gas type FORD MUSTANG 2003 User Guide

CAUTION: Vehicle cooling systems are filled with Motorcraft Premium Gold Engine
Coolant VC -7-A (in Oregon VC -7-B) or equivalent meeting Ford specification WSS- M97B51-A1
(yellow color). Always fill the cooling system with the same coolant that is present in the
system. Do not mix coolant types.
CAUTION: Engine coolant provides freeze protection, boil protection, cooling efficiency,
and corrosion protection to the engine and cooling components. In order to obtain these
protections, the engine coolant must be maintained at the correct concentration and fluid level
in the degas bottle.
When adding engine coolant, use a 50/50 mixture of engine coolant and deionized water.
To maintain the integrity of the coolant and the cooling system:
zAdd Motorcraft Premium Gold Engine Coolant VC -7-A (in Oregon VC -7-B) or equivalent
meeting Ford specification WSS- M97B51-A1 (yellow color). Use the same coolant that
was drained from the cooling system. Do not mix coolant types.
z Do not add/mix orange- colored Motorcraft Speciality Orange Engine Coolant VC- 2 or
equivalent meeting Ford specification WSS- M97B44-D. Mixing coolants may degrade the
coolant's corrosion protection.
z Do not add alcohol, methanol, or brine, or any engine coolants mixed with alcohol or
methanol antifreeze. These can cause engine damage from overheating or freezing.
z Do not mix with recycled coolant unless it meets the requirements of Ford specification
WSS- M97B51- A1. Not all coolant recycling processes meet these Ford specifications.
Use of such coolants can harm the engine and cooling system components.
NOTE: The addition of Motorcraft Cooling System Stop Leak Pellets, VC- 6, darkens Motorcraft
Premium Gold Engine Coolant from yellow to golden tan.
1. Remove the thermostat. For additional information, refer to Thermostat — 4.6L(2V) in this
section.
2. Disconnect the heater core coolant supply hose from the fitting at the rear of the manifold.
3. Add the coolant/water mixture through the thermostat opening until coolant appears at the heater core coolant supply outlet fitting at the rear of the manifold.
4. Install the heater hose, using an appropriately sized worm style clamp in place of the constant tension clamp.
5. Reinstall the thermostat gasket (O- ring) and the thermostat. For additional information, refer to
Thermostat — 4.6L(2V) in this section.
6. Add the correct engine coolant mixture to the degas bottle until the coolant level is between the Klj . 3 ba
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"COOLANT FILL LEVEL" marks and replace the pressure cap.
7. Select the maximum cool temperature setting.
8. Run the engine until it reaches operating temperature.
9. CAUTION: If the engine coolant temperature gauge does not move, the engine
coolant level in the engine is low and must be filled. Stop the engine, allow it to cool and
fill the cooling system.
Add the correct engine coolant mixture to the degas bottle until the coolant level is between the
"COOLANT FILL LEVEL" marks.
10. Repeat the two previous steps until the engine coolant mixture is between the "COOLANT FILL LEVEL" marks on the degas bottle. Turn off the engine and allow it to cool.
11. Check the freeze protection of the engine coolant mixture with the Battery/Anti- freeze Tester
014- R1060 or equivalent. Adjust freezing point range if necessary.
Filling — Cobra
CAUTION: Vehicle cooling systems are filled with Motorcraft Premium Gold Engine
Coolant VC -7-A (in Oregon VC -7-B) or equivalent meeting Ford specification WSS- M97B51-A1
(yellow color). Always fill the cooling system with the same coolant that is present in the
system. Do not mix coolant types.
CAUTION: Engine coolant provides freeze protection, boil protection, cooling efficiency,
and corrosion protection to the engine and cooling components. In order to obtain these
protections, the engine coolant must be maintained at the correct concentration and fluid level
in the degas bottle.
When adding engine coolant, use a 50/50 mixture of engine coolant and deionized water.
To maintain the integrity of the coolant and the cooling system:
zAdd Motorcraft Premium Gold Engine Coolant VC -7-A (in Oregon VC -7-B) or equivalent
meeting Ford specification WSS- M97B51-A1 (yellow color). Use the same coolant that
was drained from the cooling system. Do not mix coolant types.
z Do not add/mix orange- colored Motorcraft Speciality Orange Engine Coolant VC- 2 or
equivalent meeting Ford specification WSS- M97B44-D. Mixing coolants may degrade the
coolant's corrosion protection.
z Do not add alcohol, methanol, or brine, or any engine coolants mixed with alcohol or
methanol antifreeze. These can cause engine damage from overheating or freezing.
z Do not mix with recycled coolant unless it meets the requirements of Ford specification
WSS- M97B51- A1. Not all coolant recycling processes meet these Ford specifications.
Use of such coolants can harm the engine and cooling system components.
NOTE: The addition of Motorcraft Cooling System Stop Leak Pellets, VC- 6, darkens Motorcraft
Premium Gold Engine Coolant from yellow to golden tan.
1. Check all hose clamps for correct tightness. Make sure the radiator draincock is closed.
2. Place the heater temperature selector in maximum cool position. Klj . 4 ba
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3. Remove the pressure cap from the cooling system reservoir and the fill plug from the engine
crossover tube.
4. CAUTION: Do not fill the cooling system through the reservoir only. Coolant will not
enter the engine. Only the reservoir and the radiator will be filled and engine overheating
will occur.
Add coolant into the fill neck on the engine crossover tube until coolant reaches the top of the fill
neck on the cooling system reservoir.
5. Install the cooling system pressure cap on the reservoir.
6. Continue to fill the cooling system at the engine crossover fill neck until full.
7. Install the engine crossover tube fill plug.
8. WARNING: To avoid the possibility of personal injury or damage to the vehicle, do
not operate the engine with the hood open until the fan has been first examined for
possible cracks and separation.
CAUTION: If the engine temperature gauge does not move, coolant level is low in
the engine and must be filled. Stop the engine, allow to cool, and fill the cooling system
as outlined.
Run the engine until the thermostat opens (coolant flowing through the radiator lower hose
becomes hot).
9. Stop the engine and allow to cool.
10. Add coolant to the engine crossover tube fill neck until the cooling system is full.
11. Install the fill plug.
12. Repeat the fill procedure if necessary.
Filling — Mach I
CAUTION: Vehicle cooling systems are filled with Motorcraft Premium Gold Engine
Coolant VC -7-A (in Oregon VC -7-B) or equivalent meeting Ford specification WSS- M97B51-A1
(yellow color). Always fill the cooling system with the same coolant that is present in the
system. Do not mix coolant types.
CAUTION: Engine coolant provides freeze protection, boil protection, cooling efficiency,
and corrosion protection to the engine and cooling components. In order to obtain these
protections, the engine coolant must be maintained at the correct concentration and fluid level
in the degas bottle.
When adding engine coolant, use a 50/50 mixture of engine coolant and deionized water.
To maintain the integrity of the coolant and the cooling system:
zAdd Motorcraft Premium Gold Engine Coolant VC -7-A (in Oregon VC -7-B) or equivalent
meeting Ford specification WSS- M97B51-A1 (yellow color). Use the same coolant that Klj . 5 ba
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SPECIFICATIONS
a
Use the same type coolant that was drained from the cooling system. Do not mix coolant types.
b The addition of Motorcraft Cooling System Stop Leak Pellets, VC- 6, darkens Motorcraft Premium
Gold Engine Coolant from yellow to golden tan. SECTION 303-
03B: Supercharger Cooling 2003 Mustang Workshop Manual General Specifications
Item Specification
Cooling System Capacity
System capacity L (qts) 3.75 (4.0)
Coolant Type
Motorcraft Premium Engine Coolant VC-4-
A (CXC-10 in
Canada, VC- 5 in Oregon) a ESE-
M97B44- A Motorcraft Premium Gold Engine Coolant VC-7-
A (in
Oregon VC-7- B)
a b WSS-
M97B51- A1 Other Chemicals
Premium Cooling System Flush VC-
1 ESR-
M14P7-A Premium Long Life Grease XG-1-
C ESA-
M1C75- B Cooling System Stop Leak Pellets
VC-
6 ESE-
M99B37- 5 except as noted in ES-
F65E-19A511- AA Cooling System Pressure Test Specifications
System (radiator) kPa (psi) 138 (20)
System (intercooler) kPa (psi) 138 (20)
Cap (relief opening pressure)
kPa (psi) 69 (10)
Torque Specifications Description Nm lb-
ft lb-
in Water pump bolts 20 — 15
Dropping resistor screw 6 53 —
Degas bottle bolt 10 89 —
Intercooler radiator support bracket-
to-bumper bolts 12 — 9
Intercooler radiator support bracket bolts 10 89 — Klj . 1 ba
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DESCRIPTION AND OPERATION
Supercharger Cooling
CAUTION: Some vehicle cooling systems are filled with Motorcraft Premium Engine
Coolant VC -4-A (in Oregon VC- 5, in Canada CXC- 10) or equivalent meeting Ford specification
ESE- M97B44- A (green color). Others are filled with Motorcraft Premium Gold Engine Coolant
VC -7-A or equivalent meeting Ford specification WSS- M97B51-A1 (yellow color). Always fill the
cooling system with the same coolant that is present in the system. Do not mix coolant types.
NOTE: The addition of Motorcraft Cooling System Stop Leak Pellets, VC- 6, darkens Motorcraft
Premium Gold Engine Coolant from yellow to golden tan.
NOTE: The air that is produced from the supercharger is cooled by the intercooler.
Walter C. Avrea, the owner of patents 3,601,181 and RE 27,965, has granted Ford Motor Company
rights with respect to cooling systems covered by these patents.
The cooling system components include the:
zintercooler
z intercooler radiator (8K226)
z pressure relief cap
z degas bottle
z electric water pump (8501)
The degas bottle:
zprovides a location for system fill.
z contains coolant expansion and system pressurization.
z provides air separation during operation.
z replenishes the intercooler coolant to the system.
The intercooler coolant flows:
zfrom the intercooler to the degas bottle.
z from the degas bottle to the water pump.
z from the water pump to the intercooler radiator.
z from the intercooler radiator to the intercooler.
Engine coolant provides freeze protection, boil protection, cooling efficiency and corrosion protection to
the engine and cooling components. In order to obtain these protections, the engine coolant must be
maintained at the correct concentration and fluid level in the degas bottle.
When adding engine coolant, use a 50/50 mixture of engine coolant and clean, drinkable water.
To maintain the integrity of the coolant and the cooling system: SECTION 303-
03B: Supercharger Cooling 2003 Mustang Workshop Manual Klj . 1 ba
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CAUTION: Some vehicle cooling systems are filled with Motorcraft Premium Engine
Coolant VC -4-A (in Oregon VC- 5, in Canada CXC- 10) or equivalent meeting Ford specification
ESE- M97B44- A (green color). Others are filled with Motorcraft Premium Gold Engine Coolant
VC -7-A or equivalent meeting Ford specification WSS- M97B51-A1 (yellow color). Always fill the
cooling system with the same coolant that is present in the system. Do not mix coolant types.
NOTE: The addition of Motorcraft Cooling System Stop Leak Pellets, VC- 6, darkens Motorcraft
Premium Gold Engine Coolant from yellow to golden tan.
1. Verify the customer's concern by operating the engine 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 that can be readily identified, repair it as necessary.
4. Inspect the coolant condition. 1. WARNING: Never remove the pressure relief cap while the engine is
operating or when the cooling system is hot. Failure to follow these instructions
can result in damage to the cooling system or engine or personal injury. To avoid
having scalding hot coolant or steam blow out of the degas bottle when removing
the pressure relief cap, wait until the engine has cooled, then wrap a thick cloth
around the pressure relief cap and turn it slowly. Step back while the pressure is
released from the cooling system. When you are sure all the pressure has been
released, (still with a cloth) turn and remove the pressure relief cap.
Allow the engine to cool. Once pressure is released, remove the pressure relief cap.
2. CAUTION: Check the coolant and engine oil level and top off the coolant if
needed. If there is engine coolant in the engine oil the cause must be corrected
and oil/fluid changed or major component damage can occur.
CAUTION: Some vehicle cooling systems are filled with Motorcraft Premium
Engine Coolant VC -4-A (in Oregon VC- 5, in Canada CXC- 10) or equivalent meeting
Ford specification ESE- M97B44-A (green color). Others are filled with Motorcraft
Premium Gold Engine Coolant VC -7-A or equivalent meeting Ford specification
WSS- M97B51- A1 (yellow color). Always fill the cooling system with the same
coolant that is present in the system. Do not mix coolant types.
Inspect the coolant color:
„If Motorcraft Premium Engine Coolant (green color) VC-4- A or equivalent meeting
Ford specification ESE-M97B44- A has a clear, light green or blue color, this Visual Inspection Chart
Mechanical Electrical
z
Radiator brackets
z Leaks
z Damaged hoses
z Hose clamps
z Water pump
z Radiator
z Degas bottle
z Water pump bracket z
Damaged water pump wiring Klj . 2 ba
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GENERAL PROCEDURES
Supercharger Cooling System Draining, Filling and
Bleeding
Draining
WARNING: Never remove the pressure relief cap while the engine is operating or when the
cooling system is hot. Failure to follow these instructions can result in damage to the cooling
system or engine or personal injury. To avoid having scalding hot coolant or steam blow out of
the degas bottle when removing the pressure relief cap, wait until the engine has cooled, then
wrap a thick cloth around the pressure relief cap and turn it slowly. Step back while the
pressure is released from the cooling system. When certain all the pressure has been released,
(still with a cloth) turn and remove the pressure relief cap.
CAUTION: The coolant must be recovered in a suitable, clean container for reuse. If the
coolant is contaminated, it must be recycled or disposed of correctly and replaced.
CAUTION: Some vehicle cooling systems are filled with Motorcraft Premium Engine
Coolant VC -4-A (in Oregon VC- 5, in Canada CXC- 10) or equivalent meeting Ford specification
ESE- M97B44- A (green color). Others are filled with Motorcraft Premium Gold Engine Coolant
VC -7-A or equivalent meeting Ford specification WSS- M97B51-A1 (yellow color). Always fill the
cooling system with the same coolant that is present in the system. Do not mix coolant types.
NOTE: The addition of Motorcraft Cooling System Stop Leak Pellets, VC- 6, darkens Motorcraft
Premium Gold Engine Coolant from yellow to golden tan.
NOTE: Less than 80% of coolant capacity can be recovered with the engine in the vehicle. Dirty, rusty
or contaminated coolant requires replacement.
1. Raise and support the vehicle. For additional information, refer to Section 100 - 02 .
2. Remove the lower hose from the intercooler radiator and allow the coolant to drain.
Filling and Bleeding
CAUTION: Engine coolant provides freeze protection, boil protection, cooling efficiency
and corrosion protection to the engine and cooling components. In order to obtain these
protections, the engine coolant must be maintained at the correct concentration and fluid level
in the degas bottle.
CAUTION: Some vehicle cooling systems are filled with Motorcraft Premium Engine
Coolant VC -4-A (in Oregon VC- 5, in Canada CXC- 10) or equivalent meeting Ford specification
ESE- M97B44- A (green color). Others are filled with Motorcraft Premium Gold Engine Coolant
VC -7-A or equivalent meeting Ford specification WSS- M97B51-A1 (yellow color). Always fill the
cooling system with the same coolant that is present in the system. Do not mix coolant types.
NOTE: The addition of Motorcraft Cooling System Stop Leak Pellets, VC- 6, darkens Motorcraft
Premium Gold Engine Coolant from yellow to golden tan.
NOTE: When adding engine coolant, use a 50/50 mixture of engine coolant and clean, drinkable
water. SECTION 303-
03B: Supercharger Cooling 2003 Mustang Workshop Manual Klj . 1 ba
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1. To maintain the integrity of the coolant and the cooling system:
1. Add Motorcraft Premium Engine Coolant VC-4- A (in Oregon VC-5, in Canada CXC-10)
or equivalent meeting Ford specification ESE-M97B44- A (green color), or Motorcraft
Premium Gold Engine Coolant VC-7- A or equivalent meeting Ford specification WSS-
M97B51- A1 (yellow color). Use the same coolant that was drained from the cooling
system. Do not mix coolant types.
2. Do not add/mix orange-colored Motorcraft Speciality Orange Engine Coolant VC- 2 or
equivalent meeting Ford specification WSS-M97B44- D. Mixing coolants may degrade the
coolant's corrosion protection.
3. Do not add alcohol, methanol, brine, or any engine coolants mixed with alcohol or
methanol antifreeze. These can cause engine damage from overheating or freezing.
4. Do not mix with recycled coolant unless it meets the requirements of Ford specification ESE- M97B44- A or WSS-M97B51- A1. Not all coolant recycling processes meet these
Ford specifications. Use of such coolants can harm the engine and cooling system
components.
2. Fill the degas bottle. Use Motorcraft Premium Engine Coolant VC-4- A (in Oregon VC-5, in
Canada CXC- 10) or equivalent meeting Ford specification ESE-M97B44- A (green color), or
Motorcraft Premium Gold Engine Coolant VC-7- A or equivalent meeting Ford specification
WSS- M97B51- A1 (yellow color). Use the same coolant that was drained from the cooling
system. Do not mix coolant types.
3. Start the engine and allow to run until coolant circulation is observed in the intercooler degas bottle. Absence of circulation indicates air is trapped in the system.
zTurn the engine off.
4. Add coolant as needed. Use Motorcraft Premium Engine Coolant VC -4-A (in Oregon VC-5, in
Canada CXC- 10) or equivalent meeting Ford specification ESE-M97B44- A (green color), or
Motorcraft Premium Gold Engine Coolant VC-7- A or equivalent meeting Ford specification
WSS- M97B51- A1 (yellow color). Use the same coolant that was drained from the cooling
system. Do not mix coolant types.
5. Repeat the above procedure to make sure all entrapped air is released. Klj . 2 ba
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REMOVAL AND INSTALLATION
Throttle Body
Removal and Installation
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 ignite. Failure to follow these instructions may result in personal injury.
CAUTION: The throttle body bore and plate area have a special coating and cannot be
cleaned.
1. Remove the air cleaner outlet tube (9B659). For additional information, refer to Section 303 - 12 .
2. Disconnect the throttle position (TP) sensor electrical connector.
3. Disconnect the accelerator cable (9A758) and (if equipped) the speed control actuator cable (9A825).
4. NOTE: Discard the throttle body gasket after removing the throttle body.
Remove the throttle body. zRemove the nuts.
z Remove the bolts.
SECTION 303-
04A: Fuel Charging and Controls — 3.8L 2003 Mustang Workshop Manual Klj . 1 ba
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REMOVAL AND INSTALLATION
Throttle Body
Removal
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. Failure to follow these instructions may result in personal injury.
CAUTION: The throttle body bore and plate area have a special coating and cannot be
cleaned.
1. Remove the air cleaner outlet tube (9B659). For additional information, refer to Section 303 - 12 .
2. Disconnect the throttle position (TP) sensor electrical connector.
3. Disconnect the accelerator controls. zDisconnect the accelerator cable (9E926).
z Disconnect the speed control cable (9A825).
z Disconnect the return spring.
4. NOTE: Discard the throttle body gasket.
Remove the throttle body. zRemove the bolts.
z Remove the throttle body.
SECTION 303-
04B: Fuel Charging and Controls — 4.6L (2V) 2003 Mustang Workshop Manual Klj . 1 ba
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