power steering FORD MUSTANG 2003 Workshop Manual

REMOVAL AND INSTALLATION
Water Pump —
3.8L
Removal and Installation 1. Drain the engine coolant. For additional information, refer to Cooling System Draining, Filling and Bleeding in this section.
2. Loosen the coolant pump pulley bolts.
3. Remove the power steering (PS) pump pulley. For additional information, refer to Section 211 -
02 .
4. Remove the bolts and the coolant pump pulley.
5. Remove the PS bracket. zRemove the bolts.
z Remove the nuts. 6. Disconnect the lower radiator hose from the coolant pump. SECTION 303-
03A: Engine Cooling 2003 Mustang Workshop Manual Material
Item Specification
Motorcraft Premium Gold
Engine Coolant
VC
-7-A (in Oregon VC-7- B)
(yellow color) WSS-
M97B51-
A1 Klj . 1 ba
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14. Lower the vehicle.
15. Disconnect the coolant reservoir electrical connector.
16. Disconnect the following connectors:
zCamshaft position (CMP) sensor
z LH radio ignition interference capacitor
17. Separate the wiring harness from the power steering reservoir bracket. Klj . 4 ba
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10. Connect the following connectors:
zLH fuel injectors
z LH ignition coils
11. Connect the following generator connectors: zVoltage regulator
z Battery supply
12. Install the wiring harness retainers to the power steering reservoir bracket.
13. Connect the following connectors: zLH radio ignition interference capacitor
z CMP sensor 14. Connect the coolant reservoir electrical connector. Klj . 10 ba
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22. Remove the wiring harness.
zSeparate the wiring harness from the LH valve cover stud bolt.
z Separate the wiring harness from the power steering reservoir bracket.
Installation 1. Position the wiring harness: zInstall the wiring harness retainer onto the LH valve cover stud bolt.
z Install the wiring harness retainer into the power steering reservoir.
2. Connect the ECT sensor electrical connector.
3. Connect the CMP sensor electrical connector. Klj . 6 ba
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DESCRIPTION AND OPERATION
Accessory Drive
Component Locations—
3.8L
Component Locations— 4.6L
SECTION 303-
05: Accessory Drive 2003 Mustang Workshop Manual Item Part Number Description
1 19D784 A/C clutch pulley
2 8620 Drive belt
3 8509 Coolant pump pulley
4 8678 Belt idler pulley
5 10344 Generator pulley
6 10344 Power steering pump pulley
7 63126 Crankshaft vibration damper
8 6B209 Drive belt tensioner
9 — Drive belt tensioner (part of 6B209)
Item Part Number Description
1 10344 Generator pulley
2 8620 Drive belt
3 8A528 Coolant pump pulley
4 3D673 Power steering pump pulley
5 6316 Crankshaft vibration damper
6 19D784 A/C clutch pulley Klj . 1 ba
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Item Part Number Description
1 8678 Belt idler pulley
2 8678 Belt idler pulley
3 8678 Belt idler pulley
4 3A733 Power steering pulley
5 10344 Coolant pump pulley
6 6C254 Crankshaft pulley
7 6B209 Belt tensioner
8 19D784 A/C clutch pulley
9 8620 Drive belt Klj . 2 ba
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Component Tests
Drive Belt Noise/Flutter
Drive belt chirp occurs due to pulley misalignment or excessive pulley runout. It can be the result of a
damaged pulley or an incorrectly aligned pulley.
To correct, determine the area where the noise comes from. Check each of the pulleys in that area
with a straightedge to the crankshaft pulley, looking for accessory pulleys out of position in the fore/aft
direction or at an angle to the straightedge.
Drive belt squeal is an intermittent noise that occurs when the drive belt slips on a pulley during certain
conditions, such as: engine start up, rapid engine acceleration, or A/C clutch engagement.
Drive belt squeal can occur:
zif any of the accessories are damaged, have a worn or damaged bearing, internal torsional
resistance above normal. All accessories should be rotatable by hand in the unloaded condition.
If not, inspect the accessory.
z if fluid gets on the drive belt. This includes power steering fluid, engine coolant, engine oil or air
conditioning system lubricant. If fluid does get on the drive belt during service, clean the drive
belt with soap and water and thoroughly rinse with clean water.
z NOTE: The drive belt tensioner arm should rotate freely without binding.
if the drive belt is too long. A drive belt that is too long will allow the drive belt tensioner arm to
go all the way to the arm travel stop under certain load conditions, which will release tension to
the drive belt. If the drive belt tensioner indicator is outside the installation wear range window,
install a new drive belt.
z if the drive belt tensioner is worn or damaged.
Belt Tension
NOTE: Drive belt tension is not adjustable.
The drive belt tensioner automatically adjusts drive belt tension. Symptom Chart Condition
Possible Sources Action
z Drive belt
noise, chirping,
flutter z
Defective/worn drive
belt.
z Misaligned pulley.
z Pulley runout.
z Damaged
accessories.
z Fluid contamination
of drive belt. z
GO to Component Tests, Drive
Belt, Noise/Flutter.
z Damaged or worn
drive belt tensioner. z
GO to Component Tests, Belt
Tensioner, Automatic.
z Premature
drive belt wear z
Defective drive belt.
z Misaligned pulley.
z Pulley runout.
z Damaged
accessories.
z Incorrectly installed
drive belt. z
GO to Component Tests, Drive
Belt Noise/Flutter and Drive
Belt Misalignment diagnosis. Klj . 2 ba
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SPECIFICATIONS
SECTION 303-
14: Electronic Engine Controls 2003 Mustang Workshop Manual General Specifications
Item Specification
Lubricants
Super premium SAE 5W-
20 Engine Oil XO-5W20-DSP WSS-
M2C914- A Penetrating and Lock Lubricant E8AZ-19A501-
B N/A
Pipe Sealant with Teflon D8AZ-19554-
A WSK-
M26350- A2
Torque Specifications Description Nm lb-
ft lb-
in Cylinder head temperature (CHT) sensor —
3.8L 10 — 89
Engine coolant temperature (ECT) sensor —
4.6L (2V) 20 — 15
Engine coolant temperature (ECT) sensor —
4.6L (4V) 24 18 —
Heated oxygen sensors (HO2S) 41 30 —
Catalyst monitor sensors 41 30 —
Crankshaft position (CKP) sensor bolts —
3.8L 6 — 53
Crankshaft position (CKP) sensor bolts —
4.6L 10 — 89
Power steering reservoir bolts 10 — 89
Camshaft position (CMP) sensor bolt —
4.6L 10 — 89
PCM connector to module bolt 6 — 53
Idle air control (IAC) valve bolts 10 — 89
Camshaft synchronizer housing bolt 25 18 —
Throttle position (TP) sensor screws 3 — 27
Fuel pressure sensor bolts 4 — 35
Air intake scoop bolts 25 18 —
Air intake scoop bracket bolt 25 18 —
Air intake scoop bracket nuts 25 18 —
Air intake scoop bracket throttle body nut 9 — 80
Exhaust gas recirculation (EGR) vacuum regulator solenoid bolts 10 — 89 Klj . 1 ba
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REMOVAL AND INSTALLATION
Camshaft Position (CMP) Sensor —
4.6L
Removal and Installation 1. Disconnect the battery ground cable. For additional information, refer to Section 414 - 01 .
2. Remove the bolts and position aside the power steering pump reservoir.
3. Remove the camshaft position (CMP) sensor. zDisconnect the connector.
z Remove the bolt and the sensor.
4. To install, reverse the removal procedure.
SECTION 303-
14: Electronic Engine Controls 2003 Mustang Workshop Manual Klj . 1 ba
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z
Other
component
leaking. z
IDENTIFY leaking fluid
as engine, power
steering, or transmission
fluid. REPAIR as
necessary.
z False report. zREMOVE all traces of
lube on the exposed
transmission surfaces.
CHECK the vent for free
breathing. OPERATE
the transmission and
INSPECT for new
leakage. REPAIR as
necessary. REFER to
Section 308 - 03A or
Section 308 - 03B .
z Internal
components. z
INSPECT for leaks at
the input shaft bearing
retainer seal and the
shift rail expansion plug.
REFER to Section 308 -
03A or
Section 308 -
03B . INSPECT for leaks
at the top cover gasket.
INSPECT the case for
sand holes or cracks.
REPAIR or INSTALL a
new case as necessary.
REFER to Section 308 -
03A or
Section 308 -
03B .
z Fill and drain
plugs. z
CHECK fill and drain
plugs and bore threads.
REPAIR as necessary.
TIGHTEN plugs to
specified torque value.
REFER to Section 308 -
03A or
Section 308 -
03B .
z Bearing failure zOther part
failure.
z Raceways or
rollers.
z Lubricant.
z Towing vehicle
further than 80
km (50 miles)
with driveshaft
installed.
Mainshaft
tapered bearing
and needle
caged bearings
are especially
susceptible to
damage. z
REMOVE,
DISASSEMBLE and
CLEAN the
transmission. Inspect for
damaged parts and
install new components
as necessary. (Note:
RESET the bearing
preload if any new
tapered bearings are
installed). REFER to
Section 308 - 03A or
Section 308 - 03B .
z Vibration break-
up of retainer
and brinelling of
races.
z Bearing(s). z
DETERMINE the cause
of vibration and
CORRECT. Otherwise
PROCEED as above. Klj . 6 ba
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