service FORD MUSTANG 2003 4.G Service Manual

Usethe following guidelines to avoid static build-up
when filling an ungrounded fuel container:
•Place approved fuel container on the ground.
•DO NOT fill a fuel container while it is in the
vehicle (including the cargo area).
•Keep the fuel pump nozzle in contact with the
fuel container while filling.
•DO NOT use a device that would hold the fuel
pump handle in the fill position.
Fuel Filler Cap
Your fuel tank filler cap has an indexed design with
a 1/8 turn on/off feature.
When fueling your vehicle:
1. Turn the engine off.
2. Carefully turn the filler cap counterclockwise 1/8
of a turn until it stops.
3. Pull to remove the cap from the fuel filler pipe.
4. To install the cap, align the tabs on the cap with
the notches on the filler pipe.
5. Turn the filler cap clockwise 1/8 of a turn until it
stops.
“Check Fuel Cap”illuminates when the ignition is
turned to the ON position to ensure your bulb is
working. When this light turns on, check the fuel
filler cap. Continuing to operate the vehicle with the
Check Fuel Cap light on, can activate the Service
Engine Soon warning. When the fuel filler cap is
properly re-installed, the light(s) will turn off after a
period of normal driving.It may take a long
period of time for the system to detect an
improperly installed fuel filler cap.
If you must replace the fuel filler cap, replace
it with a fuel filler cap that is designed for
your vehicle. The customer warranty may be
void for any damage to the fuel tank or fuel
system if the correct genuine Ford or
Motorcraft fuel filler cap is not used.
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216

The fuel system may be under pressure. If
the fuel filler cap is venting vapor or if you
hear a hissing sound, wait until it stops before
completely removing the fuel filler cap. Otherwise,
fuel may spray out and injure you or others.
If you do not use the proper fuel filler cap,
excessive pressure or vacuum in the fuel
tank may damage the fuel system or cause the fuel
cap to disengage in a collision, which may result in
possible personal injury.
Choosing the right fuel
Use only UNLEADED FUEL. The use of leaded fuel
is prohibited by law and could damage your vehicle.
Do not use fuel containing methanol. It can damage
critical fuel system components.
Your vehicle was not designed to use fuel or fuel
additives with metallic compounds, including
manganese-based compounds containing MMT.
Repairs to correct the effects of using a fuel for
which your vehicle was not designed may not be
covered by your warranty.
Octane recommendations
Your vehicle is
designed to use
“Regular”unleaded
gasoline with pump
(R+M)/2 octane rating of 87. We do not recommend
the use of gasolines labeled as“Regular”that are
sold with octane ratings of 86 or lower in high
altitude areas.
Do not be concerned if your engine sometimes
knocks lightly. However, if it knocks heavily under
most driving conditions while you are using fuel with
the recommended octane rating, see your dealer or
a qualified service technician to prevent any engine
damage.
87(R+M)/2 METHOD
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217

Fuelquality
If you are experiencing starting, rough idle or
hesitation driveability problems during a cold start,
try a different brand of“Regular”unleaded gasoline.
“Premium”unleaded gasoline is not recommended
(particularly in the United States) because it may
cause these problems to become more pronounced.
If the problems persist, see your dealer or a qualified
service technician.
It should not be necessary to add any aftermarket
products to your fuel tank if you continue to use
high quality fuel of the recommended octane rating.
Aftermarket products could cause damage to the
fuel system. Repairs to correct the effects of using
an aftermarket product in your fuel may not be
covered by your warranty.
Many of the world’s
automakers issued the
World-wide Fuel
Charter that
recommends gasoline
specifications to
provide improved
performance and
emission control
system protection for your vehicle. Gasolines that
meet the World-wide Fuel Charter should be used
when available. Ask your fuel supplier about
gasolines that meet the World-wide Fuel Charter. In
Canada, look for fuels that display theAuto
Makers’Choice
logo.
Cleaner air
Ford endorses the use of reformulated
“cleaner-burning”gasolines to improve air quality.
Running out of fuel
Avoid running out of fuel because this situation may
have an adverse affect on powertrain components.
If you have run out of fuel:
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218

•You may need to cycle the ignition from OFF to
ON several times after refueling, to allow the fuel
system to pump the fuel from the tank to the
engine.
•Your“Service Engine Soon”indicator may come
on. For more information on the“Service Engine
Soon”indicator, refer to theInstrument cluster
chapter.
Fuel Filter
For fuel filter replacement, see your dealer or a
qualified service technician. Refer to the scheduled
maintenance guide for the appropriate intervals for
changing the fuel filter.
Replace the fuel filter with an authorized
Motorcraft part. The customer warranty may
be void for any damage to the fuel system if an
authorized Motorcraft fuel filter is not used.
ESSENTIALS OF GOOD FUEL ECONOMY
Measuring techniques
Your best source of information about actual fuel
economy is you, the driver. You must gather
information as accurately and consistently as
possible. Fuel expense, frequency of fill-ups or fuel
gauge readings are NOT accurate as a measure of
fuel economy. We do not recommend taking fuel
economy measurements during the first 1,600 km
(1,000 miles) of driving (engine break-in period).
You will get a more accurate measurement after
3,000 km–5,000 km (2,000 miles-3,000 miles).
Filling the tank
The advertised fuel capacity of the fuel tank on your
vehicle is equal to the rated refill capacity of the fuel
tank as listed in theRefill capacitiessection of this
chapter.
The advertised capacity is the amount of the
indicated capacity and the empty reserve combined.
Indicated capacity is the difference in the amount of
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219

service of components affecting emission control,
such non-Ford parts should be equivalent to genuine
Ford Motor Company parts in performance and
durability.
Do not park, idle, or drive your vehicle in
dry grass or other dry ground cover. The
emission system heats up the engine compartment
and exhaust system, which can start a fire.
Illumination of the“Service Engine Soon”light,
charging system warning light or the temperature
warning light, fluid leaks, strange odors, smoke or
loss of engine power, could indicate that the
emission control system is not working properly.
Exhaust leaks may result in entry of harmful
and potentially lethal fumes into the
passenger compartment.
Do not make any unauthorized changes to your
vehicle or engine. By law, vehicle owners and anyone
who manufactures, repairs, services, sells, leases,
trades vehicles, or supervises a fleet of vehicles are
not permitted to intentionally remove an emission
control device or prevent it from working.
Information about your vehicle’s emission system is
on the Vehicle Emission Control Information Decal
located on or near the engine. This decal identifies
engine displacement and gives some tune up
specifications.
Please consult yourWarranty Guidefor complete
emission warranty information.
Readiness for Inspection/Maintenance (I/M)
testing
In some localities, it may be a legal requirement to
pass an I/M test of the on-board diagnostics system.
If your“Check Engine/Service Engine Soon”light is
on, refer to the description in theWarning lights
and chimessection of theInstrument cluster
chapter. Your vehicle may not pass the I/M test with
the“Check Engine/Service Engine Soon”light on.
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224

If the vehicle’s powertrain system or its battery has
just been serviced, the on-board diagnostics system
is reset to a“not ready for I/M test”condition. To
ready the on-board diagnostics system for I/M
testing, a minimum of 30 minutes of city and
highway driving is necessary as described below:
•First, at least 10 minutes of driving on an
expressway or highway.
•Next, at least 20 minutes driving in stop-and-go,
city-type traffic with at least four idle periods.
Allow the vehicle to sit for at least eight hours
without starting the engine. Then, start the engine
and complete the above driving cycle. The engine
must warm up to its normal operating temperature.
Once started, do not turn off the engine until the
above driving cycle is complete.
CHECKING AND ADDING POWER STEERING
FLUID
Check the power steering fluid. Refer to the
scheduled maintenance guide for the service interval
schedules. If adding fluid is necessary, use only
MERCONAT F.
If your vehicle is
equipped with the
3.8L V6 engine,check
the power steering
fluid level with the
engine at normal
operating temperature.
1. Start the engine and
let it run until it
reaches normal
operating temperature
(the engine coolant
temperature gauge
indicator will be near
the center of the
normal area between H
and C).
FILL
HOT
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225

2. While the engine idles, turn the steering wheel
left and right several times.
3. Turn the engine off.
4. Check the fluid level on the dipstick. It should be
within the FULL HOT range. Do not add fluid if the
level is within this range.
5. If the fluid is low, add fluid in small amounts,
continuously checking the level until it reaches the
correct operating range. Be sure to put the cap back
on the reservoir.
If your vehicle is
equipped with a 4.6L
V8 engine,check the
power steering fluid
level with the engine at
ambient temperature.
Allow at least one-half
hour after driving for
the power steering
fluid to cool.
1. Start the engine and
allow the engine to
idle.
2. Turn the steering
wheel left and right
several times.
3. Turn the engine off.
4. Check the fluid level in the reservoir. It should be
between the MIN and MAX lines. Do not add fluid if
the level is within this range.
5. If the fluid is low, add fluid in small amounts,
continuously checking the level until it reaches the
correct operating range. Be sure to put the cap back
on the reservoir.
BRAKE FLUID
Checking and adding brake fluid
Brake fluid should be checked and refilled as
needed. Refer to the scheduled maintenance guide
for the service interval schedules.
MAXMIN
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226

If you use a brake fluid that is not DOT 3,
you will cause permanent damage to your
brakes.
Do not let the reservoir for the master
cylinder run dry. This may cause the brakes
to fail.
CLUTCH ADJUSTMENT (IF EQUIPPED)
Check the clutch
adjustment. Refer to
the scheduled
maintenance guide for
the service interval
schedules.
The clutch on your
vehicle is operated by a
cable. As necessary, adjust the clutch as described
below.
1. Turn the engine off and shift into 1 (First).
2. Put your foot under the clutch pedal and gently
pull it up until the pedal stops.
3. Push the clutch pedal down slowly. You will hear a
click as the clutch adjusts itself.
TRANSMISSION FLUID
Checking automatic transmission fluid
(if equipped)
Refer to your scheduled maintenance guide for
scheduled intervals for fluid checks and changes.
Your transmission does not consume fluid. However,
the fluid level should be checked if the transmission
is not working properly, i.e., if the transmission slips
or shifts slowly or if you notice some sign of fluid
leakage.
Automatic transmission fluid expands when warmed.
To obtain an accurate fluid check, drive the vehicle
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228

INFORMATION ABOUT UNIFORM TIRE QUALITY
GRADING
New vehicles are fitted
with tires that have a
rating on them called
Tire Quality Grades.
The Quality grades can
be found where
applicable on the tire sidewall between tread
shoulder and maximum section width. For example:
•Treadwear 200 Traction AA Temperature A
These Tire Quality Grades are determined by
standards that the United States Department of
Transportation has set.
Tire Quality Grades apply to new pneumatic tires for
use on passenger cars. They do not apply to deep
tread, winter-type snow tires, space-saver or
temporary use spare tires, tires with nominal rim
diameters of 10 to 12 inches or limited production
tires as defined in Title 49 Code of Federal
Regulations Part 575.104(c)(2).
U.S. Department of Transportation-Tire quality
grades:The U.S. Department of Transportation
requires Ford to give you the following information
about tire grades exactly as the government has
written it.
Treadwear
The treadwear grade is a comparative rating based
on the wear rate of the tire when tested under
controlled conditions on a specified government test
course. For example, a tire graded 150 would wear
one and one-half (1 1/2) times as well on the
government course as a tire graded 100. The relative
performance of tires depends upon the actual
conditions of their use, however, and may depart
significantly from the norm due to variations in
driving habits, service practices, and differences in
road characteristics and climates.
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232

•If possible, avoid fully loading your vehicle.
•Remove the tire chains when they are no longer
needed. Do not use tire chains on dry roads.
•The suspension insulation and bumpers will help
prevent vehicle damage. Do not remove these
components from your vehicle when using snow
tires and chains.
MOTORCRAFT PART NUMBERS
Component 3.8L OHV V6
engine4.6L SOHC V8
engine
Air filter element FA-1611 FA-1634
Fuel filter FG-986 FG-986B
Battery BXT-59 BXT-59
Oil filter FL-400S FL-820S
PCV valve EV-152 EV-98
Spark plugs* AWSF-42EE** AWSF-32P
* Refer to Vehicle Emissions Control Information
(VECI) decal for spark plug gap information.
**If a spark plug is removed for inspection, it must
be reinstalled in the same cylinder. If a spark plug
needs to be replaced, use only spark plugs with the
same service part number suffix letter as shown on
the engine decal.
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237