instrument panel FORD MUSTANG 2003 User Guide

14. Install the air intake scoop. For additional information, refer to
Section 303 - 12 .
Bleeding 1. Select the maximum heater temperature and blower motor speed settings. Position the control to discharge air at A/C vents in instrument panel.
2. Start the engine and allow to idle. While engine is idling, feel for hot air at A/C vents.
3. CAUTION: If the air discharge remains cool and the engine coolant temperature
gauge does not move, the engine coolant level is low and must be filled. Stop the engine,
allow the engine to cool and fill cooling system.
Start the engine and allow it to idle until normal operating temperature is reached. Hot air should
discharge from A/C vents. The engine coolant temperature gauge should maintain a stabilized
reading in the middle of the NORMAL range. The upper radiator hose should feel hot to the
touch.
4. Shut the engine off and allow the engine to cool.
5. Check the engine for coolant leaks.
6. Check the engine coolant level in the degas bottle/coolant expansion tank and fill as necessary. Klj . 7 ba
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3. If the concern remains after the inspection, connect the scan tool to the data link connector
(DLC) located beneath the instrument panel and select the vehicle to be tested from the scan
tool menu. If the scan tool does not communicate with the vehicle:
zcheck that the program card is correctly installed.
z check the connections to the vehicle.
z check the ignition switch position.
4. If the scan tool still does not communicate with the vehicle, refer to the scan tool manual.
5. Carry out the DATA LINK DIAGNOSTICS test. If the scan tool responds with:
z CKT914, CKT915 or CKT70 = ALL ECUS NO RESP/NOT EQUIP, refer to Section 418 - 00 .
z NO RESP/NOT EQUIP for PCM, refer to the Powertrain Control/Emissions Diagnosis (PC/ED)
manual.
z SYSTEM PASSED, retrieve and record the continuous diagnostic trouble codes (DTCs), erase
the continuous DTCs and carry out the PCM KOEO self- test.
6. If the DTCs retrieved are related to the concern, go to the PCM Diagnostic Trouble Code (DTC) Index to continue diagnostics.
7. If the concern remains after the inspection, determine the symptom. GO to Symptom Chart .
PCM Diagnostics Trouble Code (DTC) Index
Symptom Chart z
EVAP lines or hoses
z Vacuum lines or hoses DTC Description Source Action
P0442 Small leak detected in EVAP system
(As small as 1.02 mm [0.040 inch]) PCM Go To Pinpoint Test A .
P0455 Major leak or no flow detected PCM Go To Pinpoint Test B .
P0457 Check for missing or leaking fuel filter
cap PCM Go To Pinpoint Test A .
P1443 Very small or no purge flow detected PCM Go To Pinpoint Test B .
P1450 Excessive vacuum detected in the fuel
tank PCM Go To Pinpoint Test C .
— Any other PCM DTC PCM REFER to the Powertrain
Control/Emissions Diagnosis (PC/ED)
manual.
SYMPTOM CHART Condition
Possible Sources Action
z Hissing sound when
removing fuel cap z
Canister vent solenoid.
z Evaporative emissions
canister.
z Fuel vapor control valve z
Go To Pinpoint Test D . Klj . 4 ba
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8. Disconnect the shift interlock cable.
9. Remove the instrument panel steering column cover.
1. Remove the screws.
2. Remove the instrument panel steering column cover.
10. Remove the instrument panel reinforcement. 1. Remove the screws.
2. Remove the instrument panel reinforcement.
11. Remove the nuts and lower the steering column. Klj . 3 ba
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SPECIFICATIONS
SECTION 308-
02: Clutch Controls 2003 Mustang Workshop Manual General Specifications
Item Specification
Clutch System
System adjustment Self adjusting
Fluid and Lubricant
Super Premium SAE 10W-30
XO- 10W-30- BSP WSS-
M2C153- G
Torque Specifications Description Nm lb-
ft lb-
in Brake booster nuts 25 18 —
Brake pedal support bracket to cowl bolt 25 18 —
Clutch pedal retaining nut 40 30 —
Clutch release lever cable bracket screw (3.8L) 10 — 89
Clutch release lever cable to bulkhead screws 4 — 35
Clutch release lever cable to crossmember retaining screw 8 — 71
Clutch release lever cable to master cylinder retaining screw (4.6L) 8 — 71
Instrument panel reinforcement screws 9 — 80
Instrument panel steering column cover screws 9 — 80 Klj . 1 ba
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REMOVAL AND INSTALLATION
Release Cable —
Clutch
Removal
CAUTION: Whenever the clutch release lever cable (7K553) is disconnected for any
reason, such as transmission removal, clutch pedal components or clutch release lever cable
replacement, it is imperative the correct method for installing the clutch release lever cable be
followed. Incorrect installation may damage components or cause system failure.
1. Remove the instrument panel steering column cover. 1. Remove the screws.
2. Remove the instrument panel steering column cover.
2. Remove the instrument panel reinforcement. 1. Remove the screws.
2. Remove the instrument panel reinforcement.
3. Lift the clutch pedal (7519) to its most upward position.
SECTION 308-
02: Clutch Controls 2003 Mustang Workshop Manual Klj . 1 ba
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System Air Flow Description
MAX A/C
When MAX A/C is selected:
zThe air inlet door vacuum control motor is at full vacuum, closing off outside air and admitting
only recirculated air.
z The panel/defrost door vacuum control motor is at full vacuum and the panel/floor door vacuum
control motor is at no vacuum, directing airflow to the instrument panel A/C registers. A small
amount of airflow from the side window demisters will be present.
z Blended air temperature is available.
z The A/C compressor will operate if the outside temperature is above approximately 6°C (43°F).
z The blower motor is on.
NORM A/C
When NORM A/C is selected:
zThe air inlet door vacuum control motor is at no vacuum, admitting only outside air into the
passenger compartment. 9 19D990 A/C evaporator core orifice
10 19860 A/C evaporator core
11 — Low pressure vapor
12 — High pressure vapor
13 — Low pressure liquid
14 — High pressure liquid Klj . 6 ba
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z
The panel/defrost door vacuum control motor is at full vacuum and the panel/floor door vacuum
control motor is at no vacuum, directing airflow to the instrument panel A/C registers. A small
amount of airflow from the side window demisters will be present.
z Blended air temperature is available.
z The A/C compressor will operate if the outside air temperature is above approximately 6°C (43°
F).
z The blower motor is on.
PANEL
When PANEL is selected:
zThe air inlet door vacuum control motor is at no vacuum, admitting only outside air into the
passenger compartment.
z The panel/defrost door vacuum control motor is at full vacuum and the panel/floor door vacuum
control motor is at no vacuum, directing airflow to the instrument panel A/C registers. A small
amount of airflow from the side window demisters will be present.
z The temperature can be adjusted to heat the air, but the air cannot be cooled below the outside
temperature.
z The A/C compressor will not operate.
z The blower motor is on.
OFF
When OFF is selected:
zThe air inlet door vacuum control motor is at full vacuum, closing off outside air from entering
the passenger compartment.
z The panel/floor door vacuum control motor is at full vacuum and the panel/defrost door vacuum Klj . 7 ba
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control motor is at no vacuum, closing off airflow to the defrost duct, side window demisters,
floor duct and instrument panel A/C registers.
z The A/C compressor will not operate.
z The blower motor is off.
FLOOR
When FLOOR is selected:
zThe air inlet door vacuum control motor is at no vacuum, admitting only outside air into the
passenger compartment.
z The panel/floor door vacuum control motor is at full vacuum and the panel/defrost door vacuum
control motor is at no vacuum, directing airflow to the floor duct. A small amount of airflow from
the side window demisters will be present.
z The temperature can be adjusted to heat the air, but the air cannot be cooled below the outside
temperature.
z The A/C compressor will not operate.
z The blower motor is on.
FLOOR/DEFROST
When FLOOR/DEFROST is selected:
zThe air inlet door vacuum control motor is at no vacuum, admitting only outside air into the
passenger compartment.
z The panel/floor door vacuum control motor is at partial vacuum and the panel/defrost door
vacuum control motor is at no vacuum, directing airflow to the floor duct, the defroster duct, and
the side window demisters.
z The temperature can be adjusted to heat or cool the air below the outside temperature. Klj . 8 ba
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2. Inspect to determine if one of the following mechanical or electrical concerns apply:
a A leak in the vacuum control circuit may occur during acceleration (slow leak), at all times
(large leak), or only when specific functions are selected (indicating a leak in that portion of the
circuit). The vacuum hoses used in the passenger compartment control circuit are constructed
from PVC plastic material. The vacuum hoses used in the engine compartment are constructed
of Hytrel® . Because of the materials used, never pinch the vacuum hoses off during diagnosis
to locate a leak. A wood golf tee can be used as a plug when it is necessary to plug one end of
a vacuum hose for leak test purposes.
3. If the inspection reveals obvious concerns that can be readily identified, repair as required.
4. If the concern remains after the inspection, connect the scan tool to the data link connector (DLC) located beneath the instrument panel and select the vehicle to be tested from the scan
tool menu. If the vehicle selection cannot be entered:
zcheck that the program card is correctly installed.
z check the connections to the vehicle.
z check the ignition switch position.
If the scan tool still does not allow the vehicle selection to be entered, refer to the scan tool manual. 5. Carry out the DATA LINK DIAGNOSTIC TEST using the scan tool. If the scan tool responds with:
zCKT 914, CKT 915 or CKT 70 = ALL MODULE NO RESPONSE/NOT EQUIPPED, go to
Communication System Diagnostics in Section 418 - 00 to diagnose network concern.
z If the powertrain control module (PCM) is not listed for a communication concern, turn
the A/C function selector switch to OFF and execute self- test diagnostics for the PCM.
6. If any PCM DTCs are retrieved, and are related to the concern, go to the Powertrain Control Module Diagnostic Trouble Code (DTC) Index to continue diagnostics.
7. If no DTCs related to the concern are retrieved, go to the Symptom Chart to continue diagnostics.
Symptom Chart Visual Inspection Chart Mechanical Electrical
z
Loose, missing or damaged A/C compressor
drive belt.
z Loose or disconnected A/C clutch.
z Loose, misrouted or damaged vacuum lines. a
z Broken or leaking refrigerant lines.
z Broken or leaking vacuum control motor. z
Open fuses.
z Blower motor inoperative.
z A/C compressor inoperative.
z Circuitry open/shorted.
z Disconnected electrical
connectors.
Powertrain Control Module Diagnostic Trouble Code (DTC) Index DTC Description Action
P1460 WOT A/C cutout circuit
malfunction Refer to the Powertrain Control/Emissions Diagnosis
(PC/ED) manual.
P1464 A/C demand out of self-
test
range GO to DTC P1464. Klj . 5 ba
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SPECIFICATIONS
SECTION 412-
01: Air Distribution and Filtering 2003 Mustang Workshop Manual Torque Specifications
Description Nm lb-
in Steering column reinforcement 9 80
Instrument panel steering column cover bolts 9 80
Duct RH instrument panel register 9 80 Klj . 1 ba
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