warning FORD MUSTANG 2003 Workshop Manual

GENERAL PROCEDURES
Heater Hose Coupling
Disconnect
CAUTION: Do not attempt to install a new bushing, spacer or O- rings in the heater hose
coupling; damage to the heater hose coupling can result. If the heater hose coupling is the
cause of a coolant leak, the affected heater hose must be replaced as an assembly.
1. WARNING: The engine must be off, fully cool and the cooling system fully
depressurized before attempting to disconnect any heater water hoses. Failure to comply
with this warning can result in serious injury or burns from hot liquid escaping out of the
engine cooling system.
Depressurize the engine cooling system.
2. Push the heater hose toward the tube to fully expose the locking tabs.
3. NOTE: When compressing the white coupling retainer with the special tool, the special tool
must be perpendicular to and on the highest point of the coupling.
NOTE: If the heater hose coupling is accessible, the retainer tabs can be compressed by hand
to disconnect the heater hose.
Push the special tool over the coupling retainer windows to compress the retainer locking tabs.
SECTION 412-
00: Climate Control System - General Information 2003 Mustang Workshop Manual Special Tool(s)
Remover, Heater Hose Inlet
Tube
412-
042 (T85T-18539- AH) Disconnect Tool, Heater Hose
412-
127
Material Item Specification
MERPOL®
—
ESE-
M99B144- B Klj . 1 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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GENERAL PROCEDURES
Vacuum Hose Repair —
Mini-Tube
1. Measure the length of the damaged area of the mini-tube vacuum hose.
2. Cut a piece of standard 1/8 inch inner diameter vacuum hose approximately 25 mm (1 inch longer than the damaged area of the mini- tube vacuum hose).
3. Cut off the mini-tube vacuum hose on each side of the damaged area.
4. WARNING: Read the warning information on the product label to prevent possible
personal injury.
Dip the mini- tube hose ends in commercially available paint thinner containing methyl ethyl
ketone (MEK). This solvent will seal the mini- tube in the vacuum hose.
5. Insert the ends of the mini- tube vacuum hose approximately 9 mm (3/8 inch) into the ends of
the standard 1/8 inch repair vacuum hose section.
6. Shake the repair joint after assembly to make sure the solvent is dispersed and the vacuum line is not plugged.
7. Test the system for a vacuum leak in the repair area. zUse the Vacuum Tester or equivalent.
SECTION 412-
00: Climate Control System - General Information 2003 Mustang Workshop Manual Special Tool(s)
Vacuum Pump Kit
416-
D002 (D95L-7559- A) or
equivalent Klj . 1 ba
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DESCRIPTION AND OPERATION
Instrument Cluster
The instrument cluster (10849) consists of the following components:
Instrument Cluster—
Base 3.8L Engine
SECTION 413-
01: Instrument Cluster 2003 Mustang Workshop Manual Item Part
Number Description
1 — Fuel gauge
2 — Engine coolant temperature gauge
3 — Speedometer
4 — Turn signal/hazard indicator
5 — High beam indicator
6 — Tachometer
7 — Odometer
8 — Trip odometer reset button
9 — Voltmeter gauge
10 — Oil pressure gauge
11 — CHECK FUEL CAP indicator
12 — BRAKE warning indicator
13 — ABS warning indicator
14 — Traction control indicator
15 — Overdrive off (O/D OFF) indicator (automatic Klj . 1 ba
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Instrument Cluster—
Base 4.6L Engine transmission)
16 — LOW FUEL level indicator
17 — SERVICE ENGINE SOON indicator
18 — THEFT indicator
19 — AIR BAG warning indicator
20 — Charging system indicator
21 — Safety belt warning indicator
Item Part
Number Description
1 — Fuel gauge
2 — Engine coolant temperature gauge
3 — Speedometer
4 — Turn signal/hazard indicator
5 — High beam indicator
6 — Tachometer
7 — Odometer
8 — Trip odometer reset button
9 — Voltmeter gauge
10 — Oil pressure gauge
11 — CHECK FUEL CAP indicator
12 — BRAKE warning indicator
13 — ABS warning indicator Klj . 2 ba
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Instrument Cluster—
Cobra 14 — Traction control indicator
15 — Overdrive off (O/D OFF) indicator (automatic
transmission)
16 — LOW FUEL level indicator
17 — SERVICE ENGINE SOON indicator
18 — THEFT indicator
19 — AIR BAG warning indicator
20 — Charging system indicator
21 — Safety belt warning indicator
Item Part
Number Description
1 — Fuel gauge
2 — Engine coolant temperature gauge
3 — Speedometer
4 — Turn signal/hazard indicator
5 — High beam indicator
6 — Tachometer
7 — Odometer
8 — Trip odometer reset button
9 — Boost gauge
10 — Oil pressure gauge
11 — CHECK FUEL CAP indicator
12 — BRAKE warning indicator Klj . 3 ba
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13 — ABS warning indicator
14 — Traction control indicator
15 — Overdrive off (O/D OFF) indicator (automatic
transmission)
16 — LOW FUEL level indicator
17 — SERVICE ENGINE SOON indicator
18 — THEFT indicator
19 — AIR BAG warning indicator
20 — Charging system indicator
21 — Safety belt warning indicator Klj . 4 ba
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DIAGNOSIS AND TESTING
Instrument Cluster
Refer to Wiring Diagrams Cell
60 , Instrument Cluster for schematic and connector information.
Principles of Operation
NOTE: A new instrument cluster must be reconfigured. Refer to Section 418 - 01 .
The instrument cluster is a hybrid electronic cluster (HEC). The instrument cluster uses both hardwired
and the standard corporate protocol (SCP) communication network to transmit and receive
information. As a technician it is very important to understand:
zwhere the input originates from.
z all information necessary in order for a feature to operate.
z which module(s) receive(s) the input or command message.
z does the module which received the input control the output of the feature, or does it output a
message over the SCP network to another module?
z which module controls the output of the feature.
The instrument cluster carries out a display prove- out to verify that the warning/indicator miniature
bulbs for monitored systems are functioning correctly. When the ignition switch is in the ON position
with the engine off, the following warning indicators will prove out:
zanti- lock brake (ABS) warning indicator
SECTION 413-
01: Instrument Cluster 2003 Mustang Workshop Manual Special Tool(s)
Worldwide Diagnostic System
(WDS)
418-
F224,
New Generation STAR (NGS)
Tester
418- F052, or equivalent
diagnostic tool Instrument Gauge System
Tester
014-
R1063 or equivalent 73III Automotive Meter
105-
R0057 or equivalent Klj . 1 ba
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z
air bag warning indicator
z BRAKE warning indicator
z charging system indicator
z fail safe cooling warning indicator
z low coolant level indicator
z low fuel warning indicator
z traction control indicator
Instrument Cluster Replacement
When it is necessary to install a new instrument cluster, contact the Instrument Cluster Program.
Gauge Indication Systems
Tachometer
Engine rpm information is relayed to the instrument cluster from the powertrain control module (PCM)
over the standard corporate protocol (SCP) network.
Speedometer
The instrument cluster receives the vehicle speed signal from the PCM over the SCP network and
displays it on the speedometer gauge. If the instrument cluster receives no vehicle speed signal after
one second, the speedometer defaults to 0.0 km/h (0.0 mph).
Odometer
The instrument cluster receives an odometer message from the PCM and stores the mileage in
memory. When the instrument cluster fails to receive the odometer message for more than two
seconds, the odometer will display dashes.
Fuel Gauge
The fuel sender is hardwired to the fuel gauge. When the instrument cluster fails to receive the fuel
level signal for more than 33 seconds, the fuel level gauge will move below E (empty). If the fuel level
signal operates correctly for more than 33 seconds, the fuel gauge will return to the correct position.
Fuel fills of less than 9.5 liters (2.5 gallons) require at least 10 minutes to update the fuel gauge
indication.
Engine Coolant Temperature Gauge
Engine coolant temperature information is received by the instrument cluster from the PCM over the
SCP network. Engine coolant temperatures above 121°C (250°F) will cause the gauge to indicate
above the normal band. If the engine coolant temperature information is missing or invalid for five
seconds, the temperature gauge will indicate below the cold (C) position.
Voltage Gauge (except Cobra)
The voltage gauge displays the system voltage as measured at the instrument cluster run input. Boost Gauge (Cobra only) Klj . 2 ba
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The boost pressure gauge on the instrument cluster receives and measures the boost pressure
directly from the intake manifold. The boost pressure gauge will display between 0.0-
0.48 kpa (0.0-10
psi) boost pressure dependent upon accelerator position, engine load, and engine rpm.
LOW FUEL Level Indicator
The low fuel level indicator is hardwired from the fuel sender to the instrument cluster. The instrument
cluster will illuminate the low fuel indicator when the usable fuel quantity is less than 1/8 tank (15%) of
fuel tank capacity.
Oil Pressure Gauge
The oil pressure gauge is hardwired from the oil pressure switch to the instrument cluster. The oil
pressure gauge will indicate either normal or no oil pressure.
CHECK FUEL CAP
The CHECK FUEL CAP indicator is used to indicate significant leaks in the fuel tank evaporative
system due to a loose fuel cap. Fuel tank pressure is monitored by the PCM. If a leak is detected the
PCM signals a fault to the instrument cluster via the SCP network. Once the PCM has detected a
loose fuel cap and the CHECK FUEL CAP indicator is illuminated, the indicator will remain illuminated
until the fuel cap is secured and the vehicle has been running for several minutes. For additional
information, refer to the Powertrain Control/Emissions Diagnosis (PC/ED) manual.
BRAKE Warning Indicator
The BRAKE warning indicator activates when the generic electronic module (GEM) detects the ignition
switch circuits are in the RUN state, when the GEM detects low brake fluid level, or that the parking
brake is applied. The BRAKE warning indicator will prove out starting when the GEM detects that the
ignition circuits have made a transition to RUN or START from OFF, ACC, or keyout and ending when
either three seconds have elapsed or when the GEM detects the ignition circuits have made a
transition to OFF, ACC, or keyout.
Safety Belt Warning Indicator
The safety belt switch is hardwired to the GEM. The safety belt warning indicator will be illuminated
when the GEM sends a ground signal to the instrument cluster.
ABS Warning Indicator
The ABS warning indicator will be illuminated when the anti- lock brake control module sends a ground
signal to the instrument cluster. The prove- out of the ABS indicator is controlled by the anti- lock brake
control module.
SERVICE ENGINE SOON Indicator
The SERVICE ENGINE SOON indicator receives its signal from the PCM over the SCP network. If the
instrument cluster does not receive a message from the PCM within five seconds, the instrument
cluster will illuminate the SERVICE ENGINE SOON indicator and log a diagnostic trouble code (DTC).
High Beam Indicator
The high beam indicator will illuminate when the steering column multifunction switch is in the high
beam position by sending a battery signal to the instrument cluster. Right and Left Turn Indicator Klj . 3 ba
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