radio FORD MUSTANG 2003 Workshop Manual

Vehicle Certification (VC) Label Reference
Paint Codes Item Description
1 Exterior paint color code
2 Region code
3 Special order code
(DSO —
domestic special order
FSO — foreign special order
PTO — paint, tire option special order) 4 Brake type code
5 Interior trim code
6 Tape/paint stripe code
7 Radio type code
8 Axle ratio code
9 Transmission code
10 Spring code
11 Powertrain calibration code Klj . 6 ba
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The interior trim codes are listed below. The first letter/number is for the interior fabric. The second
letter is for the interior color.
z9 — Quantum/Rhodes cloth (base coupe)
z A — Link weave cloth (Mach One)
z M — Nudo Leather (Cobra)
z T — Lea cloth with vinyl (base coupe/convertible)
z U — Shadow/Twill cloth (GT)
z X — Lea cloth with vinyl (GT)
The interior trim colors are:
z2 — Medium Graphite
z 2 — Medium Graphite/Midnight Black (Cobra)
z H — Medium Parchment
z H — Midnight Black/Medium Parchment (Cobra)
z R — Midnight Black/Colorado Red (Cobra)
z W — Midnight Black
z Z — Oxford White
Tape/Paint Stripe Codes
zP — White/Gray (tape applique emblem)
z X — Black (hood and body tape stripe) — Mach One Radio Codes Klj . 9 ba
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The radio type codes are:
z2 — Premium electronic AM/FM stereo with compact disc (CD) player and clock
z 9 — CDX6+, AM/FM stereo with 6- disc compact disc (CD) changer and MACH 460 subwoofer
sound system
z Z — AM/FM stereo, dual media (MP3) with compact disc (CD) player
Axle Ratio Codes Klj . 10 ba
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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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PINPOINT TEST C: NO POWER IN ACC
PINPOINT TEST D: NO POWER IN RUN
PINPOINT TEST E: NO POWER IN START No
INSTALL a new ignition switch. REFER to
Ignition Switch
. TEST the system for
normal operation. Test Step Result / Action to Take
C1 CHECK THE RADIO FOR NORMAL OPERATION
z
Key in ON position.
z Check the radio for normal operation.
z Does the radio operate correctly? Yes
GO to
C2 .
No
Go To Pinpoint Test D .
C2 CHECK THE VOLTAGE AT THE IGNITION SWITCH
z
Disconnect: Ignition Switch C250 .
z Measure the voltage between ignition switch C250 Pin B5,
Circuit 1050 (LG/VT), harness side and ground.
z Is the voltage greater than 10 volts? Yes
INSTALL a new ignition
switch. REFER to
Ignition Switch . TEST the system for
normal operation.
No
REPAIR the circuit. TEST the
system for normal operation. Test Step Result / Action to Take
D1 CHECK THE IGNITION SWITCH
z
Carry out the ignition switch component test.
REFER to Wiring Diagrams Cell 149,
Component Testing.
z Is the ignition switch OK ? Yes
INSTALL a new BJB. TEST the system for
normal operation.
No
INSTALL a new ignition switch. REFER to
Ignition Switch
. TEST the system for
normal operation. Test Step Result / Action to Take
E1 CHECK THE VOLTAGE TO THE IGNITION SWITCH
z
Key in OFF position.
z Disconnect: Ignition Switch C250 . Yes
GO to
E2 . Klj . 6 ba
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Cylinder Block and Lower End Components 9 18801 Radio ignition interference capacitor
10 12281 Ignition wire set —
LH 11 18696 Tube assembly
12 9424 Intake manifold (lower)
13 9439 Intake manifold gasket —
RH 14 9439 Intake manifold gasket —
LH 15 9A424 Intake manifold seal (rear)
16 6A008 Cylinder head-
to-block dowel 17 6010 Cylinder block
18 6A373 Engine rear plate (automatic transmission)
19 6375 Flywheel (automatic transmission)
20 6375 Flywheel (manual transmission)
21 6A372 Engine rear plate (manual transmission)
22 6723 Oil pan rear seal
23 6675 Oil pan
24 7120 Pilot bushing
25 9278 Oil pressure sensor
26 9B339 Oil pressure sensor fitting
27 9A424 Intake manifold seal (front)
28 18663 Heater water outlet tube
29 8255 Thermostat housing-
to-intake manifold gasket 30 8592 Water outlet connection
31 9875 Water thermostat
32 9D475 EGR valve
33 9H465 Vacuum control solenoid
34 9723 Accelerator cable bracket
35 9E936 Throttle body gasket
36 9J433 EGR transducer
37 9E498 Vacuum hose
38 12280 Ignition wire set —
RH Klj . 5 ba
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11. Disconnect the following:
zIgnition coil electrical connector.
z Radio interference capacitor electrical connector.
z Spark plug wires.
12. Disconnect the vacuum hose.
13. NOTE: For ease in installation, record the location of the long bolts and the short bolts.
Remove the upper intake manifold. 1. Remove the 12 bolts.
2. Remove the upper intake manifold. Klj . 3 ba
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z
Stage 1: Tighten to 10 Nm (89 lb- in).
z Stage 2: Rotate an additional 90 degrees (1/4 turn).
3. Connect the vacuum hose.
4. Connect the following: zIgnition coil electrical connector.
z Radio interference capacitor electrical connector.
z Spark plug wires. Klj . 5 ba
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10. Disconnect the idle air control (IAC) valve and throttle position (TP) sensor electrical
connectors.
11. Position the RH spark plug wires aside.
12. Position the LH spark plug wires aside. 13. Disconnect the ignition coil and the radio interference capacitor electrical connectors. Klj . 4 ba
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70. Connect the differential pressure feedback EGR system electrical and vacuum connections.
71. Connect the vacuum hoses.
72. Install the positive crankcase ventilation (PCV) tube.
73. Connect the ignition coil and the radio interference capacitor electrical connectors.
74. Position and connect the LH spark plug wires. Klj . 23 ba
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