oil level FORD MUSTANG 2003 Repair Manual

"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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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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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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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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CAUTION: The use of any other type of transmission fluid than specified could result in
transmission failure.
If fluid needs to be added, add fluid in 0.25L (1/2 pint) increments through the filler tube. Do not overfill
the fluid. For fluid type, refer to the specification chart.
Fluid Condition Check
1. Check the fluid level.
2. Observe the color and the odor. The color under normal circumstances should be dark reddish, not brown or black or have a burnt odor.
3. Hold the fluid level indicator over a white facial tissue and allow the fluid to drip onto the facial tissue and examine the stain.
4. If evidence of solid material is found, the transmission fluid pan should be removed for further inspection.
5. If the stain is a foamy pink color this may indicate coolant in the transmission. The engine cooling system should also be inspected at this time.
6. If fluid contamination or transmission failure is confirmed by the sediment in the bottom of the fluid pan, the transmission must be disassembled and completely cleaned. This includes the
torque converter and cooler tubes. The oil- to-air cooler will need to be installed.
7. Carry out diagnostic checks and adjustments. Refer to Diagnosis By Symptom in this section. Klj . 3 ba
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following areas of possible leakage should also be checked to determine if engine oil leakage is
causing the concern.
a. Leakage at the engine valve cover gasket may allow oil to flow over the torque converter housing or seep down between the torque converter housing and cylinder block causing oil to
be present in or at the bottom of the torque converter housing.
b. Oil galley plug leaks will allow oil to flow down the rear face of the cylinder block to the bottom of the torque converter housing.
c. Leakage at the crankshaft rear oil seal will work back to the flexplate, and then into the torque converter housing.
d. Leakage at engine oil pressure sensor.
Leak Check Test 1. Remove the fluid level indicator and note the color of the fluid. Original factory fill fluid is dyed red to aid in determining if leakage is from the engine or transmission. Unless a considerable
amount of makeup fluid has been added or the fluid has been changed, the red color should
assist in pinpointing the leak.
2. Remove the torque converter housing cover. Clean off any fluid from the top and bottom of the torque converter housing, front of the case and rear face of the engine and oil pan. Clean the
torque converter area by washing with a suitable nonflammable solvent and blow dry with
compressed air.
3. Wash out the torque converter housing, the front of the flexplate and the converter drain plugs. The torque converter housing may be washed out using cleaning solvent and a squirt- type oil
can. Blow all washed areas dry with compressed air.
4. Start and run the engine until the transmission reaches its normal operating temperature. Observe the back of the cylinder block and top of the torque converter housing for evidence of
fluid leakage. Raise the vehicle on a hoist; refer to Section 100 - 02 and run the engine at fast
idle, then at engine idle, occasionally shifting to the Overdrive and Reverse ranges to increase
pressure within the transmission. Observe the front of the flexplate, back of the cylinder block
(in as far as possible), and inside the torque converter housing and front of the case. Run the
engine until fluid leakage is evident and the probable source of leakage can be determined.
Leak Check Test With Black Light Used With 12 Volt Master UV Diagnostic Inspection Kit
Oil soluble aniline or fluorescent dyes premixed at the rate of 2.5ml (1/2 teaspoon) of dye powder to
0.235L (1/2 pint) of transmission fluid have proved helpful in locating the source of fluid leakage. Such
dyes may be used to determine whether an engine oil or transmission fluid leak is present, or if the
fluid in the fluid cooler leaks into the engine cooling system. A black light must be used with the
fluorescent dye solution. Klj . 4 ba
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