the highest pressure reading obtained.
5. If the pressure relief cap does not hold pressure, remove and wash the pressure relief cap in clean water to dislodge all foreign particles from the gaskets. Check the sealing surface in the
filler neck.
6. If 110 kPa (16 psi) cannot be reached, install a new pressure relief cap. If more than 124 kPa (18 psi) shows on gauge, install a new pressure relief cap.
7. CAUTION: If the pressure drops, check for leaks at the engine- to-heater core hoses,
engine- to-radiator hoses, water valve hose (if applicable), oil cooler return tube gasket
(6N789), radiator and heater core or other system components and connections. Any
leaks which are found must be corrected and the system rechecked.
Pressurize the engine cooling system as described in Step 4 (using a pressure relief cap that
operates within the specified upper and lower pressure limits). Observe the gauge reading for
approximately two minutes; refer to General Specifications. Pressure should not drop during this
time.
8. Release the system pressure by loosening the pressure relief cap. Check the engine coolant level and replenish, if necessary, with the correct engine coolant mixture; refer to Cooling System Draining, Filling and Bleeding in this section.
Cap — 3.8L
1. Inspect the radiator cap and seals for damage or deterioration. Install a new radiator cap if necessary.
2. Fit the radiator cap to Radiator/Heater Core Pressure Tester Kit, using the aftermarket adapter.
3. NOTE: If the plunger of the pressure tester is depressed too fast, an incorrect pressure reading
will result. Slowly pump the pressure tester until the pressure gauge stops increasing and note the highest Klj . 7 ba
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3.
NOTE: Running this test with the vehicle in gear or with the A/C compressor clutch engaged
(running) will cause incorrect diagnosis.
Place the transmission in PARK (P) or NEUTRAL (N).
4. Start the engine and allow the engine to idle throughout this test. Allow the engine to run for 2 minutes, then record the ECT (4.6L) or CHT (3.8L) voltage. Record the ECT (4.6L) or CHT
(3.8L) voltage every 60 seconds. When the ECT (4.6L) or CHT (3.8L) voltage trend changes
direction or only changes slightly (0.03 volts or less) from the previous reading, record this as
the thermostat opening voltage. Use the voltage and corresponding coolant temperature chart
listed below for 4.6L engines only.
5. If the thermostat opening voltage is greater than 0.75 volts and less than 82°C (180°F), install a new water thermostat.
6. If the thermostat opening voltage is less than 0.75 volts and greater than 82°C (180°F), the water thermostat is good and a new water thermostat should not be installed. GO to Symptom Chart for further instructions.
Thermostat — Mechanical Test
1. Remove the water thermostat.
2. Check the water thermostat for seating. Hold the water thermostat up to a lighted background. Leakage of light around the thermostat valve at room temperature indicates that a new water
thermostat should be installed. Some water thermostats have a small leakage notch at one
location on the perimeter of the thermostat valve, which is considered normal.
3. Immerse the water thermostat in a boiling coolant and water mixture.
4. See the General Specifications chart for water thermostat opening temperatures.
Radiator Leak Test, Removed From the Vehicle CAUTION: Never leak test an aluminum radiator in the same water that copper/brass
radiators are tested in. Flux and caustic cleaners may be present in the cleaning tank and they
will damage aluminum radiators.
NOTE: Always install plugs in the oil cooler fittings before leak- testing or cleaning any radiator.
NOTE: Clean the radiator before leak- testing to avoid contamination of tank. Coolant Temperature °C (°F) ECT (Volts)
22 (71) 3.00
43 (109) 2.01
71 (159) 1.01
82 (180) 0.75
91 (195) 0.059
97 (206) 0.050
105 (221) 0.040 Klj . 9 ba
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"COOLANT FILL LEVEL" marks and replace the pressure cap.
7. Select the maximum cool temperature setting.
8. Run the engine until it reaches operating temperature.
9. CAUTION: If the engine coolant temperature gauge does not move, the engine
coolant level in the engine is low and must be filled. Stop the engine, allow it to cool and
fill the cooling system.
Add the correct engine coolant mixture to the degas bottle until the coolant level is between the
"COOLANT FILL LEVEL" marks.
10. Repeat the two previous steps until the engine coolant mixture is between the "COOLANT FILL LEVEL" marks on the degas bottle. Turn off the engine and allow it to cool.
11. Check the freeze protection of the engine coolant mixture with the Battery/Anti- freeze Tester
014- R1060 or equivalent. Adjust freezing point range if necessary.
Filling — Cobra
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
was drained from the cooling system. Do not mix coolant types.
z Do not add/mix orange- colored Motorcraft Speciality Orange Engine Coolant VC- 2 or
equivalent 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.
NOTE: The addition of Motorcraft Cooling System Stop Leak Pellets, VC- 6, darkens Motorcraft
Premium Gold Engine Coolant from yellow to golden tan.
1. Check all hose clamps for correct tightness. Make sure the radiator draincock is closed.
2. Place the heater temperature selector in maximum cool position. Klj . 4 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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Component Tests
Drive Belt Noise/Flutter
Drive belt chirp occurs due to pulley misalignment or excessive pulley runout. It can be the result of a
damaged pulley or an incorrectly aligned pulley.
To correct, determine the area where the noise comes from. Check each of the pulleys in that area
with a straightedge to the crankshaft pulley, looking for accessory pulleys out of position in the fore/aft
direction or at an angle to the straightedge.
Drive belt squeal is an intermittent noise that occurs when the drive belt slips on a pulley during certain
conditions, such as: engine start up, rapid engine acceleration, or A/C clutch engagement.
Drive belt squeal can occur:
zif any of the accessories are damaged, have a worn or damaged bearing, internal torsional
resistance above normal. All accessories should be rotatable by hand in the unloaded condition.
If not, inspect the accessory.
z if fluid gets on the drive belt. This includes power steering fluid, engine coolant, engine oil or air
conditioning system lubricant. If fluid does get on the drive belt during service, clean the drive
belt with soap and water and thoroughly rinse with clean water.
z NOTE: The drive belt tensioner arm should rotate freely without binding.
if the drive belt is too long. A drive belt that is too long will allow the drive belt tensioner arm to
go all the way to the arm travel stop under certain load conditions, which will release tension to
the drive belt. If the drive belt tensioner indicator is outside the installation wear range window,
install a new drive belt.
z if the drive belt tensioner is worn or damaged.
Belt Tension
NOTE: Drive belt tension is not adjustable.
The drive belt tensioner automatically adjusts drive belt tension. Symptom Chart Condition
Possible Sources Action
z Drive belt
noise, chirping,
flutter z
Defective/worn drive
belt.
z Misaligned pulley.
z Pulley runout.
z Damaged
accessories.
z Fluid contamination
of drive belt. z
GO to Component Tests, Drive
Belt, Noise/Flutter.
z Damaged or worn
drive belt tensioner. z
GO to Component Tests, Belt
Tensioner, Automatic.
z Premature
drive belt wear z
Defective drive belt.
z Misaligned pulley.
z Pulley runout.
z Damaged
accessories.
z Incorrectly installed
drive belt. z
GO to Component Tests, Drive
Belt Noise/Flutter and Drive
Belt Misalignment diagnosis. Klj . 2 ba
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DESCRIPTION AND OPERATION
Intake Air Distribution and Filtering —
Supercharger,
Charge Air Cooler
The supercharger (SC) is a positive displacement pump. Its purpose is to supply an excess volume of
intake air to the engine by increasing air pressure and density in the intake manifold. The supercharger
is matched to the engine by its displacement and belt ratio, and can provide excess airflow at any
engine speed.
NOTE: The supercharger is repaired only as an assembly. Disassembly of the supercharger unit may
void the warranty.
NOTE: The supercharger is not a bolt- on option. It is part of an integrated engine system. Many
components of the supercharged engine are not interchangeable with similar parts from a non-
supercharged engine.
The supercharger contains two three- lobed rotors. The helical shape and specialized porting provide a
smooth discharge flow and low level of noise during operation. The rotors are supported by ball
bearings in front and needle bearings at the rear. The drive gears are pressed into place, therefore the
supercharger is installed new as a unit, and is not repairable.
The supercharger system is a blow- through type with the fuel injected directly into the intake ports. The
supercharger is belt driven off the crankshaft through an idler pulley. The throttle body controls the
amount of intake air to the supercharger through the intake plenum. Air from the supercharger is
routed through the charge air cooler (CAC), then to the intake manifold. The resulting denser air
charge in the combustion chamber provides for a higher power output of the engine over a non-
supercharged engine of the same displacement.
NOTE: It is not possible to increase manifold pressure or engine power output by altering the bypass
valve or the actuator.
At partial- throttle opening or when vacuum is present in the intake system, a vacuum- controlled
bypass valve reroutes some discharged air from the supercharger back through the intake plenum.
This prevents the supercharger from cavitating, causing reduced performance, increased
temperatures, and poor fuel economy.
The supercharger has a self- contained oiling system that does not require a fluid change for the life of
the vehicle. However, at every 30,000 mile interval, the supercharger fluid level should be checked.
The vehicle should be parked on a level surface, the engine cool, and not running. To check the oil,
remove the Allen head plug located at the front of the supercharger. The oil level should be at the
bottom of the fill plug threads when cold. If the fluid level is low, add Synthetic Supercharger Fluid
E9SZ- 19577- A or equivalent meeting Ford specification ESE-M99C115–A
Supercharged vehicles are equipped with a charge air cooler (CAC). The CAC cools the pressurized
air from the supercharger, increasing the air density, which improves combustion efficiency, engine
horsepower and torque. SECTION 303-
12: Intake Air Distribution and Filtering 2003 Mustang Workshop Manual Klj . 1 ba
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