AC system FORD MUSTANG 2003 Workshop Manual

DESCRIPTION AND OPERATION
Body
Body and Sheet Metal
The body:
zIs a unibody open cowl structure.
z Is constructed of a lightweight, all- steel material with removable bolted hood (16612), front
fenders (16005), doors, and luggage compartment lid.
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DESCRIPTION AND OPERATION
Insulation
Insulation is comprised of urethane, PVC, and recycled felt. Insulation is installed:
zUnder the roof panel (50202).
z Above and below the instrument panel (04304).
z On the cowl sides.
z Over the front and rear floor areas.
z On a Coupe, in the B and C- pillar sections.
z Under the hood.
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DESCRIPTION AND OPERATION
Body Sealer Types And Applications
Liquid Butyl Sealer
HB Fuller E709-19554-
B or equivalent meeting Ford Specification ESB-M4G162- A:
z Does not run.
z Is fast drying.
z Remains semi-elastic.
z Can be used for seam sealing on the floorpan, wheelhouse, body rocker panels, door openings,
and drip rails.
Caulking Cord
3M Strip Caulk- Black 051135-08578 or equivalent meeting Ford specification ESB-M4G32- A:
z Is a heavy- bodied, plastic base with a filler.
z Is commonly known as perma-gum.
z Is used on spot- welds holes, around moulding clips, and between surfaces not sealed with a
gasket.
Weatherstrip Adhesive
Weatherstrip and Rubber Adhesive E8AZ-19552- A or equivalent meeting Ford specification ESB-
M2G14- A:
z Is a quick drying, strong adhesive designed to hold weatherstripping onto all body panels and
surrounding metal.
Silicone Lubricant
Silicone Lubricant C0AZ-19553-AA meeting Ford specification ESR- M13P4-A:
z Is used to keep the door and the window weatherstrip pliable and soft.
z Should be applied to the weatherstrip at every lubrication period.
z Makes the door easier to close.
z Retards weatherstrip squeaks.
z Retards weatherstrip wear.
z Helps retain door window alignment by reducing friction between the glass frame and the rubber
weatherstrip.
z Should not be used prior to painting.
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DIAGNOSIS AND TESTING
Body System
Inspection and Verification
Leaks
NOTE:
Trim will reveal the location of most leaks.
1. Remove any trim or carpet in the general area of the leak.
2. Road test or water test the vehicle.
3. Inspect for a dust pattern around the area in question. Inspect for water paths near and above the area in question.
4. Some leaks can be located by placing bright light under the vehicle, removing any necessary trim or carpet, and inspecting the interior of the body at joints and weld lines.
Noise
Wind noise, rattles, and their sources are detected by driving the vehicle at highway speeds. The
vehicle should be driven in four different directions with all of the windows closed, the radio off, the
blower motor off, and all of the ventilation ducts open.
Most wind noise leaks will occur at the door and window seals or at the sheet metal joints in the door
or the door opening.
Symptom Chart SECTION 501-
00: Body System — General Information 2003 Mustang Workshop Manual Symptom Chart
Condition
Possible Sources Action
z Dust and
Water Leaks z
Body sealer missing.
z Opening in weldings
or body joints.
z Components not fully
installed.
z Components missing.
z Components
damaged. z
REMOVE trim panel. CHECK
for leaks and SEAL with
appropriate sealer. ROAD
TEST or WATER TEST for
leaks. RECHECK for leaks;
USE light under the vehicle
with trim removed. CHECK
interior of body at joints and
weld lines.
z Dust/Water
Leaks at Floor
Pan and
Grommets z
Missing or damaged
plugs and/or
grommets. z
CHECK plugs for proper
installation. REPLACE if
necessary.
z Door Drain
Holes
Collecting
Water z
Holes clogged with
mud or road tar. z
CLEAN drain holes of dirt and
foreign material. CHECK drain
holes regularly. TEST the
system for normal operation. Klj . 1 ba
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4. Remove the cover.
Vehicles with Mach 460 Premium Sound System 5. Remove the screw and the speaker. zDisconnect the electrical connector.
All vehicles 6. Remove the screws. Klj . 2 ba
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DESCRIPTION AND OPERATION
Rear View Mirrors
The rear view mirror system consists of the following components:
zexterior rear view mirror
z exterior rear view mirror control
z exterior rear view mirror glass
z exterior rear view mirror motor
z interior rear view mirror
z exterior rear view mirror (Cobra) (manual folding)
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DIAGNOSIS AND TESTING
Rear View Mirrors
Refer to Wiring Diagrams Cell
124 , Power Mirrors for schematic and connector information.
Inspection and Verification 1. Verify the customer concern by operating the system.
2. Visually inspect for obvious signs of mechanical or electrical damage.
3. If an obvious cause for an observed or reported concern is found, correct the cause (if possible) before proceeding to the next step.
4. If the concern is not visually evident, verify the symptom and refer to the Symptom Chart.
Symptom Chart
Refer to the Wiring Diagrams for connector numbers stated in the pinpoint tests. SECTION 501-
09: Rear View Mirrors 2003 Mustang Workshop Manual Special Tool(s)
73III Automotive Meter
105-
R0057 or equivalent Flex Probe Kit
105-
R025B or equivalent
Visual Inspection Chart Mechanical Electrical
z
Exterior rear view mirrors
z Interior rear view mirror z
Central junction box (CJB) fuse 19 (15A)
z Wiring harness
z Connections
z Exterior rear view mirror control
z Exterior rear view mirror motor
SYMPTOM CHART Condition
Possible Sources Action
z The mirrors are inoperative zExterior rear view
mirror control. z
Go To Pinpoint Test A . Klj . 1 ba
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Pinpoint Tests
PINPOINT TEST A: THE MIRRORS ARE INOPERATIVE z
Central junction box
(CJB) fuse 19 (15A).
z Circuitry.
z A single mirror is inoperative zExterior rear view
mirror control.
z Exterior rear view
mirror motor.
z Circuitry. z
Go To Pinpoint Test B .
z A single mirror does not
function with switch logic z
Exterior rear view
mirror control.
z Exterior rear view
mirror motor.
z Circuitry. z
Go To Pinpoint Test C .
Test Step Result / Action to
Take A1 CHECK CIRCUIT 326 (WH/VT)
z
Disconnect: Exterior Rear View Mirror Control C527.
z Measure the voltage between exterior rear view mirror control
C527 pin 1, circuit 326 (WH/VT), harness side and ground.
z Is the voltage greater than 10 volts? Yes
GO to
A2 .
No
REPAIR the circuit.
TEST the system for
normal operation. A2 CHECK CIRCUIT 1205 (BK) FOR AN OPEN
z
Measure the resistance between exterior rear view mirror control
C527 pin 5, circuit 1205 (BK), harness side and ground.
z Is the resistance less than 5 ohms? Yes
GO to
A3 .
No
REPAIR the circuit.
TEST the system for
normal operation. A3 CHECK CIRCUIT 542 (YE) FOR AN OPEN Klj . 2 ba
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PINPOINT TEST B: A SINGLE MIRROR IS INOPERATIVE z
Measure the resistance between passenger exterior rear view
mirror C622 pin C, circuit 542 (YE), harness side and exterior
rear view mirror control C527 pin 6, circuit 542 (YE), harness
side.
z Is the resistance less than 5 ohms? Yes
INSTALL a new exterior
rear view mirror control.
REFER to
Switch —
Exterior Rear View
Mirror Control in this
section.
No
REPAIR the circuit.
TEST the system for
normal operation. Test Step Result / Action to
Take B1 CHECK THE COMMON FEED INPUT
z
Disconnect: Exterior Rear View Mirror C516 (Driver) C622
(Passenger).
z Disconnect the inoperative exterior rear view mirror C516 driver
side or C622 passenger side.
z Measure the voltage between driver exterior rear view mirror C516
pin C, circuit 542 (YE), harness side and ground; or between
passenger exterior rear view mirror C622 pin C, circuit 542 (YE),
harness side and ground.
z Select the inoperative side and actuate the exterior rear view
mirror control to the down position, then the right position.
z Are the voltages greater than 10 volts? Yes
GO to
B3 .
No
GO to B2 .
B2 CHECK CIRCUIT 542 (YE) FOR AN OPEN
z
Disconnect: Exterior Rear View Mirror Control C527.
z Measure the resistance between exterior rear view mirror control
C527 pin 6, circuit 542 (YE), harness side and driver exterior rear
view mirror C516 pin C, circuit 542 (YE), harness side; or between
exterior rear view mirror control C527 pin 6, circuit 542 (YE),
harness side and passenger exterior rear view mirror C622 pin C,
circuit 542 (YE), harness side. Yes
INSTALL a new
exterior rear view
mirror control.
REFER to
Switch —
Exterior Rear View
Mirror Control in this
section. TEST the
system for normal
operation. Klj . 3 ba
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z
Is the resistance less than 5 ohms? No
REPAIR the circuit.
TEST the system for
normal operation.
B3 CHECK THE UP/DOWN INPUT
z
Measure the voltage between driver exterior rear view mirror C516
pin B, circuit 541(DB), harness side and ground; or between
passenger exterior rear view mirror C622 pin A, circuit 544 (VT),
harness side and ground.
z Actuate the exterior rear view mirror control to the up position.
z Are the voltages greater than 10 volts? Yes
GO to
B6 .
No
GO to B4 for driver
inoperative or GO to
B5 for passenger
inoperative. B4 CHECK CIRCUIT 541 (DB) FOR AN OPEN
z
Disconnect: Exterior Rear View Mirror Control C527.
z Measure the resistance between exterior rear view mirror control
C527 pin 3, circuit 541 (DB), harness side and driver exterior rear
view mirror C516 pin B, circuit 541 (DB), harness side.
z Is the resistance less than 5 ohms? Yes
INSTALL a new
exterior rear view
mirror control.
REFER to
Switch —
Exterior Rear View
Mirror Control in this
section. TEST the
system for normal
operation.
No
REPAIR the circuit.
TEST the system for
normal operation. B5 CHECK CIRCUIT 544 (VT) FOR AN OPEN
z
Disconnect: Exterior Rear View Mirror Control C527.
z Measure the resistance between exterior rear view mirror control
C527 pin 7, circuit 544 (VT), harness side and passenger exterior
rear view mirror C622 pin A, circuit 544 (VT), harness side. Yes
INSTALL a new
exterior rear view
mirror control.
REFER to
Switch —
Exterior Rear View
Mirror Control in this
section. TEST the
system for normal Klj . 4 ba
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