pinpoint FORD MUSTANG 2003 Manual PDF

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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Symptom Chart
Pinpoint Tests
PINPOINT TEST A: THE ENGINE DOES NOT CRANK AND THE
RELAY DOES CLICK
SYMPTOM CHART Condition
Possible Sources Action
z The engine does
not crank and the
relay does click z
Battery.
z Fuse.
z Starter
motor/solenoid.
z Ignition switch.
z Circuit. z
Go To Pinpoint Test A .
z The engine does
not crank and the
relay does not
click z
Fuse.
z Battery.
z Starter relay.
z Ignition switch.
z Digital transmission
range (TR) sensor.
z Starter solenoid.
z Clutch pedal
position (CPP)
switch.
z Circuit. z
Go To Pinpoint Test B .
z The engine
cranks slowly z
Battery.
z Starter
motor/solenoid.
z Circuit. z
Go To Pinpoint Test C .
z Unusual starter
noise z
Starter motor
mounting.
z Starter motor.
z Incorrect starter
drive engagement. z
Go To Pinpoint Test D .
z The starter spins
but the engine
does not crank z
Starter Motor zINSPECT the starter motor
mounting and engagement.
REPAIR as necessary.
z Damaged
flywheel/ring gear
teeth. z
INSPECT the flywheel/ring
gear for damaged, missing or
worn teeth. REPAIR as
necessary. Test Step Result / Action to Take
A1 CHECK THE VOLTAGE TO THE STARTER RELAY
z
Measure the voltage between the starter relay pin 30,
circuit 1050 (LG/VT) and ground. Yes
GO to
A2 .
No
REPAIR circuit 1050 (LG/VT) Klj . 2 ba
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PINPOINT TEST B: THE ENGINE DOES NOT CRANK AND THE
RELAY DOES NOT CLICK
Test Step Result / Action to Take
B1 CHECK CIRCUIT 33 (WH/PK) FOR VOLTAGE
z
Disconnect: Starter Motor Relay.
z Key in START position.
z Measure the voltage between the starter motor relay pin 85,
circuit 33 (WH/PK) and ground while holding the key in the
START position.
z Is the voltage greater than 10 volts? Yes
GO to
B10 .
No
For automatic
transmissions, GO to
B2 . For manual
transmissions, GO to
B5 .
B2 CHECK CIRCUIT 32 (RD/LB) FOR VOLTAGE AT THE DIGITAL
TR SENSOR z
Key in OFF position.
z Disconnect: Digital TR Sensor C110.
z Key in START position.
z Measure the voltage between the digital TR sensor C110 pin
10, circuit 32 (RD/LB) and ground while holding the key in the
START position.
z Is the voltage greater than 10 volts? Yes
GO to
B3 .
No
GO to B7 .
B3 CHECK CIRCUIT 33 (WH/PK) FOR OPEN
z
Key in OFF position.
z Measure the resistance between the digital TR sensor C110 pin Yes
GO to
B4 .
No
REPAIR circuit 33
(WH/PK). TEST the
system for normal
operation. Klj . 4 ba
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PINPOINT TEST C: THE ENGINE CRANKS SLOWLY
PINPOINT TEST D: UNUSUAL STARTER NOISE z
Measure the resistance between the starter motor relay pin 86,
circuit 1205 (BK) and ground.
z Is the resistance less than 5 ohms? Test Step Result / Action to Take
NOTE:
Before beginning this test, be sure that the battery is tested and fully charged. C1 CHECK THE VOLTAGE TO THE STARTER
z
Key in OFF position.
z Measure the voltage between the starter motor
solenoid positive terminal and ground.
z Is the voltage 12.5 volts or greater? Yes
GO to
C2 .
No
REPAIR the circuit between the
battery and the starter solenoid.
CLEAN and TIGHTEN the
connections at the battery terminals.
TEST the system for normal
operation. C2 CHECK MOTOR GROUND CIRCUIT
z
Carry out the Motor Ground Circuit test; refer to
Component Tests in this section.
z Is the ground OK? Yes
INSTALL a new starter motor.
REFER to
Starter Motor — 3.8L or
Starter Motor — 4.6L . TEST the
system for normal operation.
No
REPAIR the ground circuit as
necessary. TEST the system for
normal operation. Test Step Result / Action to Take
D1 CHECK THE STARTER MOTOR
MOUNTING z
Inspect the starter motor mounting Yes Klj . 7 ba
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3. If the concern remains after the inspection, connect the scan tool to the data link connector
(DLC) located beneath the instrument panel and select the vehicle to be tested from the scan
tool menu. If the scan tool does not communicate with the vehicle:
zcheck that the program card is correctly installed.
z check the connections to the vehicle.
z check the ignition switch position.
4. If the scan tool still does not communicate with the vehicle, refer to the scan tool manual.
5. Carry out the DATA LINK DIAGNOSTICS test. If the scan tool responds with:
z CKT914, CKT915 or CKT70 = ALL ECUS NO RESP/NOT EQUIP, refer to Section 418 - 00 .
z NO RESP/NOT EQUIP for PCM, refer to the Powertrain Control/Emissions Diagnosis (PC/ED)
manual.
z SYSTEM PASSED, retrieve and record the continuous diagnostic trouble codes (DTCs), erase
the continuous DTCs and carry out the PCM KOEO self- test.
6. If the DTCs retrieved are related to the concern, go to the PCM Diagnostic Trouble Code (DTC) Index to continue diagnostics.
7. If the concern remains after the inspection, determine the symptom. GO to Symptom Chart .
PCM Diagnostics Trouble Code (DTC) Index
Symptom Chart z
EVAP lines or hoses
z Vacuum lines or hoses DTC Description Source Action
P0442 Small leak detected in EVAP system
(As small as 1.02 mm [0.040 inch]) PCM Go To Pinpoint Test A .
P0455 Major leak or no flow detected PCM Go To Pinpoint Test B .
P0457 Check for missing or leaking fuel filter
cap PCM Go To Pinpoint Test A .
P1443 Very small or no purge flow detected PCM Go To Pinpoint Test B .
P1450 Excessive vacuum detected in the fuel
tank PCM Go To Pinpoint Test C .
— Any other PCM DTC PCM REFER to the Powertrain
Control/Emissions Diagnosis (PC/ED)
manual.
SYMPTOM CHART Condition
Possible Sources Action
z Hissing sound when
removing fuel cap z
Canister vent solenoid.
z Evaporative emissions
canister.
z Fuel vapor control valve z
Go To Pinpoint Test D . Klj . 4 ba
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Pinpoint Tests
NOTE:
Reinstall or install new evaporative emission hose clamps removed or damaged during testing
procedures.
PINPOINT TEST A: DTC P0442 SMALL LEAK IN EVAP SYSTEM tube assembly.
z EVAP canister tube.
z EVAP canister purge
outlet tube.
z Excessive fuel odor zCanister vent solenoid.
z Evaporative emissions
canister.
z Fuel vapor control valve
tube assembly.
z Evaporative emissions
test port.
z EVAP canister purge
outlet tube. z
Go To Pinpoint Test E .
z Unable to refuel vehicle zFuel filler pipe.
z Canister vent solenoid.
z Fuel vapor control valve
tube assembly. z
Go To Pinpoint Test D .
Test Step Result / Action to Take
NOTE:
Condition P0442 DTC set: less than 0.625 kPa (2.5 inches H
2 O) bleed-
up over 15
seconds at 75% fuel fill. Vapor generation limit: more than 0.625 kPa (2.5 inches H 2 O) over 120
seconds. A1 VISUALLY INSPECT THE
COMPONENTS FOR SMALL LEAKS z
Check for the presence of a fuel filler
cap. Do not tighten or check for correct
installation at this time.
z Verify the canister vent solenoid is
correctly seated on the EVAP canister.
z Check for cut or loose connections to
fuel vapor hoses, tubes and
connections in the following locations:
„EVAP canister to EVAP canister
purge valve
„ EVAP canister to fuel vapor vent
valve assembly
„ fuel vapor control valve tube
assembly to fuel tank
z Check the fuel filler pipe for damage.
z Is a concern with a hose, tube,
connection or valve visually
evident? Yes
REPAIR or INSTALL new components as
necessary.GO to
A2 .
No
GO to A2 .
A2 CHECK AT THE EVAP TEST PORT
FOR SMALL SYSTEM LEAKS z
Disconnect and plug the evaporative
emission return tube at the intake Yes
GO to
A3 . Klj . 5 ba
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manifold.
z Complete the evaporative emission
system leak test. Refer to Evaporative Emission System Leak Test in this
section.
z Does the system pass the leak test? No
GO to
A4 .
A3 VISUALLY INSPECT THE FUEL
FILLER CAP z
Visually inspect the fuel filler cap for
damage.
z Is the fuel filler cap damaged? Yes
INSTALL a new fuel filler cap. GO to
A4 .
No
GO to A4 .
A4 CHECK FOR SMALL LEAKS AT THE
FUEL FILLER CAP AND EVAP TEST PORT z
Connect the Evaporative Emission
System Leak Tester to the fuel filler
pipe.
z Key in ON position.
z Close the canister vent solenoid. Refer
to Canister Vent Solenoid Closing Procedure in this section.
z Pressurize the EVAP system to 3.48
kPa (14 inches H
2 O).
z Using the ultrasonic leak detector,
check the fuel filler cap and EVAP test
port for leaks.
z Is a leak detected? Yes
REPAIR or INSTALL new components as
necessary. GO to
A5 .
No
INSTALL the fuel filler cap. CARRY OUT the
evaporative emission system leak test. REFER
to Evaporative Emission System Leak Test in
this section. If the system passes the leak test,
CARRY OUT the evaporative emissions repair
verification drive cycle. REFER to Evaporative Emission Repair Verification Drive Cycle in this
section. A5 CHECK FOR CONCERN OTHER THAN
THE FUEL FILLER CAP z
Refer to previous test results.
z Did the system pass the evaporative
emission system leak test carried
out in pinpoint test Step A2? Yes
CARRY OUT the evaporative emission system
leak test. REFER to
Evaporative Emission System Leak Test in this section. If the system
passes the leak test, CARRY OUT the
evaporative emission repair verification drive
cycle. REFER to Evaporative Emission Repair Verification Drive Cycle in this section.
No
INSTALL the fuel filler cap. GO to A6 .
A6 CHECK FOR SMALL LEAK WITH
TESTER SET AT FILL POSITION z
Connect the Evaporative Emission
System Leak Tester to the EVAP test
port.
z Key in ON position.
z Close the canister vent solenoid. Refer
to Canister Vent Solenoid Closing Procedure in this section.
z Turn the selector on the Evaporative
Emission System Leak Tester to the
FILL position.
z Pressurize the EVAP system to 3.48
kPa (14 inches H
2 O).
z Does the pressure on the EVAP
system hold between 3.43 kPa and
3.53 kPa (13.80 inches and 14.20 Yes
GO to
A7 .
No
DISCONTINUE pressurizing the system. GO to
A8 . Klj . 6 ba
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PINPOINT TEST B: DTC P0455 MAJOR LEAK OR NO FLOW
DETECTED OR DTC P1443 VERY SMALL OR NO PURGE FLOW
DETECTED IN SYSTEM Procedure in this section.
z Pressurize the EVAP system to 3.48
kPa (14 inches H
2 O).
z Using the ultrasonic leak detector,
check the fuel vapor control valve tube
to the fuel tank for leaks. Check the
fuel tank pressure sensor, fuel vapor
control valve tube and the fuel filler
pipe. Check fuel tank to EVAP canister
-canister vent solenoid.
z Is a leak detected? A10 CHECK EVAP SYSTEM AT FUEL
FILLER PIPE z
Reconnect the EVAP canister purge
outlet tube to the fuel vapor tee.
z Complete the evaporative emission
system leak test. Refer to Evaporative Emission System Leak Test in this
section.
z Does the EVAP system pass the
leak test? Yes
RESTORE the system to normal operation.
CARRY OUT the evaporative emission system
leak test. REFER to
Evaporative Emission System Leak Test in this section. If the system
passes the leak test, CARRY OUT the
evaporative emissions repair verification drive
cycle. REFER to Evaporative Emission Repair Verification Drive Cycle in this section.
No
GO to A6 .
Test Step Result / Action to Take
NOTE:
Condition DTC P0455 set: – 1.74 kPa (-7.0 inches H
2 O) over 30 seconds. NOTE:
Condition DTC P1443 set: – 1.74 kPa (-7.0 inches H
2 O) over 30 seconds with more than
0.02 lb/min vapor flow. B1 CHECK FOR DIAGNOSTIC
TROUBLE CODE P0455 OR
P1443 z
Use the recorded results
from the PCM DTCs.
z Is DTC P0455 present? Yes
GO to
B2 .
No
GO to B3 .
B2 VISUALLY CHECK FOR
GROSS EVAP SYSTEM LEAKS z
Check for the presence of a
fuel filler cap. Do not tighten
or check for correct
installation at this time.
z Check the input port
vacuum and EVAP return
tube are connected to the
EVAP canister purge valve.
z Check that the canister vent
solenoid is correctly
attached to the EVAP Yes
REPAIR or INSTALL new EVAP components as necessary.
GO to
B3 .
No
GO to B3 . Klj . 8 ba
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PINPOINT TEST C: DTC P1450 EXCESSIVE VACUUM DETECTED IN
THE FUEL TANK Tester to the fuel filler pipe.
z Pressurize the EVAP
system to 6.47 to 6.97 kPa
(26 to 28 inches H
2 O).
z Does the pressure drop
immediately? No
INSTALL new fuel tank vapor line(s). REPEAT pinpoint test
Step B5 to verify the repair. CARRY OUT the evaporative
emission system leak test. REFER to
Evaporative Emission System Leak Test in this section. If the system passes the
leak test, CARRY OUT the evaporative emission repair
verification drive cycle. REFER to Evaporative Emission Repair Verification Drive Cycle in this section.
B6 CHECK FOR FAILED EVAP
CANISTER PURGE VALVE OR
FUEL TANK PRESSURE
SENSOR z
Use the recorded results
from the PCM DTCs.
z Are DTC codes P0455 and
P1443 present? Yes
INSTALL a new EVAP canister purge valve. REFER to
Evaporative Emission Canister Purge Valve
in this section.
CARRY OUT the evaporative emission system leak test.
REFER to Evaporative Emission System Leak Test in this
section. If no leak is detected, CARRY OUT the evaporative
emissions repair verification drive cycle. REFER to
Evaporative Emission Repair Verification Drive Cycle in this
section.
No
INSTALL a new fuel tank pressure sensor. REFER to Fuel Tank Pressure Sensor in this section. CARRY OUT the
evaporative emission system leak test. REFER to
Evaporative Emission System Leak Test in this section. If
the system passes the leak test, CARRY out the
evaporative emission repair verification drive cycle. REFER
to Evaporative Emission Repair Verification Drive Cycle in
this section. Test Step Result / Action to Take
NOTE:
Condition P1450 DTC set: more than - 1.79 kPa (-7.2 inches H
2 O) over 30 seconds. C1 CHECK FOR VISUAL CAUSES OF EXCESSIVE
FUEL TANK VACUUM z
Check for kinks or bends in the fuel vapor hoses
and tubes.
z Visually check the EVAP canister inlet port,
canister vent solenoid filter or outlet hose for
contamination or foreign material.
z Check the canister vent solenoid for blockage or
contamination.
z Is a concern with a hose, tube, connection or
component visually evident? Yes
REMOVE any contamination or foreign
material around fuel vapor hoses and
tubes. REPAIR the hoses, tubes or
components as necessary. After all
visual concerns are repaired, GO to
C2
.
No
GO to C2 .
C2 CHECK FOR BLOCKAGE BETWEEN EVAP
TEST PORT AND CANISTER VENT SOLENOID z
Disconnect and plug the EVAP return tube at the
intake manifold.
z Connect the Evaporative Emissions System Leak
Tester to the EVAP test port. Yes
GO to
C3 .
No Klj . 10 ba
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PINPOINT TEST D: HISSING SOUND WHEN REMOVING FUEL CAP z
Pressurize the EVAP system to 3.48 kPa (14
inches H
2 O).
z Does the pressure drop immediately? GO to
Pinpoint Test D .
C3 CHECK FOR BLOCKAGE BETWEEN THE FUEL
FILLER PIPE AND THE FUEL VAPOR TEE z
Connect the Evaporative Emission System Leak
Tester to the fuel filler pipe.
z Pressurize the EVAP system to 3.48 kPa (14
inches H
2 O).
z Does the pressure drop immediately? Yes
GO to
C4 .
No
GO to Pinpoint Test D .
C4 CHECK FOR FUEL TANK PRESSURE SENSOR
PID WITHOUT PRESSURE APPLIED z
Disconnect the EVAP canister outlet tube at the
EVAP canister.
z Key in ON position.
z Access PCM PID FTP V.
z Record the reading.
z Is PID FTP V reading between 2.40 and 2.80
volts? Yes
GO to
C5 .
No
REFER to Powertrain
Control/Emissions Diagnosis (PC/ED)
manual to continue diagnosis. C5 CHECK FOR STUCK OPEN EVAP CANISTER
PURGE VALVE CONDITION AT IDLE z
Connect the EVAP canister outlet tube.
z Remove the plug from the EVAP return tube and
reconnect the tube to the intake manifold.
z Verify that the fuel filler cap is correctly installed.
z Key in ON position.
z Access PCM PIDs FTP V and EVAPPDC.
z Start the engine and allow to idle.
z Monitor the FTP V and EVAPPDC PIDs.
z When PID EVAPPDC is zero, is PID FTP V
reading below 2.40 volts? Yes
INSTALL a new EVAP canister purge
valve. REFER to
Evaporative Emission Canister Purge Valve in this section.
CARRY OUT an EVAP system leak
test. REFER to Evaporative Emission System Leak Test in this section. If the
system passes the leak test, CARRY
OUT an evaporative emissions repair
verification drive cycle. REFER to
Evaporative Emission Repair Verification Drive Cycle in this section.
No
CARRY OUT the EVAP system leak
test. REFER to Evaporative Emission System Leak Test in this section. If the
system passes the leak test, CARRY
OUT the evaporative emissions repair
verification drive cycle. REFER to
Evaporative Emission Repair Verification Drive Cycle in this section. Klj . 11 ba
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