warning FORD MUSTANG 2003 Workshop Manual

GENERAL PROCEDURES
Fittings
—R-Clip
Disconnect WARNING: Do not smoke or carry lighted tobacco or open flame of any type when
working on or near any fuel- related components. Highly flammable mixtures are always present
and may be ignited, resulting in possible personal injury.
WARNING: Fuel in the fuel system remains under high pressure even when the engine is
not running. Before servicing or disconnecting any of the fuel lines or fuel system components,
the fuel system pressure must be relieved to prevent accidental spraying of fuel, causing
possible personal injury or a fire hazard.
CAUTION: Do not use any tools. The use of tools may cause a deformity in the clip
components which may cause fuel leaks.
1. Relieve the fuel system pressure. For additional information, refer to Pressure Relief in this
section.
2. Remove the shipping tab by bending.
3. Spread the R- clip legs and push the clip into the fitting.
SECTION 310-
00: Fuel System — General Information 2003 Mustang Workshop Manual Material
Item Specification
SAE 5W-
20 Super Premium
Synthetic Blend Motor Oil
XO- 5W20- QSP or equivalent WSS-
M2C153-
H Klj . 1 ba
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GENERAL PROCEDURES
Fittings —
Vapor Tube
Disconnect
1. WARNING: The evaporative emission system contains fuel vapor and condensed
fuel vapor. Although not present in large quantities, it still presents the danger of
explosion or fire. Disconnect the battery ground cable from the battery to minimize the
possibility of an electrical spark occurring, possibly causing a fire or explosion if fuel
vapor or fuel liquid is present in the area.
Disconnect the battery ground cable.
2. Disconnect the vapor tube from the fitting. 1. Squeeze the fitting.
2. Disconnect the vapor tube from the fitting.
Connect 1. Clean and inspect the fitting and the tube for damage.
2. Push the tube into the fitting until it snaps in place.
3. Pull on the connection to make sure the fitting is secure.
SECTION 310-
00: Fuel System — General Information 2003 Mustang Workshop Manual Klj . 1 ba
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DESCRIPTION AND OPERATION
Fuel Tank And Lines
WARNING: Do not smoke, carry lighted tobacco or an open flame of any type when
working on or near any fuel- related component. Highly flammable mixtures are always present
and may be ignited, possibly resulting in personal injury.
The vehicle utilizes a returnless fuel system consisting of:
zthe fuel tank.
z a fuel tank filler pipe which contains a restrictor plate to permit only unleaded fuel to be pumped
into the fuel tank.
z a 1/8 turn fuel tank filler cap.
z a fuel filter providing filtration to protect the fuel injectors.
z a single fuel line accommodating the returnless fuel system.
z a fuel injection supply manifold which contains a differential pressure sensor and a fuel
temperature sensor.
z a fuel pump and sender assembly which provides pressurized fuel to the engine and contains:
„an inlet filter.
„ a check valve which maintains system pressure after the pump is shut off.
„ a pressure relief valve for overpressure protection in the event of restricted flow.
The fuel pump is controlled by an electronic fuel pump driver module which is enabled by the
powertrain control module (PCM). Electrical power to the fuel pump is provided through the inertia fuel
shutoff (IFS) switch, which is located in the luggage compartment. SECTION 310-
01: Fuel Tank and Lines 2003 Mustang Workshop Manual Klj . 1 ba
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REMOVAL AND INSTALLATION
Fuel Tank
Removal
WARNING: Do not smoke, carry lighted tobacco or an open flame of any type when
working on or near any fuel- related components. Highly flammable mixtures are always present
and may be ignited, possibly resulting in personal injury.
WARNING: Fuel supply lines on all vehicles equipped with fuel injected engines will
remain pressurized for long periods of time after engine shutdown. Fuel system pressure must
be relieved prior to fuel system service to prevent possible personal injury or a fire hazard.
1. Disconnect the battery. For additional information, refer to Section 414 - 01 .
2. Relieve the fuel system pressure. For additional information, refer to Section 310 - 00 .
3. Drain the fuel tank. For additional information, refer to Section 310 - 00 .
4. Raise the vehicle. For additional information, refer to Section 100 - 02 .
5. Remove the filler pipe bolt and disconnect the filler pipe hose connections to the fuel tank.
6. Disconnect the fuel tank electrical connector.
SECTION 310-
01: Fuel Tank and Lines 2003 Mustang Workshop Manual Material
Item Specification
Serfactant
(Merpol)
ESE-
M99B144- B Klj . 1 ba
52003 Mustang Workshop Manual
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REMOVAL AND INSTALLATION
Support Straps
Removal
WARNING: Do not smoke, carry lighted tobacco or an open flame of any type when
working on or near any fuel- related components. Highly flammable mixtures are always present
and may be ignited, possibly resulting in personal injury.
WARNING: Fuel supply lines on all vehicles equipped with fuel injected engines will
remain pressurized for long periods of time after engine shutdown. Fuel system pressure must
be relieved prior to fuel system service to prevent possible personal injury or a fire hazard.
1. Remove the fuel tank. For additional information, refer to Fuel Tank in this section.
2. Slide the strap and the retaining pin into the recess and remove the strap retaining pin.
3. Remove the strap.
Installation 1. To install, reverse the removal procedure.
SECTION 310-
01: Fuel Tank and Lines 2003 Mustang Workshop Manual Klj . 1 ba
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REMOVAL AND INSTALLATION
Fuel Filter
Removal
WARNING: Fuel supply lines on all vehicles equipped with fuel injected engines will
remain pressurized for long periods of time after engine shutdown. Fuel system pressure must
be relieved prior to fuel system service to prevent possible personal injury or a fire hazard.
1. Disconnect the battery. For additional information, refer to Section 414 - 01 .
2. Relieve the fuel system pressure. For additional information, refer to Section 310 - 00 .
3. Raise the vehicle. For additional information, refer to Section 100 - 02 .
4. Disconnect the filter push connect fittings. For additional information, refer to Section 310 - 00 .
5. Unsnap the filter from the bracket and remove.
Installation 1. To install, reverse the removal procedure.
SECTION 310-
01: Fuel Tank and Lines 2003 Mustang Workshop Manual Klj . 1 ba
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DESCRIPTION AND OPERATION
Climate Control System
WARNING: To avoid accidental deployment and possible injury, the air bag system
backup power supply must be depleted before repairing any climate control components. To
deplete the backup power supply, disconnect the battery ground cable and wait one minute.
Failure to follow these instructions may result in personal injury.
WARNING: Carbon monoxide is colorless, odorless and dangerous. If it is necessary to
operate the engine with the vehicle in a closed area such as a garage, always use an exhaust
collector to vent the exhaust gases outside the closed area.
WARNING: R- 134a is classified as a safe refrigerant, but misuse can make it dangerous.
The following precautions must be observed:
zAlways wear safety goggles when repairing an air conditioning system.
z Avoid contact with liquid refrigerant R- 134a. R-134a vaporizes at approximately - 25°C (-
13°F) under atmospheric pressure and it will freeze skin tissue.
z Never allow refrigerant R- 134a gas to escape in quantity in an occupied space. R- 134a is
non- toxic, but it will displace the oxygen needed to support life.
z Never use a torch in an atmosphere containing R- 134a gas. R-134a is non-toxic at all
normal conditions, but when it is exposed to high temperatures, such as a torch flame, it
decomposes. During decomposition it releases irritation and toxic gases (as described in
the MSDS sheet from the manufacturer). Decomposition products are hydrofluoric acid,
carbon dioxide and water.
z Do not allow any portion of the charged air conditioning system to become too hot. The
pressure in an air conditioning system rises as the temperature rises and temperatures
of approximately 85°C (185°F) can be dangerous.
z Allow the engine to cool sufficiently prior to carrying out maintenance or serious burns
and injury can occur.
CAUTION: To avoid damaging the vehicle or A/C components, the following precautions
must be observed:
zThe A/C refrigerant of all vehicles must be identified and analyzed prior to refrigerant
charging. Failure to due so can contaminate the shop bulk refrigerant and other vehicles.
z Do not add R- 12 refrigerant to an A/C system that requires the use of R- 134a refrigerant.
These two types of refrigerant must never be mixed. Doing so can damage the A/C
system.
z Charge the A/C system with the engine running only at the low- pressure side to prevent
refrigerant slugging from damaging the A/C compressor.
z Use only R- 134a refrigerant. Due to environmental concerns, when the air conditioning
system is drained, the refrigerant must be collected using refrigerant recovery/recycling
equipment. Federal law REQUIRES that R- 134a be recovered into appropriate recovery
equipment and the process be conducted by qualified technicians who have been
certified by an approved organization, such as MACS, ASI etc. Use of a recovery machine
dedicated to R- 134a is necessary to reduce the possibility of oil and refrigerant
incompatibility concerns. Refer to the instructions provided by the equipment manufacturer when removing refrigerant from or charging the air conditioning system. SECTION 412-
00: Climate Control System - General Information 2003 Mustang Workshop Manual Klj . 1 ba
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PINPOINT TEST B: INSUFFICIENT, ERRATIC, OR NO HEAT z
Does the vacuum control motor hold a vacuum? A20 CHECK THE VACUUM CONTROL MOTOR INSTALLATION
z
Key in OFF position.
z Check the attachment of the vacuum control motor arm to
damper door.
z Is the vacuum control motor arm attached to the door or
door crank arm? Yes
REPAIR or INSTALL a
new damper door.
TEST the system for
normal operation.
No
CONNECT the vacuum
control motor arm to
the door and check
operation. TEST the
system for normal
operation.
Test Step Result / Action to Take
B1 CHECK FOR CORRECT ENGINE COOLANT LEVEL
z
Key in OFF position.
z Check the engine coolant level when hot and cold.
z Is the engine coolant at the correct level (hot/cold) as
indicated on the engine coolant recovery reservoir? Yes
GO to
B2 .
No
GO to B3 .
B2 CHECK FOR HOT WATER TO THE HEATER CORE INLET
HOSE WARNING: The heater core inlet hose will become
too hot to handle and may cause serious burns if the
system is working correctly.
z Key in START position.
z Allow the engine to reach normal operating temperature.
z Feel the heater core inlet hose. Yes
GO to
B4 .
No
TEST the engine cooling
system for correct
operation. REFER to
Section 303 - 03A or
Section 303 - 03B . Klj . 14 ba
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Heater Core
WARNING: Carbon monoxide gas is colorless, odorless and dangerous. If it is necessary
to operate the engine with the vehicle in a closed area such as a garage, always use an exhaust
collector to vent the exhaust gases outside the closed area. Failure to follow these instructions
may result in personal injury.
1. NOTE: Testing of returned heater cores reveals that a large percentage of heater cores are
good and did not require installation of a new heater core. If a heater core leak is suspected, the
heater core must be tested by following the Plugged Heater Core Component Test before the
Heater Core Pressure Test. Carry out a system inspection by checking the heater system
thoroughly as follows:
Inspect for evidence of coolant leakage at the heater water hose to heater core attachments. A
coolant leak in the heater water hose could follow the heater core tube to the heater core and
appear as a leak in the heater core.
CAUTION: Spring- type clamps are installed as original equipment. Installation and
overtightening of non- specification clamps can cause leakage at the heater water hose
connection and damage the heater core.
2. Check the integrity of the heater water hose clamps.
Heater Core— Plugged
WARNING: The heater core inlet hose will become too hot to handle if the system is
working correctly.
1. Check to see that the engine coolant is at the correct level.
2. Start the engine and turn on the heater.
3. When the engine coolant reaches operating temperature, feel the heater core outlet hose to see if it is hot.
If it is not hot:
zthe heater core may have an air pocket.
z the heater core may be plugged.
z the thermostat is not working correctly.
Heater Core— Pressure Test
Use the radiator/heater core pressure tester to carry out the pressure test. 1. NOTE: Due to space limitations, a bench test may be necessary for pressure testing.
Drain the coolant from the cooling system. For additional information, refer to Section 303 - 03A
or
Section 303 - 03B .
2. Disconnect the heater water hoses from the heater core. For additional information, refer to Klj . 37 ba
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GENERAL PROCEDURES
Air Conditioning (A/C) System Check —
Retail Procedure
NOTE: This Retail Procedure is not eligible for claiming on Ford paid repairs (warranty and ESP).
NOTE: The engine should be run at idle for 10 minutes with the air conditioning on and set to MAX A/C
before carrying out this retail procedure.
NOTE: Read and follow all of the Warnings, Cautions and Notes at the beginning of this section before
continuing.
1. Visual inspection
Open the hood and visually inspect the heating and air conditioning systems for the following:
zCoolant reservoir for correct coolant level
z Heater hoses for deterioration or loose connections
z Radiator and condenser for debris or damaged fins restricting airflow, loose mounting or
connections
z Accessory drive belt(s) and cooling fan(s) for wear or physical damage
z Refrigerant lines and connections for physical damage or loose connections
z Compressor for physical damage or loose connections
z Suction accumulator/drier for physical damage or loose connections
z Wiring and connectors for excessive wear, loose or damaged connections, or incorrect
routing
2. A/C refrigerant analysis
zCarry out air conditioning refrigerant analysis. For additional information, refer to
Refrigerant Identification Testing in this section.
z If the refrigerant fails the analysis, discontinue diagnosis and make recommendations for
repairs.
z If the refrigerant passes the analysis, carry out the air conditioning system check.
3. Air conditioning system check
zConnect manifold gauge set or charging station with gauges to refrigerant system.
z With the vehicle in park, parking brake set, thermometer installed in center panel vent,
and air conditioning system on and set to MAX A/C, start the engine.
z Record air refrigerant system pressures while running the engine at 1,500 rpm and allow
engine to return to idle.
z Operate the blower motor in all control positions and check for correct blower speed
changes.
z With the blower motor on HI, operate air discharge mode selector in all positions and
check for correct airflow in each position.
z Operate the temperature blend selector in all positions and check for correct change in
discharge temperature. Check the air discharge temperature with the selector in the
coolest position and the air conditioning on and set to MAX A/C to determine if the air
discharge temperature is acceptable for the current ambient air temperature.
z Carry out the EATC self- test (if applicable).
If the refrigerant system pressures were low, carry out the refrigerant system leak test.
SECTION 412-
00: Climate Control System - General Information 2003 Mustang Workshop Manual Klj . 1 ba
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