light FORD MUSTANG 2003 Repair Manual

11. Turn (or have an assistant turn) the steering wheel slightly in both directions and release quickly
while watching the pressure gauge.
zThe pressure reading should move from the normal back pressure reading and snap
back as the steering wheel is released.
z If the pressure returns slowly or sticks, the rotary valve in the steering gear is sticking or
the steering column is binding. Check the steering column and linkages before servicing
the steering gear.
Tie- Rod Articulation Torque
1. NOTE: This check may be done with the steering gear on or off the vehicle.
Disconnect the tie- rod end from the front wheel spindle. For additional information, refer to
Section 211 - 02 .
2. Move the front wheel spindle tie- rod back and forth three times.
3. Hook the special tool 211- 034 (T74P-3504-Y) over the tie-rod end or the threaded portion of the
front wheel spindle tie- rod and measure the force required to move the front wheel spindle tie-
rod. Refer to Tie- Rod Articulation Torque in General Specifications in this section.
4. If the force required to move the front wheel spindle tie- rod does not meet the specifications,
install a new front wheel spindle tie- rod. For additional information, refer to Section 211 - 02 .
Steering Gear Valve 1. With the vehicle in motion, place the transmission in NEUTRAL and turn the engine OFF. zIf the vehicle does not pull with the engine OFF, install a new steering gear. For
additional information, refer to Section 211 - 02 .
2. If the vehicle pulls with the engine OFF, cross- switch the front wheels.
3. If the vehicle pulls to the opposite side, cross- switch the front and rear wheels on the same side.
4. If the vehicle pull direction does not change, check the front suspension components, wheel alignment and frame alignment. For additional information, refer to Section 204 - 00 or frame
dimensions manual. Klj . 10 ba
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4. WORN RINGS OR DILUTED OIL: When the engine is accelerated (dotted needle), the needle
drops to 0 kPa (0 in- Hg). Upon deceleration, the needle runs slightly above 74 kPa (22 in- Hg).
5. STICKING VALVES: When the needle (dotted) remains steady at a normal vacuum but occasionally flicks (sharp, fast movement) down and back about 13 kPa (4 in- Hg), one or more
valves may be sticking.
6. BURNED OR WARPED VALVES: A regular, evenly- spaced, downscale flicking of the needle
indicates one or more burned or warped valves. Insufficient hydraulic lash adjuster or hydraulic
lash adjuster (HLA) clearance will also cause this reaction.
7. POOR VALVE SEATING: A small but regular downscale flicking can mean one or more valves are not seating.
8. WORN VALVE GUIDES: When the needle oscillates over about a 13 kPa (4 in- Hg) range at idle
speed, the valve guides could be worn. As engine speed increases, the needle will become
steady if guides are responsible.
9. WEAK VALVE SPRINGS: When the needle oscillation becomes more violent as engine rpm is increased, weak valve springs are indicated. The reading at idle could be relatively steady.
10. LATE VALVE TIMING: A steady but low reading could be caused by late valve timing.
11. IGNITION TIMING RETARDING: Retarded ignition timing will produce a steady but somewhat low reading.
12. INSUFFICIENT SPARK PLUG GAP: When spark plugs are gapped too close, a regular, small pulsation of the needle can occur.
13. INTAKE LEAK: A low, steady reading can be caused by an intake manifold or throttle body gasket leak.
14. BLOWN HEAD GASKET: A regular drop of fair magnitude can be caused by a blown head gasket or warped cylinder head- to-cylinder block surface.
15. RESTRICTED EXHAUST SYSTEM: When the engine is first started and is idled, the reading may be normal, but as the engine rpm is increased, the back pressure caused by a clogged
muffler (5230), kinked tail pipe or other concerns will cause the needle to slowly drop to 0 kPa
(0 in-Hg). The needle then may slowly rise. Excessive exhaust clogging will cause the needle to
drop to a low point even if the engine is only idling.
16. When vacuum leaks are indicated, search out and correct the cause. Excess air leaking into the system will upset the fuel mixture and cause concerns such as rough idle, missing on
acceleration or burned valves. If the leak exists in an accessory unit such as the power brake
booster (2005), the unit will not function correctly. Always fix vacuum leaks.
Excessive Engine Oil Consumption
The amount of oil an engine uses will vary with the way the vehicle is driven in addition to normal
engine- to-engine variation. This is especially true during the first 16,100 km (10,000 miles) when a new
engine is being broken in or until certain internal engine components become conditioned. Vehicles
used in heavy- duty operation may use more oil. The following are examples of heavy- duty operation:
z trailer towing applications
z severe loading applications
z sustained high speed operation Klj . 12 ba
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GENERAL PROCEDURES
Cylinder Block Core Plug Replacement
1. Use a slide hammer or tools suitable to remove the cylinder block core plug.
2. Inspect the cylinder block plug bore for any damage that would interfere with the correct sealing of the plug. If the cylinder block plug bore is damaged, bore for the next oversize plug.
3. NOTE: Oversize plugs are identified by the OS stamped in the flat located on the cup side of
the plug.
Coat the cylinder block core plug and bore lightly with Threadlock® 262 and install the cylinder
block core plug.
Cup- Type
4. CAUTION: Use care during this procedure so as not to disturb or distort the cup
sealing surface.
CAUTION: When installed, the flanged edge must be below the chamfered edge of
the bore to effectively seal the bore. Use a tool suitable to seat the cup - type cylinder block core plug. SECTION 303-
00: Engine System — General Information 2003 Mustang Workshop Manual Special Tool(s)
Slide Hammer
100-
001 (T50T-100- A)
Material Item Specification
Threadlock® 262
E2FZ-
19554- B or equivalent WSK-
M2G351- A6 Klj . 1 ba
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4. Inspect for normal burning.
zCheck for light tan or gray deposits on the firing tip.
5. Inspect for pre- ignition, identified by melted electrodes and a possibly damaged insulator.
Metallic deposits on the insulator indicate engine damage. This may be caused by incorrect
ignition timing, wrong type of fuel or the unauthorized installation of a heli- coil insert in place of
the spark plug threads.
zInstall a new spark plug.
6. Inspect for overheating, identified by a white or light gray spots and with bluish- burnt
appearance of electrodes. This is caused by engine overheating, wrong type of fuel, loose spark
plugs, spark plugs with an incorrect heat range, low fuel pump pressure or incorrect ignition
timing.
zInstall a new spark plug. Klj . 2 ba
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REMOVAL
Engine
Removal
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.
All vehicles
1. Drain the engine cooling system. For additional information, refer to Section 303 - 03A .
2. Recover the A/C refrigerant. For additional information, refer to Section 412 - 00 .
3. Disconnect the battery negative cable (14301). For additional information, refer to Section 414 -
01 .
4. Relieve the fuel pressure. For additional information, refer to Section 310 - 00 .
5. Disconnect the hood ground strap. SECTION 303-
01A: Engine — 3.8L 2003 Mustang Workshop Manual Special Tool(s)
Lifting Bracket Set, Engine
303-
D095 (D94L-6001- A) or
equivalent Spreader Bar
303-
D089 (D93P-6001- A3) or
equivalent Heavy Duty Floor Crane
014-
00071 or equivalent Klj . 1 ba
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53. Separate the harness from the bracket.
zRaise the engine slightly to gain access to the transmission wiring support bracket.
54. NOTE: Adjust the transmission support jack as necessary to aid in the removal of the engine.
Using the special tool, remove the engine from the vehicle. Klj . 12 ba
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2.
CAUTION: Cylinder head machining or milling is not authorized by the Ford Motor
Company. Cylinder head flatness must be within 0.0254 mm (0.001 in) across a 38.1 mm
(1.5 in) square area.
CAUTION: The use of sealing aids (aviation cement, copper spray and glue) is not
permitted. The gasket must be installed dry.
CAUTION: Do not allow the dowels to scratch the sealing surface of the cylinder
head during cylinder head installation.
NOTE: The new cylinder head bolts must be lightly oiled with a rag, and allowed to drain for a
few minutes prior to installation.
NOTE: RH head gasket shown; LH head gasket similar.
Install the cylinder head on the dowels and the head gasket. Loosely install new bolts.
NOTE: Position the cylinder head(s) over the dowels on the head gasket(s).
3. NOTE: LH shown, RH similar.
Tighten the bolts in six stages in the sequence shown. zStage 1: Tighten to 40 Nm (30 lb- ft).
z Stage 2: Tighten an additional 90 degrees.
z Stage 3: Loosen the bolts a minimum of one full turn.
z Stage 4: Tighten to 40 Nm (30 lb- ft).
z Stage 5: Tighten an additional 90 degrees.
z Stage 6: Tighten an additional 90 degrees. Klj . 3 ba
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8. Remove the ten bolts in the sequence shown and raise the lower intake manifold slightly.
9. Disconnect the fuel charging wiring harness from the rear of the lower intake manifold and
remove the manifold.
10. Remove the intake manifold gaskets. zClean and inspect the sealing surfaces.
Installation 1. Install the lower intake manifold gaskets. Klj . 2 ba
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35.
NOTE: If necessary, adjust the camshaft sprocket slightly to obtain timing mark alignment.
Position the RH timing chain on the camshaft sprocket. Make sure the two copper- colored links
align with the camshaft sprocket timing mark.
36. As a post- check, verify correct alignment of all timing marks.
37. Position the LH and RH timing chain tensioner arms on the dowel pins. Position the timing chain tensioner assemblies, and install the bolts.
38. Remove the retaining clips from the timing chain tensioners. Klj . 13 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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