Test G FORD MUSTANG 2003 Workshop Manual

z
Is the resistance less than 5 ohms? A12 CHECK CIRCUIT 902 (YE) FOR AN OPEN
z
Disconnect: Lower Relay C4064.
z Measure the resistance between lower relay C4064 pin 30, circuit
902 (YE), harness side and convertible top motor C4062, circuit
902 (YE), harness side.
z Is the resistance less than 5 ohms? Yes
INSTALL a new lower
relay. TEST the
system for normal
operation.
No
REPAIR the circuit.
TEST the system for
normal operation.
A13 CHECK THE LOWER INPUT TO THE MOTOR
z
Key in ON position.
z Measure the voltage between convertible top motor C4062, circuit
902 (YE), harness side and ground.
z Depress and hold the convertible top switch in the LOWER
position.
z Is the voltage greater than 10 volts? Yes
GO to
A14 .
No
INSTALL a new lower
relay. TEST the
system for normal
operation. A14 CHECK THE CONVERTIBLE TOP MOTOR RAISE CIRCUIT
z
Key in OFF position.
z Measure the resistance between convertible top motor C4062,
circuit 903 (RD), harness side and ground. Yes
GO to
A16 .
No
GO to A15 . Klj . 6 ba
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PINPOINT TEST B: THE CONVERTIBLE TOP HESITATES/COMES UP
UNEVEN z
Is the resistance less than 5 ohms? A15 CHECK CIRCUIT 903 (RD) FOR AN OPEN
z
Disconnect: Raise Relay C4063.
z Measure the resistance between raise relay C4063 pin 30, circuit
903 (RD), harness side and convertible top motor C4062, circuit
903 (RD), harness side.
z Is the resistance less than 5 ohms? Yes
INSTALL a new raise
relay. TEST the
system for normal
operation.
No
REPAIR the circuit.
TEST the system for
normal operation.
A16 CHECK THE RAISE INPUT TO THE MOTOR
z
Key in ON position.
z Depress and hold the convertible top switch in the RAISE position.
z Measure the voltage between convertible top motor C4062, circuit
903 (RD), harness side and ground.
z Is the voltage greater than 10 volts? Yes
INSTALL a new
convertible top motor;
REFER to
Hydraulic System, Lift Cylinder
and Motor in this
section. TEST the
system for normal
operation.
No
INSTALL a new raise
relay. TEST the
system for normal
operation. Test Step Result / Action to Take
B1 CHECK THE CONVERTIBLE TOP UP/DOWN
OPERATION NOTE:
The parking brake must be applied for the Yes Klj . 7 ba
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PINPOINT TEST C: THE CONVERTIBLE TOP DOES NOT RAISE OR
DOES NOT GO UP ALL THE WAY
PINPOINT TEST D: THE CONVERTIBLE TOP HYDRAULIC SYSTEM convertible top system to operate.
z Key in ON position.
z Actuate the convertible top switch to the LOWER
and RAISE positions.
z Did the convertible top operate to the full down
and full up position without hesitating? ADJUST the convertible top linkage.
TEST the system for normal
operation.
No
GO to
B2 .
B2 CHECK THE MOTOR OPERATION
z
Gain access to the convertible top motor/pump
assembly.
z Operate the convertible top to the LOWER and
RAISE positions while listening to the motor.
z Did the motor stop and then continue at any
time? Yes
Go To Pinpoint Test A
.
No
GO to B3 .
B3 CHECK THE CONVERTIBLE TOP LINKAGE
z
Operate the convertible top to the LOWER and
RAISE positions while observing the convertible
top linkage.
z Did the linkage operate smoothly without
binding? Yes
Go To Pinpoint Test D
.
No
ADJUST the convertible top linkage.
TEST the system for normal
operation. Test Step Result / Action to Take
C1 CHECK THE CONVERTIBLE TOP OPERATION
NOTE:
The parking brake must be applied for the
convertible top system to operate.
z Key in ON position.
z Actuate the convertible top switch to the RAISE
position.
z Did the motor operate? Yes
GO to
C2 .
No
Go To Pinpoint Test A .
C2 CHECK THE CONVERTIBLE TOP LINKAGE
z
Operate the convertible top to the LOWER and
RAISE positions while observing the convertible
top linkage.
z Did the linkage bind and prevent the
convertible top from raising? Yes
ADJUST the convertible top linkage.
TEST the system for normal
operation.
No
Go To Pinpoint Test D
.
Test Step Result / Action to Take
D1 CHECK THE FLUID LEVEL
NOTE:
The fluid level should be even
with the bottom of the filler plug hole.
NOTE: Place an absorbent cloth
below the filler plug when checking
the fluid level.
z Remove the filler plug and check the Yes
GO to
D3 .
No
GO to D2 . Klj . 8 ba
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fluid level.
z Is the fluid level OK? D2 CHECK THE HYDRAULIC SYSTEM
FOR LEAKS z
Inspect all fittings and hoses for leaks.
z Are any leaks noticed? Yes
REPAIR the leaking fittings or INSTALL new
hoses as necessary. TEST the system for normal
operation.
No
GO to
D3 .
D3 BLEED THE HYDRAULIC SYSTEM
z
Bleed the hydraulic system. Refer to
System Bleeding in this section.
z Does the system operate correctly
after bleeding? Yes
OPERATE the convertible top up and down three
times. INSPECT the hydraulic system for leaks or
loss of fluid. REPAIR as necessary if loss of fluid
is detected.
No
GO to
D4 .
D4 CHECK THE CONVERTIBLE TOP
z
Remove the hydraulic system from
the vehicle. Refer to Hydraulic System, Lift Cylinder and Motor in this
section.
z Operate the convertible top assembly
up and down manually.
z Does the convertible top bind? Yes
ADJUST the convertible top. INSTALL the
hydraulic system; REFER to
Hydraulic System, Lift Cylinder and Motor in this section. TEST the
system for normal operation.
No
GO to D5 .
D5 CHECK THE HYDRAULIC SYSTEM
OUT OF THE VEHICLE z
Bleed the hydraulic system. Refer to
System Bleeding in this section.
z Does the system operate correctly
after bleeding? Yes
CHECK all fittings and hoses for leaks. REPAIR
as necessary if loss of fluid is detected. INSTALL
the hydraulic system; REFER to
Hydraulic System, Lift Cylinder and Motor in this section.
TEST the system for normal operation.
No
GO to D6 .
D6 CHECK THE LIFT CYLINDERS
z
Operate the hydraulic system using a
12 volt power source.
z Did the lift cylinders extend and
retract? Yes
INSTALL a new motor/pump assembly. REFER to
Hydraulic System, Lift Cylinder and Motor
in this
section. TEST the system for normal operation.
No
INSTALL a new lift cylinder. REFER to Hydraulic System, Lift Cylinder and Motor in this section.
TEST the system for normal operation. Klj . 9 ba
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DIAGNOSIS AND TESTING
Safety Belt System
Inspection and Verification
1. Verify the customer's concern by operating the active restraint system 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(s) that can be readily identified, repair as required. With the exception of removing a twist from the safety belt webbing, do not attempt to repair a
component of the safety belt system; new components must be installed.
4. If the concern remains after the inspection, determine the symptom. GO to Symptom Chart .
Symptom Chart SECTION 501-
20A: Safety Belt System 2003 Mustang Workshop Manual Visual Inspection Chart
Mechanical Electrical
z
Inspect the safety belt webbing for
integrity. z
Open fuse.
z Bare, broken or disconnected wire.
z Connector not tightly engaged.
z Safety belt warning indicator lamp burned out or
broken.
Symptom Chart Condition
Possible Sources Action
z The safety belt warning
chime does not operate, the
safety belt warning indicator
lamp is OK z
Virtual
image
cluster
(VIC).
z Circuitry.
z Driver seat
module. z
REFER to Section 413 -
01 .
z The safety belt warning
indicator lamp does not
operate, the safety belt
warning chime is OK z
Burned- out
bulb.
z Circuitry.
z Driver seat
module. z
REFER to Section 413 -
01 .
z Neither the safety belt
warning chime nor the
safety belt warning indicator
lamp operates z
Safety belt
buckle
switch.
z Driver seat
module. z
REFER to Section 413 -
01 . Klj . 1 ba
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Component Test
Carry out the appropriate Functional Test(s) as determined in Inspection and Verification.
Functional Test I (Buckle and Tongue)
The safety belt buckle and tongue assembly must operate freely during the latching and unlatching
function. Fasten the safety belt by inserting the tongue (male portion) into the buckle (female portion).
1. Verify the following during the latching sequence: zTongue insertion is not hindered by excessive effort.
z A click is heard when the buckle latches the tongue.
2. Verify the system integrity by forcefully pulling on the belt webbing.
3. Unlatch the belt by fully depressing the buckle release button, and allowing the belt to release and retract.
4. Verify the following during the unlatching process: zPush-button depression does not require excessive effort.
z Tongue can be removed easily from the buckle.
5. Repeat the above steps three times.
6. If the inspection reveals an obvious concern(s) that can be readily identified, service as required. Do not attempt to carry out any repair on the buckle and tongue assembly. If a
concern exists with either component, a new safety belt buckle and safety belt and retractor
assembly must be installed.
Functional Test II (Retractor)
The safety belt and retractor assembly must be freely operational for extraction and retraction of the
safety belt webbing between full extension and in- vehicle stowed positions.
1. Extract and retract the safety belt between the full extension and stowed positions.
2. Verify the retractor operates without excessive effort or binding.
3. Install a new safety belt buckle retractor and tongue assembly if no obvious concerns are noticed and the complaint has been verified. z
Circuitry.
z Excessive pressure on the
occupant during normal
wear, the webbing cannot
be extracted, excessive
slack in webbing does not
retract z
Front safety
belt retractor
and tongue.
z Rear safety
belt retractor
and tongue. z
Carry out the Functional
Test. REFER to
Component Test.
INSTALL a new retractor
and tongue if necessary. Klj . 2 ba
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Functional Test III (System Road Test Inspection)
1. NOTE: If the RH or the rear safety belts are to be tested, the assistance of a passenger is
required.
Fasten the safety belts and proceed to a safe area.
2. Attain a speed of 8 km/h (5 mph).
3. WARNING: The driver and passenger must be prepared to brace themselves if the
retractor does not lock.
Test the safety belts. 1. Grasp the shoulder harness and prepare to lean forward.
2. WARNING: The maximum brake application should be on dry concrete or
equivalent hard surface, NEVER on wet pavement or gravel.
WARNING: The driver and passenger must be prepared to brace themselves
in the event the retractor does not lock.
Make a maximum brake application without a skid.
3. NOTE: Do not jerk on the safety belt webbing when carrying out this test. Lean forward slightly when the brake application is made.
4. The safety belts should lock up with minimum webbing extension.
5. If there is a lockup of both shoulder straps, the safety belt assemblies are functioning correctly. Should either or both retractors fail to lock up at the 8 km/h (5 mph) speed, repeat the test at a
constant 24 km/h (15 mph) speed. (This test must be carried out with the assistance of a RH
front or rear passenger if the RH front or rear safety belts are to be tested).
6. CAUTION: Before installing a new safety belt assembly, inspect the mounting area
for damage and distortion. If the retractor of a new safety belt assembly has been bolted
into a damaged or distorted mounting area, the retractor could be warped and may not
function. If this is the case, remove the retractor and return the sheet metal to the
original configuration and install another complete safety belt assembly.
If the retractors do not lock up at the 24 km/h (15 mph) test, return the vehicle for service of
malfunctioning safety belts.
Functional Test IV (Automatic Locking Retractor) WARNING: After any vehicle collision, the safety belt system at all outboard seating
positions (except driver, which has no "automatic locking retractor" feature) must be checked
by a qualified technician to verify that the "automatic locking" feature for child seats is still
functioning correctly, in addition to other checks for correct safety belt system function. A new
safety belt and retractor assembly must be installed if the safety belt assembly's "automatic
locking retractor" feature or any other safety belt function is not operating correctly when
checked according to the procedures in the workshop manual. Failure to install a new safety
belt and retractor assembly could increase the risk of injury in collisions.
1. Position the seat back into the full up position. Klj . 3 ba
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GENERAL PROCEDURES
Safety Belt Maintenance
WARNING: All safety belt assemblies include retractors, buckles, front seat belt buckle
support assemblies (slide bar, if so equipped), shoulder belt height adjuster (if equipped), child
safety seat tether bracket assemblies (if equipped) and attaching hardware should be inspected
after any collision. Ford recommends new safety belt assemblies be installed unless a qualified
technician finds the assemblies show no damage and operate correctly. Safety belt assemblies
not in use during a collision should also be inspected and new assemblies installed if either
damage or incorrect operation is noted.
1. The safety belt assemblies should be periodically inspected to make sure that they have not become damaged and that they remain in correct operating condition, particularly if they have
been subjected to severe stress.
2. Before installing the new safety belt assembly, the safety belt retaining areas must be inspected for damage and distortion. If the retaining points are damaged and distorted, the sheet metal
must be reworked back to its original shape and structural integrity.
3. Install the new safety belt(s) using the appropriate instructions. Carry- out the Functional Test
Procedure. For additional information, refer to Safety Belt System in this section.
SECTION 501-
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GENERAL PROCEDURES
Replacement of the Weld Nut and Reinforcement
1. NOTE: The following is for Coupe, Front and Rear, and Convertible rear only.
NOTE: If the safety belt anchor nuts or reinforcements are stripped or missing, a new
nut/reinforcement plate must be installed.
Expose the suspect anchor point.
2. Drill out two 8 mm (0.32 in) (5/16 inch) diameter access holes adjacent to the weld nut clearance hole.
3. Thread a length of copper welding wire through the clearance hole and position to secure the weld nut and washer.
4. Use MIG wire feed welder and plug weld a 7/16 inch weld nut and standard washer in place at the two 8 mm (5/16 inch) holes.
5. Metal finish as necessary.
6. Install the restraint system.
7. Carry out the Functional Test. For additional information, refer to Safety Belt System in this
section.
SECTION 501-
20A: Safety Belt System 2003 Mustang Workshop Manual Klj . 1 ba
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GENERAL PROCEDURES
Safety Belt Procedure After a Collision
WARNING: All safety belt assemblies include retractors, buckles, front seat belt buckle
support assemblies (slide bar, if so equipped), shoulder belt height adjuster (if equipped), child
safety seat tether bracket assemblies (if equipped) and attaching hardware should be inspected
after any collision. Ford recommends new safety belt assemblies be installed unless a qualified
technician finds the assemblies show no damage and operate correctly. Safety belt assemblies
not in use during a collision should also be inspected and new assemblies installed if either
damage or incorrect operation is noted.
1. Before installing a new safety belt assembly, the safety belt attaching areas must be inspected for damage and distortion. If the attaching points are damaged and distorted, the sheet metal
must be worked back to its original shape and structural integrity.
2. Install the new safety belt(s); refer to the procedure in this section. Carry- out the Functional
Test. For additional information, refer to Safety Belt System in this section.
SECTION 501-
20A: Safety Belt System 2003 Mustang Workshop Manual Klj . 1 ba
12003 Mustang Workshop Manual
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