cooling FORD MUSTANG 2003 Workshop Manual

z
If equipped, inspect automatic transmission fluid level with dipstick.
z Inspect brake pads, shoes, rotors, drums, brake lines, hoses and parking brake system.
z Inspect wheel ends for end play and noise.
z Inspect engine cooling system and hoses.
z Inspect steering linkage, suspension and (if equipped) driveshaft and ball joints.
z Rotate tires and inspect for wear.
z If equipped, install a new cabin air filter.
32,000 Km (20,000 Miles)
zChange engine oil and install a new oil filter.
z Inspect tires for wear. Rotation recommended for optimal tire life.
40,000 Km (25,000 Miles)
zChange engine oil and install a new oil filter.
z Inspect tires for wear. Rotation recommended for optimal tire life.
z Drain coalescent fuel filter and replace filter (NGV).
48,000 Km (30,000 Miles)
zChange engine oil and install a new oil filter.
z Inspect brake pads, shoes, rotors, drums, brake lines, hoses and parking brake system.
z Inspect wheel ends for end play and noise.
z Inspect engine cooling system and hoses.
z Inspect exhaust system and heat shields.
z Inspect steering linkage, suspension and (if equipped) driveshaft and ball joints.
z Rotate tires and inspect for wear.
z Install a new engine air filter.
z Install a new fuel filter. (See ADDITIONAL INFORMATION below.)
z If equipped, install a new cabin air filter.
z Change automatic transmission/transaxle fluid on all vehicles equipped with AX4S, 4F50N,
4R100, 4F27E. Inspect automatic transmission fluid level using dipstick on all other vehicles, if
equipped.
z If equipped, install new climate controlled seat filters (Navigator, Lincoln LS and Aviator).
ADDITIONAL INFORMATION: If vehicle is registered in California, the California Air Resources Board
(CARB) has determined that failure to install a new fuel filter at this interval will not nullify the emission
warranty or limit recall liability prior to completion of the vehicle's useful life. It is, however,
recommended that maintenance checks be carried out and recorded at the indicated intervals.
Natural gas and propane vehicles also require checking the fuel tanks and installing a new filter
(propane vehicles). 56,000 Km (35,000 Miles) Klj . 4 ba
112003 Mustang Workshop Manual
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z
Change engine oil and install a new oil filter.
z Inspect tires for wear. Rotation recommended for optimal tire life.
64,000 Km (40,000 Miles)
zChange engine oil and install a new oil filter.
z Inspect tires for wear. Rotation recommended for optimal tire life.
72,000 Km (45,000 Miles)
zChange engine oil and install a new oil filter.
z Inspect automatic transmission fluid level using dipstick, if equipped.
z Inspect brake pads, shoes, rotors, drums, brake lines, hoses and parking brake system.
z Inspect wheel ends for end play and noise.
z Inspect engine cooling system and hoses.
z Inspect steering linkage, suspension and (if equipped) driveshaft and ball joints.
z Rotate tires and inspect for wear.
z If equipped, install a new cabin air filter.
z If filled with green engine coolant, change coolant.
80,000 Km (50,000 Miles)
zChange engine oil and install a new oil filter.
z Inspect tires for wear. Rotation recommended for optimal tire life.
z Drain coalescent fuel filter and replace filter (NGV).
88,000 Km (55,000 Miles)
zChange engine oil and install a new oil filter.
z Inspect tires for wear. Rotation recommended for optimal tire life.
96,000 Km (60,000 Miles)
zChange engine oil and install a new oil filter.
z Inspect brake pads, shoes, rotors, drums, brake lines, hoses and parking brake system.
z Inspect wheel ends for end play and noise.
z Inspect engine cooling system and hoses.
z Inspect steering linkage, suspension and (if equipped) driveshaft and ball joints.
z Rotate tires and inspect for wear.
z Install a new engine air filter.
z Install a new fuel filter. (See ADDITIONAL INFORMATION below.)
z If equipped, install a new cabin air filter.
z Change automatic transmission/transaxle fluid on all vehicles equipped with AX4S, 4F50N,
4R100, 4F27E. Inspect automatic transmission fluid level using dipstick on all other vehicles, if Klj . 5 ba
112003 Mustang Workshop Manual
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equipped.
z If equipped, install new climate controlled seat filters (Navigator, Lincoln LS and Aviator).
ADDITIONAL INFORMATION: If vehicle is registered in California, the California Air Resources Board
(CARB) has determined that failure to install a new fuel filter at this interval will not nullify the emission
warranty or limit recall liability prior to completion of the vehicle's useful life. It is, however,
recommended that maintenance checks be carried out and recorded at the indicated intervals.
Additional checks for natural gas and propane vehicles at this interval include inspecting fuel tanks, as
well as draining coalescent fuel filter and installing a new filter.
104,000 Km (65,000 Miles)
zChange engine oil and install a new oil filter.
z Inspect tires for wear. Rotation recommended for optimal tire life.
112,000 Km (70,000 Miles)
zChange engine oil and install a new oil filter.
z Inspect tires for wear. Rotation recommended for optimal tire life.
120,000 Km (75,000 Miles)
zChange engine oil and install a new oil filter.
z Inspect automatic transmission fluid level using dipstick.
z Inspect brake pads, shoes, rotors, drums, brake lines, hoses and parking brake system.
z Inspect wheel ends for end play and noise.
z Inspect engine cooling system and hoses.
z Inspect steering linkage, suspension and (if equipped) driveshaft and ball joints.
z Rotate tires and inspect for wear.
z Install a new cabin air filter.
z Drain coalescent fuel filter and replace filter (NGV).
z Change green engine coolant, if equipped.
128,000 Km (80,000 Miles)
zChange engine oil and install a new oil filter.
z Inspect tires for wear. Rotation recommended for optimal tire life.
136,000 Km (85,000 Miles)
zChange engine oil and install a new oil filter.
z Inspect tires for wear. Rotation recommended for optimal tire life.
144,000 Km (90,000 Miles)
zChange engine oil and install a new oil filter.
z Inspect brake pads, shoes, rotors, drums, brake lines, hoses and parking brake system. Klj . 6 ba
112003 Mustang Workshop Manual
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z
Inspect wheel ends for end play and noise.
z Inspect engine cooling system and hoses.
z Inspect exhaust system and heat shields.
z Inspect steering linkage, suspension and (if equipped) driveshaft and ball joints.
z Rotate tires and inspect for wear.
z Install a new engine air filter.
z Install a new fuel filter.
z If equipped, install a new cabin air filter.
z Change automatic transmission/transaxle fluid on all vehicles equipped with AX4S, 4F50N,
4R100, 4F27E. Inspect automatic transmission fluid level using dipstick on all other vehicles, if
equipped.
z If equipped, install new climate controlled seat filters (Navigator, Lincoln LS and Aviator).
Additional services for natural gas and propane vehicles include inspecting fuel tanks, as well as
draining coalescent fuel filter bowl and installing a new filter.
152,000 Km (95,000 Miles)
zChange engine oil and install a new oil filter.
z Inspect tires for wear. Rotation recommended for optimal tire life.
160,000 Km (100,000 Miles)
zChange engine oil and install a new oil filter.
z Inspect accessory drive belt(s).
z Rotate tires and inspect for wear.
z Install new spark plugs.
z If filled with yellow coolant, change coolant or at 5 years, whichever comes first.
z Install a new PCV on all cars and light trucks under 6,000 pounds Gross Vehicle Weight (GVW).
z Drain coalescent fuel filter and replace filter (NGV).
168,000 Km (105,000 Miles)
zChange engine oil and install a new oil filter.
z Inspect automatic transmission fluid level if equipped with dipstick.
z Inspect brake pads, shoes, rotors, drums, brake lines, hoses and parking brake system.
z Inspect wheel ends for end play and noise.
z Inspect engine coolant system and hoses.
z Inspect steering linkage, suspension and (if equipped) driveshaft and ball joints.
z Rotate tires and inspect for wear.
z If equipped, install a new cabin air filter.
z If filled with green engine coolant, change coolant. 176,000 Km (110,000 Miles) Klj . 7 ba
112003 Mustang Workshop Manual
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z
Change engine oil and install a new oil filter.
z Inspect tires for wear. Rotation recommended for optimal tire life.
184,000 Km (115,000 Miles)
zChange engine oil and install a new oil filter.
z Inspect tires for wear. Rotation recommended for optimal tire life.
192,000 Km (120,000 Miles)
zChange engine oil and install a new oil filter.
z Inspect brake pads, shoes, rotors, drums, brake lines, hoses and parking brake system.
z Inspect wheel ends for end play and noise.
z Inspect engine cooling system and hoses.
z Inspect exhaust system and heat shields.
z Inspect steering linkage, suspension and (if equipped) driveshaft and ball joints.
z Rotate tires and inspect for wear.
z Install a new engine air filter.
z Install a new fuel filter. (See ADDITIONAL INFORMATION below.)
z If equipped, install a new cabin air filter.
z Install new accessory drive belt(s) (Escort).
z Install a new PCV valve on all cars and light trucks over 6,000 Gross Vehicle Weight.
z Change automatic transmission/transaxle fluid on all vehicles equipped with AX4S, 4F50N,
4R100, 4F27E. Inspect automatic transmission fluid level using dipstick on all other vehicles, if
equipped.
z Install a new camshaft belt on all 2.0L, 4- cylinder engines (Escort, Focus, ZX2 and Escape).
z If equipped, install new climate controlled seat filters (Navigator, Lincoln LS and Aviator).
ADDITIONAL INFORMATION: Additional services for natural gas and propane vehicles include
inspecting fuel tanks, as well as draining coalescent fuel filter bowl and installing a new filter.
200,000 Km (125,000 Miles)
zChange engine oil and install a new oil filter.
z Inspect tires for wear. Rotation recommended for optimal tire life.
z Drain coalescent fuel filter and replace filter (NGV).
208,000 Km (130,000 Miles)
zChange engine oil and install a new oil filter.
z Inspect tires for wear. Rotation recommended for optimal tire life.
216,000 Km (135,000 Miles)
zChange engine oil and install a new oil filter. Klj . 8 ba
112003 Mustang Workshop Manual
17. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_4464/S3B~us~en~ ...

z
If equipped, inspect automatic transmission fluid level with dipstick.
z Inspect brake pads, shoes, rotors, drums, brake lines, hoses and parking brake system.
z Inspect wheel ends for end play and noise.
z Inspect engine cooling system and hoses.
z Inspect steering linkage, suspension and (if equipped) driveshaft and ball joints.
z Rotate tires and inspect for wear.
z Install a new cabin air filter.
z If filled with green engine coolant, change coolant.
224,000 Km (140,000 Miles)
zChange engine oil and install a new oil filter.
z Inspect tires for wear. Rotation recommended for optimal tire life.
232,000 Km (145,000 Miles)
zChange engine oil and install a new oil filter.
z Inspect tires for wear. Rotation recommended for optimal tire life.
240,000 Km (150,000 Miles)
zChange engine oil and install a new oil filter.
z Inspect brake pads, shoes, rotors, drums, brake lines, hoses and parking brake system.
z Inspect wheel ends for end play and noise.
z Inspect engine cooling system and hoses.
z Inspect exhaust system and heat shields.
z Inspect steering linkage, suspension and (if equipped) driveshaft and ball joints.
z Rotate tires and inspect for wear.
z Install a new engine air filter.
z Install a new fuel filter. (See ADDITIONAL INFORMATION below.)
z If equipped, install a new cabin air filter.
z If filled with yellow engine coolant, change coolant or at 8 years, whichever comes first.
z Change automatic transmission/transaxle fluid and filter.
z Change rear axle lubricant on all rear wheel (RWD) vehicles.
z Install a new accessory drive belt(s) (if a new belt has not been installed within the last 100,000
miles).
z If equipped, install new climate controlled seat filters (Navigator, Lincoln LS and Aviator).
ADDITIONAL INFORMATION: If vehicle is registered in California, the California Air Resources Board
(CARB) has determined that failure to install a new fuel filter at this interval will not nullify the emission
warranty or limit recall liability prior to completion of the vehicle's useful life. It is, however
recommended that maintenance checks be carried out and recorded at the indicated intervals.
Additional checks for natural gas and propane vehicles include inspecting fuel tanks, as well as
draining and installing a new filter. Klj . 9 ba
112003 Mustang Workshop Manual
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z
Did any abnormal occurrence coincide with or proceed its appearance?
Use the information gained from the customer to accurately begin the diagnostic process.
Pre- Drive Check
It is important to do a pre- drive check before road testing the vehicle. A pre- drive check verifies that
the vehicle is relatively safe to drive and eliminates any obvious faults on the vehicle.
The pre- drive check consists of a brief visual inspection. During this brief inspection, take note of
anything that will compromise safety during the road test and make those repairs/adjustments before
taking the vehicle on the road.
Preparing for the Road Test
Observe the following when preparing for the road test:
zReview the information recorded on the NVH Diagnostic Guide. It is important to know the
specific concern the customer has with the vehicle.
z Do not be misled by the reported location of the noise/vibration. The cause can actually be
some distance away.
z Remember that the vibrating source component (originator) may only generate a small
vibration. This small vibration can in turn cause a larger vibration/noise to emanate from another
receiving component (reactor), due to contact with other components (transfer path).
z Conduct the road test on a quiet street where it is safe to duplicate the vibration/noise. The ideal
testing route is an open, low- traffic area where it is possible to operate the vehicle at the speed
in which the condition occurs.
z If possible, lower the radio antenna in order to minimize turbulence. Identify anything that could
potentially make noise or be a source of wind noise. Inspect the vehicle for add- on items that
create vibration/noise. Turn off the radio and the heating and cooling system blower.
z The engine speed is an important factor in arriving at a final conclusion. Therefore, connect an
accurate tachometer to the engine, even if the vehicle has a tachometer. Use a tachometer that
has clearly defined increments of less than 50 rpm. This ensures an exact engine speed
reading.
Verify the Customer Concern
Verify the customer concern by carrying out a road test, an engine run- up test, or both.
The decision to carry out a road test, an engine run- up test, or both depends on the type of NVH
concern. A road test may be necessary if the symptom relates to the suspension system or is sensitive
to torque. A drive engine run- up (DERU) or a neutral engine run- up (NERU) test identifies noises and
vibrations relating to engine and drivetrain rpm. Remember, a condition will not always be identifiable
by carrying out these tests, however, they will eliminate many possibilities if carried out correctly.
Road Test Klj . 5 ba
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CARRY OUT a driveline
vibration test. REFER to
Section 205
- 00 . REPAIR as
necessary.
z Binding or
damaged
splines on the
driveshaft slip-
yoke. z
CLEAN and INSPECT the
splines of the slip- yoke,
driveshaft and coupling
shaft for wear or damage.
INSTALL a new slip- yoke or
driveshaft assembly as
necessary. REFER to
Section 205 - 01 . REPAIR as
necessary.
z Driveshaft
runout. z
CARRY OUT a Runout
Check. REFER to Section 205 - 00 . REPAIR as
necessary.
z Incorrect lateral
and radial
tire/wheel
runout. z
INSPECT the tire and
wheels. MEASURE tire
runouts. REPAIR or
INSTALL new components
as necessary. REFER to
Section 204 - 04 .
z Driveline angles
out of
specification. z
CHECK for correct driveline
angles. REPAIR as
necessary. REFER to
Section 205 - 00 .
z Incorrectly
seated CV joint
in the front
wheel hub. z
CHECK the outer CV joint
for correct seating into the
hub. REPAIR as necessary. Symptom Chart —
Engine Noise/Vibration Condition
Possible Sources Action
z Grinding noise—
occurs during
engine cranking z
Incorrect starter
motor mounting. z
INSPECT the starter motor
for correct mounting.
REPAIR as necessary.
REFER to Section 303 - 06 .
z Starter motor. zCHECK the starter motor.
REPAIR or INSTALL a new
starter motor as necessary.
REFER to Section 303 - 06 .
z Incorrect starter
motor drive
engagement. z
INSPECT the starter motor
drive and flexplate/flywheel
for wear or damage.
INSTALL a new starter
motor drive or flywheel as
necessary. REFER to
Section 303 - 06 .
z Engine ticking
noise z
Fuel injector.
z Fuel line.
z Oil pump.
z Valve lifter.
z Belt tensioner.
z Water pump.
z Obstruction of cooling
fan. z
Go To Pinpoint Test B .
z Engine drumming zPowertrain mount. zCARRY OUT Klj . 23 ba
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noise—
normally
accompanied by
vibration Powertrain/Drivetrain Mount Neutralizing in this
section.
z Damaged or
misaligned exhaust
system. z
INSPECT the exhaust
system for loose or broken
clamps and brackets.
CARRY OUT Exhaust System Neutralizing in this
section.
z Whistling noise—
normally
accompanied
with poor idle
condition z
Air intake system. zCHECK the air intake
ducts, air cleaner, throttle
body and vacuum hoses for
leaks and correct fit.
REPAIR or ADJUST as
necessary. REFER to
Section 303 - 12
z
Clunking noise zWater pump has
excessive end play or
imbalance. z
CHECK the water pump for
excessive end play.
INSPECT the water pump
with the drive belt off for
imbalance. INSTALL a new
water pump as necessary.
REFER to Section 303 -
03A .
z Generator has
excessive end play. z
CHECK the generator for
excessive end play.
REPAIR or INSTALL a new
generator. REFER to
Section 414 - 02 .
z Pinging noise zExhaust system leak. zINSPECT the exhaust
system for leaks. REPAIR
as necessary.
z Gasoline octane too
low. z
VERIFY with customer the
type of gasoline used.
CORRECT as necessary.
z Knock sensor
operation. z
CHECK the knock sensor.
INSTALL a new knock
sensor as necessary.
REFER to Section 303 - 14 .
z Incorrect spark
timing. z
CHECK the spark timing.
REPAIR as necessary.
z High operating
temperature. z
INSPECT cooling system
for leaks. CHECK the
coolant level. REFILL as
necessary. CHECK the
coolant for the correct mix
ratio. DRAIN and REFILL
as needed. CHECK engine
operating temperature is
within specifications.
REPAIR as necessary.
z Foul- out spark plug. zCHECK the spark plugs.
REPAIR or INSTALL new
spark plugs as necessary.
z Catalytic converter. zAcceptable noise.
z Knocking noise—
light knocking
noise, also z
Excessive clearance
between the piston
and the cylinder wall. z
Engine cold and at high
idle. Using an EngineEAR,
pull a spark plug or fuel Klj . 24 ba
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(+40°F) or colder at
first start of the day
between ball
bearings and
bearing race.
z Power steering moan
— occurs at high idle
and possibly at idle
during the first cold
start of the day in
temperatures of
approximately - 18°C
(0°F) or colder. Noise
can even be a severe
screech for less than
one minute in very
cold temperatures of
approximately - 29°C
(- 20°F) or colder z
High fluid
viscosity, or
plugged
reservoir screen
in power
steering
reservoir
starves pump
causing
cavitation. z
Go To Pinpoint Test D .
z Generator whine —
during high electrical
loads at idle or high
idle, a high pitch
whine or moan is
emitted from the
generator z
Generator
electrical field
noise. z
Using an EngineEAR,
PROBE near the generator
housing. LISTEN for
changes in the noise level
while changing electrical
loads (such as rear defrost,
headlamps, etc.). CARRY
OUT a generator load test. If
the system passes the load
test, the noise is from the
generator bearings,
INSTALL new bearings. If
the system fails the load
test, INSTALL a new
generator. REFER to
Section 414 - 02 .
z Engine- driven cooling
fan moan — occurs
during the first start of
the day. It is most
objectionable near
idle speeds up to
2000 rpm. The noise
increases with rpm z
The viscous
cooling fan
clutch engages
until the fluid in
the clutch
reaches normal
operating
temperature,
causing the fan
to fully engage. z
Go To Pinpoint Test E .
z Drumming noise —
occurs inside the
vehicle during idle or
high idle, hot or cold.
Very low- frequency
drumming is very rpm
dependent z
Exhaust system
vibration excites
the body
resonances
inducing interior
noise.
z Engine vibration
excites the
body
resonances
inducing interior
noise. z
Go To Pinpoint Test F .
z Hissing noise —
occurs during idle or
high idle that is
apparent with the
hood open z
Vacuum leak or
idle air control
(IAC) valve flow
noise. z
Use the Ultrasonic Leak
Detector/EngineEAR to
locate the source. Scan the
air intake system from the
inlet to each cylinder intake Klj . 29 ba
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