key FORD MUSTANG 2003 Workshop Manual

PINPOINT TEST D: HISSING SOUND WHEN REMOVING FUEL CAP z
Pressurize the EVAP system to 3.48 kPa (14
inches H
2 O).
z Does the pressure drop immediately? GO to
Pinpoint Test D .
C3 CHECK FOR BLOCKAGE BETWEEN THE FUEL
FILLER PIPE AND THE FUEL VAPOR TEE z
Connect the Evaporative Emission System Leak
Tester to the fuel filler pipe.
z Pressurize the EVAP system to 3.48 kPa (14
inches H
2 O).
z Does the pressure drop immediately? Yes
GO to
C4 .
No
GO to Pinpoint Test D .
C4 CHECK FOR FUEL TANK PRESSURE SENSOR
PID WITHOUT PRESSURE APPLIED z
Disconnect the EVAP canister outlet tube at the
EVAP canister.
z Key in ON position.
z Access PCM PID FTP V.
z Record the reading.
z Is PID FTP V reading between 2.40 and 2.80
volts? Yes
GO to
C5 .
No
REFER to Powertrain
Control/Emissions Diagnosis (PC/ED)
manual to continue diagnosis. C5 CHECK FOR STUCK OPEN EVAP CANISTER
PURGE VALVE CONDITION AT IDLE z
Connect the EVAP canister outlet tube.
z Remove the plug from the EVAP return tube and
reconnect the tube to the intake manifold.
z Verify that the fuel filler cap is correctly installed.
z Key in ON position.
z Access PCM PIDs FTP V and EVAPPDC.
z Start the engine and allow to idle.
z Monitor the FTP V and EVAPPDC PIDs.
z When PID EVAPPDC is zero, is PID FTP V
reading below 2.40 volts? Yes
INSTALL a new EVAP canister purge
valve. REFER to
Evaporative Emission Canister Purge Valve in this section.
CARRY OUT an EVAP system leak
test. REFER to Evaporative Emission System Leak Test in this section. If the
system passes the leak test, CARRY
OUT an evaporative emissions repair
verification drive cycle. REFER to
Evaporative Emission Repair Verification Drive Cycle in this section.
No
CARRY OUT the EVAP system leak
test. REFER to Evaporative Emission System Leak Test in this section. If the
system passes the leak test, CARRY
OUT the evaporative emissions repair
verification drive cycle. REFER to
Evaporative Emission Repair Verification Drive Cycle in this section. Klj . 11 ba
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Test Step Result / Action to Take
D1 TEST FOR FUEL TANK PRESSURE SENSOR
OPERATION z
Key in OFF position.
z Connect the Evaporative Emission System Leak
Tester to the fuel filler pipe.
z Close the canister vent solenoid. Refer to Canister Vent Solenoid Closing Procedure in this section.
z Pressurize the EVAP system to 3.48 kPa (14
inches H
2 O).
z Is the FTP (FTP V) PID reading 3.11 kPa to 3.86
kPa (12.5 to 15.5 inches H
2 O) (4.22 to 4.90
volts)? Yes
GO to
D2 .
No
GO to D3 .
D2 TEST FOR BLOCKAGE IN VENTING PORTION
OF EVAP SYSTEM z
Open the canister vent solenoid by selecting the
STOP button on the scan tool.
z Does the pressure drop immediately? Yes
CARRY OUT the evaporative
emission repair verification drive
cycle. REFER to
Evaporative Emission Repair Verification Drive
Cycle in this section.
No
GO to D7 .
D3 TEST FOR FUEL TANK PRESSURE SENSOR
OPERATION z
Connect the Evaporative Emission System Leak
Tester to the evaporative emission test port.
z Close the canister vent solenoid. Refer to Canister Vent Solenoid Closing Procedure in this section.
z Pressurize the EVAP system to 3.48 kPa (14
inches H
2 O).
z Is the FTP (FTP V) PID reading 3.11 kPa to 3.86
kPa (12.5 to 15.5 inches H
2 O) (4.22 to 4.90
volts)? Yes
GO to
D4 .
No
REFER to the Powertrain
Control/Emissions Diagnosis (PC/ED)
manual. D4 TEST TO DETERMINE BLOCKAGE LOCATION
z
Open the canister vent solenoid.
z Does the pressure drop immediately? Yes
GO to
D5 .
No
GO to D7 .
D5 TEST FOR PINCHED FUEL VAPOR CONTROL
VALVE TUBE z
Lower the fuel tank 19.05 mm (3/4 inch).
z Connect the Evaporative Emission System Leak
Tester to the fuel filler pipe.
z Close the canister vent solenoid. Refer to Canister Vent Solenoid Closing Procedure in this section.
z Pressurize the EVAP system to 3.48 kPa (14
inches H
2 O).
z Is the FTP (FTP V) PID reading 3.11 kPa to 3.86
kPa (12.5 to 15.5 inches H
2 O) (4.22 to 4.90
volts)? Yes
INSTALL a new fuel vapor control
valve tube assembly. REFER to
Fuel Vapor Control Tube Assembly Valve
in this section. CARRY OUT a leak
test. REFER to
Evaporative Emission System Leak Test in this section. If
the system passes the leak test,
CARRY OUT the evaporative
emission repair verification drive
cycle. REFER to Evaporative Emission Repair Verification Drive
Cycle in this section. Klj . 12 ba
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GENERAL PROCEDURES
Evaporative Emission Repair Verification Drive Cycle
Drive Cycle Recommendations
NOTE:
The following procedure is designed to execute and complete the evaporative emission repair
verification drive cycle and to clear the Ford P1000, inspection and maintenance (I/M) readiness code.
When the ambient air temperature is below 4.4°C (40°F) or above 37.8°C (100°F), or the altitude is
above 2,438 meters (8,000 feet), the EVAP monitor will not run. If the P1000 must be cleared in these
conditions, the powertrain control module (PCM) must detect them once (twice on some applications)
before the EVAP monitor can be bypassed and the P1000 cleared. The EVAP bypassing procedure is
described in the following drive cycle.
1. Most OBD II monitors will complete more readily using a steady foot driving style during cruise or acceleration modes. Operating the throttle in a smooth fashion will minimize the time
necessary for monitor completion.
2. Fuel tank level should be between one- half and three-quarters full with three- quarters full being
the most desirable.
3. The evaporative monitor can only operate during the first 30 minutes of engine operation. When executing the procedure for this monitor, stay in part throttle mode and drive in a smooth
fashion to minimize fuel slosh.
Drive Cycle Preparation
NOTE: For best results, follow each of the following steps as accurately as possible.
4. NOTE: This step bypasses the engine soak timer and resets OBD II monitor status.
Install the scan tool. Turn the key ON with the engine OFF. Cycle the key off, then on. Select
the appropriate vehicle and engine qualifier. Clear all diagnostic trouble codes (DTCs) and carry
out a PCM reset.
5. Begin to monitor the following PIDs: ECT, EVAPDC, FLI (if available) and TP MODE. Press Diagnostic Data Link, PCM, PID/Data monitor and record, press trigger to select each PID, then
start.
6. Start the engine without returning the key to the OFF position.
Preparation for Monitor Entry
WARNING: Strict observance of posted speed limits and attention to driving conditions
SECTION 303-
13: Evaporative Emissions 2003 Mustang Workshop Manual Special Tool(s)
Worldwide Diagnostic System
(WDS)
418-
F224,
New Generation STAR (NGS)
Tester
418- F052, or equivalent scan
tool Klj . 1 ba
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DESCRIPTION AND OPERATION
Range Selection
The transmission has six range positions: P, R, N, (D), 2 and 1.
Park
In the PARK position:
zthere is no powerflow through the transmission.
z the parking pawl locks the output shaft to the case.
z the engine can be started.
z the ignition key can be removed.
Reverse
In the REVERSE position:
zthe vehicle can be operated in a rearward direction, at a reduced gear ratio.
z engine braking will occur.
Neutral
In the NEUTRAL position:
zthere is no powerflow through the transmission.
z the output shaft is not held and is free to turn.
z the engine can be started.
Overdrive
Overdrive is the normal position for most forward driving.
The OVERDRIVE position provides:
zAutomatic shifts.
SECTION 307-
01: Automatic Transaxle/Transmission 2003 Mustang Workshop Manual Klj . 1 ba
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DIAGNOSIS AND TESTING
Diagnostic Strategy
Troubleshooting an electronically controlled automatic transmission is simplified by using the proven
method of diagnosis. One of the most important things to remember is that there is a definite
procedure to follow.
NOTE:
Do not take any short cuts or assume that critical checks or adjustments have already been
made.
Follow the procedures as written to avoid missing critical components or steps.
To properly diagnose a concern have the following publications available:
zTransmission Reference Manual.
z Powertrain Control/Emissions Diagnosis (PC/ED) manual.
z TSBs and OASIS Messages.
z Wiring Diagram.
These publications provide the information required when diagnosing transmission concerns.
Use the Diagnostic Flow Chart as a guide and follow the steps as indicated.
Preliminary Inspection
zKnow and understand the customer's concern.
z Verify the concern by operating the vehicle.
z Check the fluid levels and condition.
z Check for non-factory add- on items.
z Check shift linkages for proper adjustment.
z Check TSBs and OASIS messages regarding the concern.
Diagnostics
zCarry out on- board diagnostic procedures key on engine off (KOEO) and key on engine running
(KOER).
z Record all diagnostic trouble codes (DTCs).
z Repair all non- transmission codes first.
z Repair all transmission codes second.
z Erase all continuous codes and attempt to repeat them.
z Repair all continuous codes.
z If only pass codes are obtained, refer to Diagnosis By Symptom for further information and
diagnosis.
Follow the diagnostic sequence to diagnose and repair the concern the first time. SECTION 307-
01: Automatic Transaxle/Transmission 2003 Mustang Workshop Manual Klj . 1 ba
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Diagnosing an electronically controlled automatic transmission is simplified by using the following
procedures. One of the most important things to remember is that there is a definite procedure to
follow. DO NOT TAKE SHORT CUTS OR ASSUME THAT CRITICAL CHECKS OR ADJUSTMENTS
HAVE ALREADY BEEN MADE. Follow the procedures as written to avoid missing critical components
or steps. By following the diagnostic sequence, the technician will be able to diagnose and repair the
concern the first time.
On-
Board Diagnostics With Diagnostic Tool
NOTE: For detailed instruction and other diagnostic methods using the scan tool, refer to the scan tool
tester manual and the Powertrain Control/Emissions Diagnosis (PC/ED) manual. These quick tests
should be used to diagnose the powertrain control module (PCM) and should be carried out in order.
zQuick Test 1.0 - Visual Inspection
z Quick Test 2.0 - Set Up
z Quick Test 3.0 - Key On, Engine Off (KOEO)
z Quick Test 4.0 - Continuous Memory
z Quick Test 5.0 - Key On, Engine Running (KOER)
„ Special Test Mode
„ Wiggle Test
„ Output Test Mode
„ PCM Reset Mode
„ Clearing DTCs
„ OBD II Drive Cycle
z Other Scan Tool Features
For further information on other diagnostic testing features using the scan tool, refer to the Powertrain
Control/Emissions Diagnosis (PC/ED) manual. Other diagnostic methods include the following:
„Parameter Identification (PID) Access Mode
„ Freeze Frame Data Access Mode and Manual
007-
00131 or equivalent 73 III Automotive Meter
105-
R0057 or equivalent UV Leak Detector Kit
164-
R0756 or equivalent Klj . 2 ba
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z
Repair all vehicle speed DTCs.
z Make sure that the vehicle speed sensor and digital TR sensors are functional.
z Select "Active Command Modes."
z Select "Trans - Bench Mode or Trans - Drive Mode."
OSC — Transmission Bench Modes
The following Transmission Bench Modes may be used or required during diagnostics.
SSA, SSB and TCC in BENCH MODE
The BENCH MODE allows the technician to carry out electrical circuit checks on the following
components:
zSSA - activates SSA OFF or ON.
z SSB - activates SSB OFF or ON.
z Transmission converter clutch (TCC) - activates TCC OFF or ON.
OSC "SSA, SSB, TCC" BENCH MODE operates ONLY when:
zthe digital TR sensor is operational and no digital TR sensor DTCs are present.
z the vehicle speed input is operational and no VSS sensor DTCs are present.
z the transmission range selector lever is in P.
z the key is ON.
z the engine is OFF.
OSC Command Values
zOFF - turns solenoid OFF.
z ON - turns solenoid ON.
z XXX - cancels OSC value sent.
z SEND - sends the values to PCM.
BENCH MODE Procedure for SSA, SSB and TCC
Follow operating instructions from the scan tool menu screen:
zSelect "Output State Control."
z Select "Trans - Bench Mode."
z Select "PIDs" to be monitored.
z Monitor all selected PIDs during test.
z Select "Parameters - SSA, SSB or TCC."
z Select "ON" to turn solenoid ON.
z Press "SEND" to send command ON.
z Select "OFF" to turn solenoid OFF.
z Press "SEND" to send command OFF. Klj . 2 ba
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z
Select "XXX" to cancel at any time.
z Press "SEND."
EPC in BENCH MODE
The BENCH MODE is also used to test the functionality of the transmission's electronic pressure
control. During BENCH MODE, the electronic pressure control (EPC) solenoid can ramp up/down in
increments of 103 kPa (15 psi) from zero to 620 kPa (90 psi) and 620 kPa (90 psi) to zero psi.
The OSC functions for the parameter EPC allows the technician to choose the following options:
zEPC - activates EPC to selected values.
z 00 - sets EPC pressure to 00 kPa (00 psi).
z 15 - sets EPC pressure to 103 kPa (15 psi).
z 30 - sets EPC pressure to 206 kPa (30 psi).
z 45 - sets EPC pressure to 310 kPa (45 psi).
z 60 - sets EPC pressure to 411 kPa (60 psi).
z 75 - sets EPC pressure to 517 kPa (75 psi).
z 90 - sets EPC pressure to 620 kPa (90 psi).
To carry out an EPC BENCH MODE pressure functionality test, install a pressure gauge in the EPC
port. The following requirements are required to carry out this test:
zVSS and digital TR sensor operational
z No VSS and digital TR sensor DTCs
z Transmission range selector lever in P
z Key ON
z Engine ON
z Engine speed at least 1,500 rpm for accurate EPC pressure measurement
To carry out an EPC BENCH MODE solenoid circuit pinpoint test, the following requirements are
required.
zVSS and digital TR sensor operational
z No VSS and digital TR sensor DTCs
z Transmission range selector lever in P
z Key ON
z Engine OFF
OSC Command Values
z00 - sets EPC pressure to 00 kPa (00 psi).
z 15 - sets EPC pressure to 103 kPa (15 psi).
z 30 - sets EPC pressure to 206 kPa (30 psi).
z 45 - sets EPC pressure to 310 kPa (45 psi).
z 60 - sets EPC pressure to 411 kPa (60 psi). Klj . 3 ba
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pressures. The best test for the EPC is to use the BENCH MODE and a hydraulic pressure gauge.
Using EPC in the BENCH MODE will confirm that the EPC is working at both the higher and lower
pressures.
The OSC functions for the parameter EPC allows the technician to choose the following options:
zEPC - activates EPC to selected values
z 00 - sets EPC pressure to 00 kPa (00 psi).
z 15 - sets EPC pressure to 103 kPa (15 psi).
z 30 - sets EPC pressure to 206 kPa (30 psi).
z 45 - sets EPC pressure to 310 kPa (45 psi).
z 60 - sets EPC pressure to 411 kPa (60 psi).
z 75 - sets EPC pressure to 517 kPa (75 psi).
z 90 - sets EPC pressure to 620 kPa (90 psi).
OSC "EPC" DRIVE MODE operates ONLY when:
zthe digital TR sensor is operational and no digital TR sensor DTCs are present.
z the vehicle speed sensor is operational and no VSS sensor DTCs are present.
z the transmission range selector lever is in O/D.
z the pressure gauge is installed.
z the key is ON.
z the engine is ON.
z the vehicle speed is greater than 3.2 km/h (2 mph).
z the OSC value for EPC must be greater than what the PCM commands (see EPC PID).
OSC Command Values
z00 - sets EPC pressure to 00 kPa (00 psi).
z 15 - sets EPC pressure to 103 kPa (15 psi).
z 30 - sets EPC pressure to 206 kPa (30 psi).
z 45 - sets EPC pressure to 310 kPa (45 psi).
z 60 - sets EPC pressure to 411 kPa (60 psi).
z 75 - sets EPC pressure to 517 kPa (75 psi).
z 90 - sets EPC pressure to 620 kPa (90 psi).
z XXX - cancels OSC value sent.
z SEND - sends the values to PCM.
DRIVE MODE Procedure for EPC.
Follow operating instructions from the scan tool menu screen.
zSelect "Output State Control."
z Select "Trans - Drive Mode."
z Select "PIDs" to be monitored. Klj . 7 ba
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NOTE:
Refer to the Transmission Vehicle Harness Connector illustration preceding these
pinpoint tests. A1 ELECTRONIC DIAGNOSTICS
z
Select PARK.
z Key in OFF position.
z Check to make sure the transmission harness connector
is fully seated, pins are fully engaged in connector and
in good condition before proceeding.
z Connect the diagnostic tool.
z Key in ON position.
z Enter the following diagnostic mode on the diagnostic
tool: Diagnostic Data Link.
z Enter the following diagnostic mode on the diagnostic
tool: PCM.
z Enter the following diagnostic mode on the diagnostic
tool: Active Command Modes.
z Enter the following diagnostic mode on the diagnostic
tool: Output State Control (OSC).
z Enter the following diagnostic mode on the diagnostic
tool: Trans- Bench Mode.
z Does vehicle enter Trans- Bench Mode? Yes
GO to
A2 .
No
REPEAT procedure to enter
Trans-Bench Mode. If vehicle
did not enter Trans- Bench
Mode, REFER to the Powertrain
Control/Emissions Diagnosis
(PC/ED) manual for diagnosis
of PCM. A2 WIGGLE TEST
z
Select PIDs to be monitored.
z Select "ON" to turn suspect solenoid on.
z Press "SEND".
z Wiggle all wiring and connectors to the transmission.
Monitor the Solenoid State for changes.
z Select "OFF" to turn solenoid off.
z Press "SEND".
z Does the suspect solenoid(s) fault state change? PID Command PID Actual
SSA SS1F
SSB SS2F
TCC TCCF Yes
REPAIR open or short in the
vehicle harness or connector.
No
GO to
A3 .
A3 SOLENOID FUNCTIONAL CHECK
z
Monitor each solenoid state.
z Turn each solenoid ON and OFF.
z Does the solenoid turn ON and OFF when
commanded and can solenoid activation be heard? Yes
GO to
A4 .
No
GO to A5 .
A4 OSC TRANS-
DRIVE MODE (GR_CM OR TCC) z
Carry out OSC Trans- Drive Mode.
z Select GR_CM for Shift Solenoids or follow procedures
for GR_CM as listed.
z Select TCC for Torque Converter Clutch Solenoid.
Follow procedures of TCC in Drive Mode as listed.
z Does the transmission upshift and downshift or
torque converter engage/disengage when
commanded? Yes
CLEAR all DTCs. ROAD TEST
to verify if concern is still
present. If concern is still
present, REFER to
Diagnosis By Symptom in this section to
diagnose shift or torque
converter concern.
No
GO to A5 .
A5 CHECK FOR BATTERY VOLTAGE
z
Remove transmission fluid pan. Yes Klj . 4 ba
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