service FORD MUSTANG 2003 Workshop Manual

DESCRIPTION AND OPERATION
Acceleration Control
Component Locations
The throttle is controlled by the accelerator cable which is connected to the accelerator pedal and
shaft.
zThe accelerator pedal and shaft should travel smoothly from the idle to the wide- open throttle
(WOT) positions. Hesitation on return or prevention of return to the idle position must not occur.
z Surrounding components such as wiring, hoses, sound insulator and floor covering must not
contact the sliding inner member of the accelerator cable or the accelerator pedal and shaft.
z The sliding inner member of the accelerator cable should not be lubricated and is not
serviceable.
SECTION 310-
02: Acceleration Control 2003 Mustang Workshop Manual Item Part Number Description
1 9725 Accelerator pedal and shaft
2 9A758 Accelerator cable
3 9728 Accelerator cable bracket, 3.8L
4 9728 Accelerator cable bracket, 4.6L (2V)
5 — Accelerator cable bracket, Supercharged engine Klj . 1 ba
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SPECIFICATIONS
a
Manifold gauge set pressures may vary slightly depending on the distance between the service
SECTION 412-
00: Climate Control System - General Information 2003 Mustang Workshop Manual General Specifications
Item Specification
A/C Compressor
Type FS-
10 swashplate, 5 double- acting pistons Displacement 170 cc (10.4 cu in)
Rotation Clockwise
A/C Pressure Relief Valve
a Open pressures 3,792-
4,137 kPa (550- 600 psi) A/C Pressure Sensor Refer to the Powertrain Control/Emissions
Diagnosis (PC/ED) manual.
Coolant Hose Lubricant
MERPOL® ESE-
M99B144- B Evaporator Core Orifice
Color Orange
Diameter 1.45 mm (0.057 in)
Magnetic Clutch
Air gap clearance 0.35-
0.75 mm (0.014- 0.030 in) Dual Function Pressure Switch (V8)
a Fan on/open 2,137-
2,344 kPa (310- 340 psi) Fan off/close 1,655-
2,137 kPa (240- 310 psi) Clutch off/open 2,999-
3,275 kPa (435- 475 psi) Clutch on/closed 1,517-
1,931 kPa (220- 280 psi) Pressure Cutoff Switch (V6)
a Open 2,999-
3,275 kPa (435- 475 psi) Close 1,586-
1,999 kPa (230- 290 psi) A/C Cycling Switch Open and Closed Pressures
a Open pressure 145-
159 kPa (21- 23 psi) Close pressure 290 kPa (42 psi)
Refrigerant Lubricant and Capacity
PAG Refrigerant Compressor Oil (R-134a Systems)
F7AZ- 19589- DA (Motorcraft YN-12- C) WSH-
M1C231- B Capacity 254 ml (8.6 oz)
Refrigerant and Capacity
R134a Refrigerant YN-
19 WSH-
M17B19- A Capacity .96 kg (34 oz)
Refrigerant System Cleaner
A/C Systems Flushing Solvent F4AZ-19579-
A — Klj . 1 ba
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z
Refrigerant R- 134a must not be mixed with air for leak testing or used with air for any
other purpose above atmospheric pressure. R- 134a is combustible when mixed with high
concentrations of air and higher pressures.
z A number of manufacturers are producing alternative refrigerant products that are
designed to be used instead of R- 134a refrigerant. The use of any unauthorized
substitute refrigerant can severely damage the A/C components. If repair is required, use
only new or recycled refrigerant R- 134a.
CAUTION: To avoid contamination of the A/C system, always observe the following:
z Keep service tools and the work area clean.
z Never open or loosen a connection before discharging the system.
z When loosening a connection, if any residual pressure is evident, allow it to leak out
before opening the fitting.
z Evacuate a system that has been opened to install a new component or one that has
been discharged through leakage before charging.
z Seal an open fitting with a cap or plug immediately after disconnecting a component
from the system.
z Clean the outside of the fittings thoroughly before disconnecting a component from the
system.
z Do not remove the sealing caps from a new component until ready to install.
z Refrigerant oil will absorb moisture from the atmosphere if left uncapped. Do not open
an oil container until ready to use, and install the cap immediately after using. Store the
oil in a clean, moisture- free container.
z Install a new O- ring seal before connecting an open fitting. Coat the fitting and the O- ring
seal with refrigerant oil before connecting.
z When installing a refrigerant line, avoid sharp bends. Position the line away from the
exhaust or any sharp edges that can chafe the line.
z Do not open a refrigerant system or uncap a new component unless it is as close as
possible to room temperature. This will prevent condensation from forming inside a
component that is cooler than the surrounding air.
The manual climate control system heats or cools the vehicle depending on the function selector
switch position and the temperature selected.
zThe function selector switch position determines heating or cooling and air distribution.
z The temperature control setting determines the air temperature.
z The heater blower motor switch (18578) varies the blower motor speed.
Principles of Operation
There are four main principles involved with the basic theory of operation:
zheat transfer
z latent heat of vaporization
z relative humidity
z effects of pressure Heat Transfer Klj . 2 ba
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evaporator core or A/C condenser core. Then recheck for loss of vacuum.
z If a very small leak is suspected, allow the system to sit overnight with vacuum applied
and check for vacuum loss.
9. If the A/C evaporator core or A/C condenser core does leak, as verified by the above procedure, install a new A/C evaporator core or A/C condenser core. For additional information, refer to
Section 412 - 03 .
A/C Compressor— External Leak Test
1. Install the A/C pressure test adapter on the rear head of the A/C compressor using the existing manifold retaining bolt.
2. Connect the high and low pressure lines of a manifold gauge set or a refrigerant recovery/recycling station such as the R- 134a A/C Service Center to the corresponding fittings
on the A/C pressure test adapter.
3. Attach the center hose of the manifold gauge set to a refrigerant container standing in an upright position.
4. Hand- rotate the compressor shaft 10 complete revolutions to distribute the oil inside the A/C
compressor.
5. Open the low pressure gauge valve, the high pressure gauge valve and the valve on the refrigerant container to allow the refrigerant vapor to flow into the A/C compressor.
6. Using the Refrigerant Leak Detector, check for leaks at the compressor shaft seal and the compressor center seal.
7. If a shaft seal leak is found, install a new shaft seal. For additional information, refer to Section 412 - 03 . If an external leak is found at the center joint of the A/C compressor, install a new A/C
compressor.
8. When the leak test is complete, recover the refrigerant. For additional information, refer to Air Conditioning (A/C) System Recovery, Evacuation and Charging in this section. Klj . 40 ba
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4.
Refrigerant system leak test
zUse either an ultraviolet (UV) or an electronic leak detector to check for leaks at all
refrigerant lines, connections, and components.
After all tests have been completed, report all findings and recommended repairs to your
service advisor before carrying out further diagnostic procedures. Klj . 2 ba
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GENERAL PROCEDURES
Manifold Gauge Set Connection
1. Turn both valves on the R- 134a Manifold Gauge Set clockwise to close the low- and high-
pressure hoses to the center manifold and center hose.
2. Remove the A/C charging valve cap (19D702) from the low- pressure service gauge port valve.
3. Remove the A/C charging valve cap from the high- pressure service gauge port valve.
SECTION 412-
00: Climate Control System - General Information 2003 Mustang Workshop Manual Special Tool(s)
R-
134a Manifold Gauge Set
176- R032A or equivalent Klj . 1 ba
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4. Connect the R-134a Manifold Gauge Set low-
pressure hose and the R-134a low side quick
disconnect to the low- pressure service gauge port valve.
5. Connect the R-134a Manifold Gauge Set high- pressure hose and the R-134a high side quick
disconnect to the high- pressure service gauge port valve. Klj . 2 ba
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GENERAL PROCEDURES
Air Conditioning (A/C) System Flushing
WARNING: Use extreme care and observe all safety and service precautions related to the
use of refrigerants.
WARNING: Due to refrigerant hazards, always wear safety goggles and non- penetrable
gloves when working on or flushing A/C systems.
CAUTION: An A/C refrigerant analyzer must be used before the recovery of any vehicle's
A/C refrigerant. Failure to do so puts the shop's bulk refrigerant at risk of contamination. If the
vehicle's A/C refrigerant is contaminated, refer the customer to the service facility that carried
out the last A/C service. If the customer wishes to pay the additional cost, use the A/C recovery
equipment that is designated for recovering contaminated A/C refrigerant. All contaminated
A/C refrigerant must be disposed of as hazardous waste. For all equipment, follow the
equipment manufacturer's procedures and instructions.
CAUTION: Suction accumulator/drier, muffler, hoses, thermal expansion valve, and fixed
orifice tube should be removed when flushing the A/C system. Internal plumbing of these
devices makes it impossible to correctly remove any residual- flushing agent. Except for the
hoses, these components are typically discarded after A/C system contamination. Hoses can
normally be reused unless they are clogged with foreign material. The 3.785 liters (1 gallon) of
A/C Systems Flushing Solvent F4AZ-19579- A and FL1-A filter used in A/C Flush and Purge
Machine 219- 00022 are intended for use on one vehicle only. They may be used to flush both
the A/C condenser core and the A/C evaporator core on an individual vehicle, but under no
circumstances should they be used on more than one vehicle.
1. NOTE: Prior to using the A/C Flush and Purge Machine 219- 00022 for the first time, review the
operating instructions.
NOTE: Only the A/C Flush and Purge Machine kit 219- 00023, which includes A/C Flush and
Purge Machine 219- 00022, A/C Flush and Purge Fitting Kit 219- 00024, and the Ford Part
number F4AZ-19579- A A/C Systems Flushing Solvent, is approved for use on Ford vehicles. No
other flushing device or solvent is approved for flushing heat exchangers. Use of any other
flusher or solvent may cause damage to the A/C system and the flushing unit.
SECTION 412-
00: Climate Control System - General Information 2003 Mustang Workshop Manual Special Tool(s)
A/C Flush and Purge Machine
219-
00022 (part of 219- 00023)
or equivalent A/C Flush and Purge Fitting Kit
219-
00024 (part of 219- 00023)
or equivalent Klj . 1 ba
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Ford Motor Company has approved a procedure to provide technicians with a non-
CFC method
of flushing contaminated A/C system heat exchangers, A/C evaporator core, and A/C
condenser core. The procedure allows the specific components to be cleaned and flushed while
installed in their normal in- vehicle location. The types of contamination flushed include particle
matter that results from A/C compressor or desiccant failure within the suction accumulator/drier
and gummy residue that can form when refrigerant oil is overheated during A/C compressor
seizure. The flushing process is a two- step procedure that involves the use of an A/C Flush and
Purge Machine 219- 00022 to:
z Circulate the flushing solvent through the heat exchanger in the reverse direction of
normal refrigerant flow (back- flushing). Particulate matter picked up during flushing is
filtered from the returning solvent before the solvent is returned to the reservoir for
continued circulation.
z Remove the flushing solvent from the heat exchanger. In this step of the procedure,
pressurized air 621- 862 kPa (90-125 psi) is used to push and evaporate any remaining
flush solvent from the heat exchanger.
2. Discharge the A/C system. Observe all safety precautions. For additional information, refer to the procedure in this section.
3. Disconnect the refrigerant lines from the heat exchanger(s) to be flushed.
4. Connect the A/C Flush and Purge Machine 219- 00022 and A/C Flush and Purge Fitting Kit 219-
00024 to the heat exchanger to be flushed. Do not flush through the A/C evaporator core orifice,
mufflers or hoses. Internal plumbing and material make- up of these components make it
impossible to correctly remove foreign material or residual flushing solvent.
5. Use 3.785 liters (one gallon) of A/C Systems Flushing Solvent part number F4AZ-19579- A to
flush the heat exchanger for a minimum of 15 minutes. The flush solvent may be used for one
or both heat exchangers in the A/C system. However, the flush solvent is intended for one
vehicle only. The filter used on the flushing unit is also intended for use on one vehicle only.
6. Flush the component for a minimum of 15 minutes.
7. Apply 621- 862 kPa (90-125 psi) pressurized air to the component for a minimum of 30 minutes.
The 30- minute purge time is required to force and evaporate all residual solvent from the A/C
system component. Failure to successfully remove all residual solvent within the component
can result in system damage when reconnected and operated. Dispose of the used flush
solvent and filter in accordance with local, state and federal emissions.
8. NOTE: A/C system filtering as described in this section is optional if system flushing is carried
out. However, the filter kit use is recommended after flushing if the A/C system contamination is
extensive.
Install a new A/C evaporator core orifice in any vehicle being serviced for A/C compressor or
desiccant failure.
9. Install new refrigerant hoses if clogged with foreign material.
10. Reconnect the heat exchanger being serviced.
11. Add additional refrigerant oil as required. For additional information, refer to the procedure in this section.
12. Evacuate, leak test and charge the A/C system. For additional information, refer to the procedure in this section.
13. Check the system for normal operation. Klj . 2 ba
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GENERAL PROCEDURES
Air Conditioning (A/C) System Recovery, Evacuation and
Charging
Refrigerant System Recovery
NOTE:
Ford Motor Company recommends use of an A/C service center to carry out recovery,
evacuation, and charging of the refrigerant system. If an A/C service center is not available, refrigerant
system recovery, evacuation, and charging may be accomplished using a separate recovery station,
vacuum pump, charging cylinder, and manifold gauge set.
1. Prior to recovering the refrigerant system, you must verify the purity of the refrigerant. For additional information, refer to Refrigerant Identification Testing in this section.
2. NOTE: Some R- 134a service centers require the use of an A/C manifold gauge set. For
additional information, refer to Manifold Gauge Set Connection in this section.
SECTION 412-
00: Climate Control System - General Information 2003 Mustang Workshop Manual Special Tool(s)
R-
134a A/C Refrigerant Center
176- 00002 or equivalent R-
134a A/C Refrigerant Center
023- 00153 or equivalent R-
134a Manifold Gauge Set
176- R032A or equivalent 1.2 CFM Vacuum Pump
023-
00162 or equivalent 4.0 CFM Vacuum Pump
023-
00163 or equivalent Klj . 1 ba
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