AC system FORD MUSTANG 2003 Workshop Manual

DIAGNOSIS AND TESTING
Wipers and Washers
Refer to Wiring Diagrams Cell
59 , Generic Electronic Module for schematic and connector
information.
Refer to Wiring Diagrams Cell 81 , Interval Wiper/Washer for schematic and connector information.
Principles of Operation
Multifunction Wipers
The front wiper/washer feature controls the speed of the front windshield wipers and the amount of
washer fluid sprayed on the front windshield when requested by the customer. There are five (5) wiper
modes: OFF, LOW, HIGH, INTERVAL, and WASH.
Wiper Motor Speeds HIGH and LOW
There are two wiper speeds, HIGH and LOW. When the GEM detects the ignition switch circuits are in
the RUN or ACC states, and the GEM detects a high or low speed request from the wiper mode
circuits, the GEM will activate the wiper ON and OFF and the wiper speed circuits accordingly.
Wiper Motor Speeds Interval
There are one to seven wiper speed intervals, ranging from 1.5 seconds to 20 seconds in delay time
respectively, which can be selected. When the GEM detects the ignition switch circuits are in the RUN
or ACC states, and the GEM detects an interval selection of 1 through 7 from the delay/wash circuits, the GEM will activate the wiper ON and OFF and the wiper speed circuits accordingly. SECTION 501-
16: Wipers and Washers 2003 Mustang Workshop Manual Special Tool(s)
Alternator, Regulator, Battery
and Starter Tester (ARBST) or
equivalent
010-
00725 73 Digital Multimeter or
equivalent
105-
R0051 Worldwide Diagnostic System
(WDS)
418-
F224
New Generation STAR (NGS)
Tester
418- F052, or equivalent
diagnostic tool Klj . 1 ba
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Washers
When the GEM detects the ignition switch circuits are in RUN or ACC states, and the GEM detects a
WASH request from the wiper delay/wash circuits, the GEM will activate the washer pump relay circuit
for as long as the request is present up to 10 seconds.
Activation of the washer pump when in INTERVAL or OFF is delayed until a wash request is active for
a minimum amount of time. In this scenario, the wash request must be present continuously for at least
210 ms. This allows a wash request that is present for less than 210 ms, to provide additional
functionality by initiating a single wipe, called "mist wipe". The mist wipe function is a single wipe at low
speed without activating the washer motor.
When in LOW or HIGH, any WASH request, regardless of the length of time it is present, will activate
the washer pump. When in INTERVAL or OFF mode, upon deactivation of the washer motor, this
feature shall provide two wipes at low speed before returning to the INTERVAL or OFF state as
defined by the inputs. These additional wipes are provided to clear residual washer fluid from the front
windshield.
Inspection and Verification
1. Verify the customer concern by operating the wiper/washer system.
2. Visually inspect for obvious signs of mechanical and electrical damage.
3. If the concern remains after the inspection, connect the diagnostic tool to the data link connector (DLC) located beneath the instrument panel and select the vehicle to be tested from the
diagnostic tool menu. If diagnostic 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 diagnostic tool still does not communicate with the vehicle, refer to the diagnostic tool manual.
5. Carry out the DATA LINK DIAGNOSTIC TEST. If diagnostic tool responds with: zCKT914, CKT915 or CKT70 = ALL ECUS NO RESP/NOT EQUIP, refer to Section 418 -
00 .
z NO RESPONSE/NOT EQUIPPED for GEM, go to Pinpoint Test A.
z SYSTEM PASSED, retrieve and record the continuous diagnostic trouble codes (DTCs),
erase the continuous DTCs and carry out self- test diagnostics for the GEM.
Visual Inspection Chart Mechanical Electrical
z
Hoses to windshield washer pump
z Wiper linkage z
CJB Fuse 39 (5A)
z CJB Fuse 26 (30A)
z Wiring harness
z Loose or corroded connector(s)
z Relays
z Motors
z Multifunction switch
z GEM Klj . 2 ba
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Pinpoint Tests
CAUTION: Before removing and installing the GEM or its connectors, disconnect the
battery. Failure to follow this caution will result in the GEM storing many erroneous DTCs and it
may exhibit erratic operation after installation.
CAUTION: Be careful when probing the central junction box (CJB), battery junction box
(BJB) or any connectors. Damage will result to the connector receptacle if the probe being
used is too large.
CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to
these charges, damage may result.
NOTE: If continuous DTCs are recorded and the symptom is not present when carrying out the
pinpoint tests, an intermittent concern may be the cause. Always check for loose connections and
corroded terminals.
NOTE: Complete the entire pinpoint test related to the symptom before installing a new GEM.
PINPOINT TEST A: NO COMMUNICATION WITH THE GENERIC
ELECTRONIC MODULE (GEM) Test Step Result / Action to Take
CAUTION: Use the correct probe adapter(s) when making measurements. Failure to
use the correct probe adapter(s) may damage the connector. A1 CHECK THE GENERIC ELECTRONIC MODULE (GEM)
POWER SUPPLY z
Key in OFF position.
z Disconnect: Generic Electronic Module (GEM) C201a.
z Disconnect: GEM C201b.
z Key in ON position.
z Using the following table. measure the voltage between the
GEM, harness side and ground.
z Are the voltages greater than 10 volts? Connector Pin Circuit
C201a 4 400 (LB/BK)
C201a 1 1006 (DG/WH)
C201b 2 1001 (WH/YE)
C201b 3 193 (YE/LG) Yes
GO to
A2 .
No
REPAIR the circuit(s) in
question. TEST the system
for normal operation. A2 CHECK THE GEM GROUND CIRCUIT 397 (BK/WH) FOR
OPEN z
Key in OFF position.
z Measure the resistance between the GEM C201b pin 4,
circuit 397 (BK/WH), harness side and ground. Yes
GO to
A3 .
No
REPAIR the cirucit(s) in
question. TEST the system Klj . 6 ba
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PINPOINT TEST B: WINDSHIELD WIPERS DO NOT OPERATE /
OPERATE CORRECTLY z
Is the resistance less than 5 ohms? for normal operation.
A3 CHECK CIRCUIT 397 (BK/WH) FOR SHORT TO POWER
z
Measure the voltage between the GEM C201b pin 4, circuit
397 (BK/WH), harness side and ground.
z Is any voltage present? Yes
REPAIR the circuit. TEST
the system for normal
operation.
No
REFER to
Section 418 - 00 .
Test Step Result / Action to Take
B1 DETERMINE IF GEM IS RECEIVING CORRECT IGNITION
SWITCH STATUS z
Key in OFF position.
z Connect the diagnostic tool.
z NOTE: If the vehicle is equipped with a manual
transmission, depress the clutch while turning the ignition
switch to START.
z Monitor the GEM PIDs IGN_S, IGN_R IGN_A, and
IGN_KEY while turning the ignition switch through the
START, RUN, OFF and ACC positions.
z Do the GEM PID values agree with the ignition switch
positions? Yes
GO to
B2 .
No
REFER to Section 413 - 09 .
B2 DETERMINE IF GEM IS RECEIVING CORRECT WIPER
SWITCH STATUS FROM MULTIFUNCTION SWITCH z
Key in ON position.
z Monitor PID WPMODE, while moving through all wiper
control positions on the multifunction switch.
z Do the GEM PID values agree with switch positions? Yes
GO to
B3 .
No
GO to B6 .
B3 TEST GEM CONTROL OF WIPER ON/OFF RELAY
z
Trigger the GEM active command WIPER RLY ON and
OFF.
z Do the wipers turn ON and OFF? Yes
GO to
B4 . Klj . 7 ba
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DESCRIPTION AND OPERATION
Convertible Top
Rear Window Glass Assembly
The convertible top assembly is equipped with a rear window glass assembly. The rear window glass
assembly is permanently attached to the folding top rear window curtain and cannot be opened. The
rear window glass must be repaired separately.
Stay Pad
The stay pad is attached to the bows and is repaired as a component.
Hydraulic System
The convertible top hydraulic system is comprised of the lift cylinders, the motor, the connecting
hydraulic lines and a convertible top switch. The hydraulic system, except for the convertible top
switch, is removed as an assembly, but the components may be repaired separately.
SECTION 501-
18: Convertible Top 2003 Mustang Workshop Manual Item Part Number Description
1 7652500 Rear glass assembly
2 76533A00 Motor assembly
3 011702 Lift cylinder with hydraulic lines Klj . 1 ba
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DIAGNOSIS AND TESTING
Convertible Top
Refer to Wiring Diagrams Cell
103 , for schematic and connector information.
Principles of Operation
The convertible top will only operate with the parking brake engaged and the ignition switch in the RUN
position. When the parking brake is engaged, the raise and lower relay coils are grounded through the
parking brake switch. The convertible top switch supplies power to the raise or lower relay coil when
raise or lower is selected. This power energizes the coil causing the relay contacts to close which
supplies battery power to the convertible top motor/pump assembly. The normal state of the relay is
connected to ground. When the raise or lower relay is operating, the other relay remains in its normal
state supplying the motor/pump ground.
Convertible Top Adjustments
The convertible top adjustments must be made by a qualified technician.
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.
SECTION 501-
18: Convertible Top 2003 Mustang Workshop Manual Special Tool(s)
73 III Automotive Meter
105-
R0057 or equivalent
Visual Inspection Chart Mechanical Electrical
z
Convertible top brackets and
frame
z Hydraulic motor and pump
z Hydraulic lift cylinders
z Door and quarter window glass
adjustment z
Central junction box (CJB) Fuse 20 (15A)
z Battery junction box (BJB) circuit breaker
CONV TOP (30A)
z Wiring harness
z Loose or corroded connections
z Raise or lower relays
z Parking brake switch
z Convertible top switch Klj . 1 ba
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Symptom Chart
PINPOINT TEST A: THE CONVERTIBLE TOP DOES NOT
RAISE/LOWER
SYMPTOM CHART Condition
Possible Sources Action
z The convertible top does not
raise/lower z
Convertible top
switch.
z Central junction box
(CJB) Fuse 20 (15A).
z Parking brake switch.
z Lower relay.
z Raise relay.
z Circuitry. z
Go To Pinpoint Test
A .
z The convertible top
hesitates/comes up uneven z
Convertible top
adjustment.
z Hydraulic lift
cylinders.
z Hydraulic system. z
Go To Pinpoint Test
B .
z The convertible top does not
raise or does not go up all the
way z
Convertible top
adjustment.
z Hydraulic lift
cylinders.
z Hydraulic system. z
Go To Pinpoint Test
C .
z The convertible top hydraulic
system z
Convertible top
adjustment.
z Hydraulic lift
cylinders.
z Hydraulic motor/pump
assembly.
z Hydraulic system. z
Go To Pinpoint Test
D .
Test Step Result / Action to
Take A1 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 Depress the convertible top switch in RAISE and LOWER
positions while listening for motor operation.
z Does the convertible top motor assembly operate in both
directions? Yes
Go To Pinpoint Test
C .
No
GO to A2 .
A2 CHECK THE POWER SUPPLY TO THE CONVERTIBLE TOP
SWITCH z
Key in OFF position.
z Disconnect: Convertible Top Switch C3115.
z Key in ON position.
z Measure the voltage between convertible top switch C3115 pin 4,
circuit 296 (WH/PK), harness side and ground. Yes
GO to
A3 .
No
REPAIR circuit 296
(WH/PK). TEST the
system for normal
operation. Klj . 2 ba
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circuit 588 (VT), harness side.
z Is the resistance less than 5 ohms? Top Switch in this
section. TEST the
system for normal
operation.
No
REPAIR Circuit 588
(VT). TEST the
system for normal
operation. A6 CHECK CIRCUIT 688 (GY/LB) FOR OPEN
z
Key in OFF position.
z Disconnect: Convertible Top Switch C3115.
z Measure the resistance between convertible top switch C3115 pin
5, circuit 688 (GY/LB), harness side and lower relay C4064 pin 85,
circuit 688 (GY/LB), harness side.
z Is the resistance less than 5 ohms? Yes
INSTALL a new
convertible top switch.
REFER to
Convertible Top Switch in this
section. TEST the
system for normal
operation.
No
REPAIR circuit 688
(GY/LB). TEST the
system for normal
operation. A7 CHECK THE BATTERY SUPPLY TO THE RELAYS
z
Measure the voltage between raise relay C4063 pin 87, circuit 170
(RD/LB), harness side and ground; and between lower relay
C4064 pin 87, circuit 170 (RD/LB), harness side and ground.
z Are the voltages greater than 10 volts? Yes
GO to
A8 .
No
REPAIR circuit 170
(RD/LB). TEST the
system for normal
operation. A8 CHECK CIRCUIT 1205 (BK) FOR AN OPEN
z
Key in OFF position.
z Measure the resistance between raise relay C4063 pin 87A,
circuit 1205 (BK), harness side and ground; and between lower
relay C4064 pin 87A, circuit 1205 (BK), harness side and ground. Yes
GO to
A9 .
No
REPAIR the circuit.
TEST the system for
normal operation. Klj . 4 ba
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z
Are the resistances greater than 10,000 ohms? A9 CHECK FOR PARKING BRAKE GROUND
z
Measure the resistance between raise relay C4063 pin 86, circuit
977 (VT/WH), harness side and ground; and between lower relay
C4064 pin 86, circuit 977 (VT/WH), harness side and ground.
z Are the resistances less than 5 ohms? Yes
GO to
A11 .
Yes
GO to A10 .
A10 CHECK THE PARKING BRAKE SWITCH
z
Disconnect: Parking Brake Switch C306.
z Measure the resistance between raise relay C4063 pin 86, circuit
977 (VT/WH), harness side and parking brake switch C306, circuit
22 (LB/BK), harness side; and between lower relay C4064 pin 86,
circuit 977 (VT/WH), harness side and parking brake switch C306,
circuit 22 (LB/BK), harness side.
z Are the resistances less than 5 ohms? Yes
INSTALL a new
parking brake switch.
REFER to
Section 206 - 05 . TEST the
system for normal
operation.
No
REPAIR the circuit in
question. TEST the
system for normal
operation. A11 CHECK THE CONVERTIBLE TOP MOTOR LOWER CIRCUIT
z
Connect: Raise Relay C4063.
z Connect: Lower Relay C4064.
z Disconnect: Convertible Top Motor C4062.
z Measure the resistance between convertible top motor C4062,
circuit 902 (YE), harness side and ground. Yes
GO to
A13 .
No
GO to A12 . Klj . 5 ba
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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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