air condition FORD MUSTANG 2003 Workshop Manual

z
Is the voltage greater than 10 volts? B14 CHECK CIRCUIT 646 (YE/WH) FOR SHORT TO
GROUND BETWEEN GEM AND BJB z
Measure the resistance between GEM C201d Pin 12,
Circuit 646 (YE/WH), harness side and ground.
z Is the resistance greater than 10,000 ohms? Yes
GO to
B15 .
No
REPAIR Circuit 646
(YE/WH). REPEAT the self-
test. CLEAR the DTCs. B15 CHECK CIRCUIT 646 (YE/WH) FOR OPEN BETWEEN
GEM AND BJB z
Measure the resistance between GEM C201d Pin 12,
Circuit 646 (YE/WH), harness side and BJB wiper ON/OFF
relay Pin 1, Circuit 646 (YE/WH), harness side.
z Is the resistance less than 5 ohms? Yes
INSTALL a new GEM. For
additional information REFER
to
Section 419 - 10 . REPEAT
the self- test. CLEAR the
DTCs.
No
REPAIR Circuit 646
(YE/WH). REPEAT the self-
test. CLEAR the DTCs. B16 CHECK CIRCUITS 65 (DG) AND 61 (YE/RD) FOR OPEN
CONDITION BETWEEN BJB AND CJB z
Disconnect: Wiper HIGH/LOW Relay.
z Trigger the GEM active command WIPER RLY to ON.
z Measure the voltages between BJB wiper HIGH/LOW
relay Pin 86, Circuit 65 (DG), harness side and ground;
and between BJB wiper HIGH/LOW relay Pin 30, Circuit
61 (YE/RD), harness side and ground.
z Are the voltages greater than 10 volts? Yes
GO to
B17 .
No
REPAIR circuit in question.
REPEAT the self- test.
CLEAR the DTCs. B17 ISOLATE THE PROBLEM BETWEEN THE GEM AND
THE BJB z
Trigger the GEM active command WIPER RLY to ON. Yes Klj . 11 ba
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z
Is the resistance greater than 10,000 ohms? B21 CHECK CIRCUIT 647 (GY/LB) FOR OPEN CONDITION
BETWEEN GEM AND BJB z
Measure the resistance between GEM C201d Pin 5,
Circuit 647 (GY/LB), harness side and wiper HIGH/LOW
relay Pin 85, Circuit 647 (GY/LB), harness side.
z Is the resistance less than 5 ohms? Yes
INSTALL a new GEM.
REFER to
Section 419 - 10 .
REPEAT the self- test.
CLEAR the DTCs.
No
REPAIR Circuit 647 (GY/LB).
REPEAT the self- test.
CLEAR the DTCs. B22 CHECK CIRCUIT 61 (YE/RD) FOR OPEN CIRCUIT
CONDITION BETWEEN WIPER ON/OFF AND HIGH/LOW
RELAYS z
Disconnect: Wiper HIGH/LOW Relay.
z Disconnect: Wiper ON/OFF Relay.
z Measure the resistance between wiper ON/OFF relay Pin
3, Circuit 61 (YE/RD), harness side and wiper HIGH/LOW
relay Pin 30, Circuit 61 (YE/RD), harness side.
z Is the resistance less than 5 ohms? Yes
GO to
B23 .
No
REPAIR Circuit 61 (YE/RD).
REPEAT the self- test.
CLEAR the DTCs. B23 CARRY OUT THE WIPER HIGH/LOW RELAY
COMPONENT TEST z
Check the wiper HIGH/LOW relay; refer to Wiring
Diagrams, Cell 149, Component Testing.
z Is the wiper HIGH/LOW relay OK? Yes
GO to
B24 .
No
INSTALL a new wiper
HIGH/LOW relay. REPEAT
the self- test. CLEAR the Klj . 13 ba
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DTCs.
B24 CHECK CIRCUIT 56 (DB/OG) FOR AN OPEN CIRCUIT
BETWEEN THE WIPER HIGH/LOW RELAY AND THE WIPER
MOTOR z
Disconnect: Wiper Motor C125.
z Measure the resistance between wiper HIGH/LOW relay
Pin 87A, Circuit 56 (DB/OG), harness side and wiper
motor C125 Pin 4, Circuit 56 (DB/OG), harness side.
z Is the resistance less than 5 ohms? Yes
GO to
B25 .
No
REPAIR Circuit 56 (DB/OG).
REPEAT the self- test.
CLEAR the DTCs. B25 CHECK CIRCUIT 1205 (BK) FOR OPEN CIRCUIT
CONDITION BETWEEN WIPER MOTOR AND GROUND z
Measure the resistance between wiper motor C125 Pin 3,
Circuit 1205 (BK), harness side and ground.
z Is the resistance less than 5 ohms? Yes
CARRY OUT the windshield
wiper motor component test.
REFER to Component Test.
If the component fails,
INSTALL a new wiper motor;
REFER to
Motor — Windshield
Wiper . REPEAT the self-
test.
CLEAR the DTCs.
No
REPAIR Circuit 1205 (BK).
REPEAT the self- test.
CLEAR the DTCs. B26 CHECK CIRCUIT 58 (WH) FOR AN OPEN CIRCUIT
BETWEEN THE WIPER HIGH/LOW RELAY AND THE WIPER
MOTOR z
Disconnect: Wiper Motor C125.
z Measure the resistance between wiper motor C125 Pin 5,
Circuit 58 (WH), harness side and wiper HIGH/LOW relay
Pin 87, Circuit 58 (WH), harness side.
z Is the resistance less than 5 ohms? Yes
CARRY OUT the windshield
wiper motor component test.
REFER to Component Test.
If the component fails,
INSTALL a new wiper motor;
REFER to
Motor — Windshield
Wiper . REPEAT the self-
test.
CLEAR the DTCs.
No
REPAIR Circuit 58 (WH).
REPEAT the self- test.
CLEAR the DTCs. B27 CHECK CIRCUIT 28 (BK/PK) FOR OPEN CIRCUIT
CONDITION BETWEEN THE WIPER HIGH/LOW RELAY AND
THE WIPER MOTOR Klj . 14 ba
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Symptom Chart
PINPOINT TEST A: THE CONVERTIBLE TOP DOES NOT
RAISE/LOWER
SYMPTOM CHART Condition
Possible Sources Action
z The convertible top does not
raise/lower z
Convertible top
switch.
z Central junction box
(CJB) Fuse 20 (15A).
z Parking brake switch.
z Lower relay.
z Raise relay.
z Circuitry. z
Go To Pinpoint Test
A .
z The convertible top
hesitates/comes up uneven z
Convertible top
adjustment.
z Hydraulic lift
cylinders.
z Hydraulic system. z
Go To Pinpoint Test
B .
z The convertible top does not
raise or does not go up all the
way z
Convertible top
adjustment.
z Hydraulic lift
cylinders.
z Hydraulic system. z
Go To Pinpoint Test
C .
z The convertible top hydraulic
system z
Convertible top
adjustment.
z Hydraulic lift
cylinders.
z Hydraulic motor/pump
assembly.
z Hydraulic system. z
Go To Pinpoint Test
D .
Test Step Result / Action to
Take A1 CHECK THE CONVERTIBLE TOP OPERATION
NOTE:
The parking brake must be applied for the convertible top
system to operate.
z Key in ON position.
z Depress the convertible top switch in RAISE and LOWER
positions while listening for motor operation.
z Does the convertible top motor assembly operate in both
directions? Yes
Go To Pinpoint Test
C .
No
GO to A2 .
A2 CHECK THE POWER SUPPLY TO THE CONVERTIBLE TOP
SWITCH z
Key in OFF position.
z Disconnect: Convertible Top Switch C3115.
z Key in ON position.
z Measure the voltage between convertible top switch C3115 pin 4,
circuit 296 (WH/PK), harness side and ground. Yes
GO to
A3 .
No
REPAIR circuit 296
(WH/PK). TEST the
system for normal
operation. Klj . 2 ba
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DESCRIPTION AND OPERATION
Safety Belt System
WARNING: All safety belt assemblies include retractors, buckles, front seat belt buckle
support assemblies (slide bar, if so equipped), shoulder belt height adjuster (if equipped), child
safety seat tether bracket assemblies (if equipped) and attaching hardware should be inspected
after any collision. Ford recommends new safety belt assemblies be installed unless a qualified
technician finds the assemblies show no damage and operate correctly. Safety belt assemblies
not in use during a collision should also be inspected and new assemblies installed if either
damage or incorrect operation is noted.
WARNING: Each seating position in the vehicle has a specific safety belt assembly which
consists of one buckle and one tongue. The safety belt assembly is designed to be used as a
pair and is not to be used across seating positions.
A continuous- loop, single retractor active restraint system is used on this vehicle for both the front
seats and the rear seats.
Safety Belt, Lap/Shoulder— Dual Locking Mode
WARNING: Rear- facing infant seats should never be placed in the front seats. Failure to
follow these instructions may result in personal injury.
The dual locking mode retractor on the shoulder belt portion of the combination lap/shoulder safety belt
for the front seat passenger and rear seat outboard passengers operates in two ways:
1. In the vehicle- sensitive (emergency locking) mode, the shoulder belt retractor will allow the
occupant freedom of movement, locking tightly only on hard braking, hard cornering or impacts
of approximately 8 km/h (5 mph) or more. The front and rear outboard safety belt retractors can
also be made to lock by pulling/jerking on the belt.
2. In the automatic locking mode, the shoulder belt retractor locks automatically and remains locked when the combination lap/shoulder safety belt is buckled, restricting occupant
movement. This mode provides tight lap/shoulder belt fit on the occupant and on a child safety
seat or infant carrier installation restraint.
When the combination lap/shoulder belt is unbuckled and allowed to retract completely, the retractor
switches to the vehicle sensitive (emergency) locking mode.
The automatic locking mode must be used when installing a child safety seat on the front passenger
seat and rear outboard seats where dual locking retractors are provided.
Safety Belt Warning System
The safety belt warning indicator illuminates and a chime sounds to remind the occupants to fasten
their safety belts.
The conditions of operation for the safety belt warning indicator and chime are as follows:
zIf the driver safety belt is not buckled before the ignition switch is turned to ON, then the safety
belt warning indicator illuminates for one to two minutes and the warning chime sounds for four
to eight seconds.
SECTION 501-
20A: Safety Belt System 2003 Mustang Workshop Manual Klj . 1 ba
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DIAGNOSIS AND TESTING
Safety Belt System
Inspection and Verification
1. Verify the customer's concern by operating the active restraint system to duplicate the condition.
2. Inspect to determine if any of the following mechanical or electrical concerns apply:
3. If the inspection reveals an obvious concern(s) that can be readily identified, repair as required. With the exception of removing a twist from the safety belt webbing, do not attempt to repair a
component of the safety belt system; new components must be installed.
4. If the concern remains after the inspection, determine the symptom. GO to Symptom Chart .
Symptom Chart SECTION 501-
20A: Safety Belt System 2003 Mustang Workshop Manual Visual Inspection Chart
Mechanical Electrical
z
Inspect the safety belt webbing for
integrity. z
Open fuse.
z Bare, broken or disconnected wire.
z Connector not tightly engaged.
z Safety belt warning indicator lamp burned out or
broken.
Symptom Chart Condition
Possible Sources Action
z The safety belt warning
chime does not operate, the
safety belt warning indicator
lamp is OK z
Virtual
image
cluster
(VIC).
z Circuitry.
z Driver seat
module. z
REFER to Section 413 -
01 .
z The safety belt warning
indicator lamp does not
operate, the safety belt
warning chime is OK z
Burned- out
bulb.
z Circuitry.
z Driver seat
module. z
REFER to Section 413 -
01 .
z Neither the safety belt
warning chime nor the
safety belt warning indicator
lamp operates z
Safety belt
buckle
switch.
z Driver seat
module. z
REFER to Section 413 -
01 . Klj . 1 ba
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current and historical DTCs through the DLC, using a scan tool. If the air bag indicator does not
function, and the system detects a fault condition, the RCM will signal the GEM to activate an audible
chime. The chime is a series of five sets of five tone bursts. If the chime is heard, the SRS and the air
bag indicator require repair.
LFCs are prioritized. If two or more faults occur at the same time, the fault having the highest priority
will be displayed. After that fault has been corrected, the next highest priority fault will be displayed.
The RCM includes a backup power supply. This feature provides sufficient backup power to deploy the
air bags in the event that the ignition circuit is damaged in a collision before the safing and air bag
sensors determine that deployment is required. The backup power supply will deplete its stored energy
approximately one minute after the battery ground cable is disconnected.
Electrical System
The electrical system that supports the air bag supplemental restraint system (SRS):
zis powered from the battery through the ignition circuit.
z provides the electrical path from the restraints control module (RCM) to the air bag modules.
z provides the electrical path from the RCM to the air bag indicator.
z provides the electrical path from the RCM to the data link connector (DLC).
z provides the electrical path from the RCM to the generic electronic module (GEM).
Sensor WARNING: The restraints control module (RCM) orientation is critical for proper system
operation. If a vehicle equipped with an air bag supplemental restraint system (SRS) has been
involved in a collision in which the center tunnel area has been damaged, inspect the mounting
and bracket for deformation. If damaged, the RCM must be replaced whether or not the air bags
have deployed. In addition, make sure the area of the RCM mounting is restored to its original
condition.
The SRS contains two sensors which are integral to the RCM. The RCM is mounted on the center
tunnel under the instrument panel. Klj . 3 ba
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a
DTC: Diagnostic Trouble Code, retrieved using a scan tool.
b LFC: Lamp fault code, flashed on air bag indicator.
c Tone will sound only if additional DTCs are present.
Inspection and Verification 1. Verify the customer concern by checking the air bag indicator in the instrument cluster. Refer to Prove Out the System in this section.
2. Visually inspect for obvious signs of mechanical and electrical damage using the following chart:
3. If the concern is not visually evident, use the scan tool to retrieve diagnostic trouble codes (DTCs) and perform the on- demand self test.
4. WARNING: The restraint system diagnostic tool is for restraint system service only.
Remove from vehicle prior to road use. Failure to remove could result in injury and
possible violation of vehicle safety standards.
If the on- demand self test is passed and no DTCs are retrieved, GO to Symptom Chart .
5. If DTCs are retrieved, proceed to the Restraints Control Module (RCM) Diagnostic Trouble Code (DTC) Priority Table.
Symptom Chart — — — No Communication with the Restraints Control Module Go To Pinpoint
Test P .
Visual Inspection Chart Mechanical Electrical
z
Damaged restraints control module (RCM) bracket z
Open fuse(s)
z Damaged wiring harness
z Loose or corroded connectors
z Circuitry open/shorted Symptom Chart
Condition
Possible Sources Action
z Air bag warning indicator is
illuminated continuously z
Circuitry.
z Worn or damaged
connector component.
z RCM.
z Instrument cluster. z
Go To Pinpoint Test A .
z Air bag indicator flashing zAir bag SRS system
fault. z
REFER to DTC
Priority Table.
z Audible tone — DTCs
retrieved z
Air bag SRS system
fault. z
Go To Pinpoint Test N .
z Go To Pinpoint Test O .
z No communication with the zScan Tool. zGo To Pinpoint Klj . 4 ba
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Pinpoint Test B: LFC 21/DTC B1921 —
RCM Bracket Ground Resistance High
Normal Operation
WARNING: The tightening torque of the restraints control module (RCM) retaining bolts is
critical for proper air bag supplemental restraint system (SRS) operation. Refer to Restraints Control Module (RCM) in this section for correct torque values.
The restraints control module (RCM) monitors the resistance between the ground connections at its
housing and the reference ground at pin 21. If the RCM detects a resistance greater than 100 ohms, it
will store a diagnostic trouble code (DTC) B1921 in memory and flash a lamp fault code (LFC) 21 (or
higher priority code if one exists) on the air bag indicator.
Possible Causes
High resistance between the RCM housing ground and pin ground can be caused by:
zincorrect seating of the RCM retaining bolts.
z incorrect tightening torque of the RCM retaining bolts.
z high resistance on RCM logic ground circuit 397 (BK/WH).
PINPOINT TEST B: LFC 21/DTC B1921 — RCM BRACKET GROUND
RESISTANCE HIGH section for
pinpoint test
direction.
No
RECONNECT the
system.
REACTIVATE the
system. PROVE
OUT the system.
REFER to
Air Bag Supplemental
Restraint System
(SRS) in this
section. CLEAR all
DTCs. Test Step Result / Action to Take
B1 CHECK FOR A HARD OR INTERMITTENT DTC
z
Key in OFF position.
z Connect the diagnostic tool. Scan Tool
z Key in ON position.
z Enter the following diagnostic mode on the diagnostic tool:
Retrieve/Clear Continuous DTCs.
z Retrieve and record any continuous DTCs for use later in
this pinpoint test.
z Enter the following diagnostic mode on the diagnostic tool:
On- Demand Self Test.
z Was DTC B1921 retrieved during the on- demand self Yes
This is a hard fault. The fault
condition is still present. This
fault cannot be cleared until it
is corrected and the DTC is
no longer retrieved during the
on-demand self test. GO to
B2 .
No Klj . 5 ba
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test? This is an intermittent fault.
The fault condition is not
present at this time. GO to
B6
.
B2 INSPECT THE RCM MOUNTING, MOUNTING BRACKET
AND MOUNTING SURFACE z
Remove the RCM. Refer to Restraints Control Module (RCM) in the Removal and Installation portion of this
section.
z Visually inspect the RCM, mounting bracket and mounting
surface for damage, corrosion or dirt.
z Inspect the RCM mounting and make sure that the
retaining bolts are fully seated and tightened correctly.
Refer to Restraints Control Module (RCM) in the Removal
and Installation portion of this section for correct tightening
torque.
z Was a significant amount of corrosion or dirt found,
the RCM mounting bracket attached to the mounting
surface incorrectly or were the three RCM retaining
bolts not fully seated and tightened correctly? Yes
Make sure the RCM,
mounting bracket and
mounting surface are free of
damage, corrosion or dirt and
the three retaining bolts are
fully seated and correctly
tightened. Reattach the RCM
and mounting bracket to the
mounting surface. GO to
B7 .
No
GO to B3 .
B3 CHECK THE RCM HARNESS CONNECTION
z
Check the RCM harness connection.
z Is the RCM harness connector connected to the RCM
correctly? Yes
GO to
B4 .
No
ATTACH the RCM harness
connector correctly. GO to
B7 .
B4 CHECK THE VEHICLE CHASSIS GROUND
z
Measure the resistance between a known good chassis
ground and the mounting surface of the RCM.
z Is the resistance greater than 100 ohms? Yes
REPAIR the chassis
grounding system. GO to
B7 .
No
GO to B5 .
B5 CHECK THE GROUND CIRCUIT 397 (BK/WH) FOR AN
OPEN z
Key in OFF position.
z Disconnect: RCM C2041.
z Measure the resistance between RCM C2041 pin 21,
circuit 397 (BK/WH), harness side and a sheet metal
ground near the RCM.
z Is the resistance greater than 100 ohms? Yes
REPAIR the circuit. GO to
B7
.
No
INSTALL a new RCM. GO to
B7 .
B6 CHECK FOR AN INTERMITTENT FAULT
z
Refer to the continuous DTCs recorded during Step B1. Yes Klj . 6 ba
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