AC system FORD MUSTANG 2003 Workshop Manual

Inspection and Verification
1. Verify the customer concern by operating the engine to duplicate the condition.
2. Visually inspect for obvious signs of mechanical damage. Refer to the following chart.
3. If the inspection reveals obvious concerns that can be readily identified, repair as necessary.
4. If the concerns remain after the inspection, determine the symptoms. GO to Symptom Chart .
Symptom Chart Material
Item Specification
Gasoline Engine Oil
Dye
164-
R3705 or
equivalent ESE-
M99C103- B1 Engine Oil Refer to owner
literature
Visual Inspection Chart Mechanical
z
Engine coolant leaks
z Engine oil leaks
z Fuel leaks
z Damaged or severely worn parts
z Loose mounting bolts, studs and nuts
Symptom Chart Condition
Possible Sources Action
z Difficult
starting z
Damaged ignition
system. z
Refer to the appropriate section
in Group 303 for the procedure.
REFER to the Powertrain
Control/Emissions Diagnosis
(PC/ED) manual.
z Damaged fuel
system. z
Refer to the appropriate section
in Group 303 for the procedure.
REFER to the Powertrain
Control/Emissions Diagnosis
(PC/ED) manual.
z Damaged starting
system. z
Refer to the appropriate section
in Group 303 for the procedure. Klj . 2 ba
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REFER to the Powertrain
Control/Emissions Diagnosis
(PC/ED) manual.
z Damaged charging
system/battery. z
REFER to Section 414 - 00 .
z Burnt valve. zINSTALL a new valve.
z Worn piston. zINSTALL a new piston.
z Worn piston rings. zINSTALL new piston rings.
z Worn cylinder. zREPAIR or INSTALL a new
cylinder block.
z Damaged head
gasket. z
INSTALL a new head gasket.
z Damaged cooling
system. z
Refer to the appropriate section
in Group 303 for the procedure.
REFER to the Powertrain
Control/Emissions Diagnosis
(PC/ED) manual.
z Poor idling zVacuum leaks. zRefer to the appropriate section
in Group 303 for the procedure.
REFER to the Powertrain
Control/Emissions Diagnosis
(PC/ED) manual.
z Malfunctioning or
damaged ignition
system. z
Refer to the appropriate section
in Group 303 for the procedure.
REFER to the Powertrain
Control/Emissions Diagnosis
(PC/ED) manual.
z Malfunctioning or
damaged fuel
system. z
Refer to the appropriate section
in Group 303 for the procedure.
REFER to the Powertrain
Control/Emissions Diagnosis
(PC/ED) manual.
z Damaged valve
tappet or lash
adjuster. z
INSTALL a new valve tappet or
lash adjuster.
z Damaged valve
tappet guide or lash
adjuster. z
INSTALL a new valve tappet
guide or valve tappet.
z Incorrect valve-to-
valve seat contact. z
REPAIR or INSTALL a new
valve or valve seat.
z Damaged head
gasket. z
INSTALL a new head gasket.
z Abnormal
combustion z
Malfunctioning or
damaged fuel
system. z
Refer to the appropriate section
in Group 303 for the procedure.
REFER to the Powertrain
Control/Emissions Diagnosis
(PC/ED) manual.
z Malfunctioning or
damaged ignition
system. z
Refer to the appropriate section
in Group 303 for the procedure.
REFER to the Powertrain
Control/Emissions Diagnosis
(PC/ED) manual.
z Malfunctioning or
damaged air intake
system. z
Refer to the appropriate section
in Group 303 for the procedure.
REFER to the Powertrain
Control/Emissions Diagnosis Klj . 3 ba
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(PC/ED) manual.
z Damaged valve
tappet or lash
adjuster. z
INSTALL a new valve tappet or
lash adjuster.
z Damaged valve
tappet guide or
valve tappet. z
INSTALL a new valve tappet
guide or valve tappet.
z Burnt or sticking
valve. z
REPAIR or INSTALL a new
valve.
z Weak or broken
valve spring. z
INSTALL a new valve spring.
z Carbon
accumulation in
combustion
chamber. z
ELIMINATE carbon buildup.
z Excessive oil
consumption z
Leaking oil. zREPAIR oil leakage.
z Malfunctioning PCV
system. z
REPAIR or INSTALL new
necessary components.
z Worn valve stem
seal. z
INSTALL a new valve stem seal.
z Worn valve stem or
valve guide. z
INSTALL a new valve and valve
guide.
z Sticking piston
rings. z
REPAIR or INSTALL new piston
rings.
z Worn piston ring
groove. z
INSTALL a new piston and
piston pin.
z Worn piston or
cylinder. z
REPAIR or INSTALL a new
piston or cylinder block.
z Engine noise zLeaking exhaust
system. z
REPAIR exhaust leakage.
z Incorrect drive belt
tension. z
REFER to Section 303 - 05 .
z Malfunctioning
generator bearing. z
Refer to the appropriate section
in Group 414 for the procedure.
z Malfunctioning
water pump
bearing. z
REFER to Section 303 - 03A .
z Malfunctioning or
damaged cooling
system. z
REFER to Section 303 - 03A .
z Malfunctioning or
damaged fuel
system. z
Refer to the appropriate section
in Group 303 for the procedure.
REFER to the Powertrain
Control/Emissions Diagnosis
(PC/ED) manual.
z Loose timing
chain/belt (6268). z
ADJUST or INSTALL a new
timing chain/belt.
z Damaged timing
chain tensioner
(6L266). z
INSTALL a new timing chain
tensioner.
z Excessive main
bearing clearance. z
ADJUST clearance or INSTALL
a new crankshaft main bearing
(6333). Klj . 4 ba
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z
Seized or heat
damaged
crankshaft main
bearing. z
INSTALL a new crankshaft main
bearing.
z Excessive
crankshaft end
play. z
INSTALL a new thrust bearing or
crankshaft (6303).
z Excessive
connecting rod
bearing clearance. z
INSTALL a new connecting rod
bearing or connecting rod
(6200).
z Heat damaged
connecting rod
bearing (6211). z
INSTALL a new connecting rod
bearing.
z Damaged
connecting rod
bushing (6207). z
INSTALL a new connecting rod
bushing.
z Worn cylinder. zREPAIR or INSTALL a new
cylinder block (6010).
z Worn piston (6108)
or piston pin
(6135). z
INSTALL a new piston or piston
pin.
z Damaged piston
rings. z
INSTALL new piston rings.
z Bent connecting
rod. z
INSTALL a new connecting rod.
z Malfunctioning
valve tappet (6500)
or lash adjuster. z
INSTALL a new valve tappet or
lash adjuster.
z Excessive valve
tappet or lash
adjuster clearance. z
ADJUST clearance or INSTALL
a new valve tappet guide or
valve tappet.
z Broken valve spring
(6513). z
INSTALL a new valve spring.
z Excessive valve
guide clearance. z
ADJUST clearance or INSTALL
a new valve guide (6510) or
valve.
z Insufficient
power z
Malfunctioning or
damaged ignition
system. z
Refer to the appropriate section
in Group 303 for the procedure.
REFER to the Powertrain
Control/Emissions Diagnosis
(PC/ED) manual.
z Malfunctioning or
damaged fuel
system. z
Refer to the appropriate section
in Group 303 for the procedure.
REFER to the Powertrain
Control/Emissions Diagnosis
(PC/ED) manual.
z Malfunctioning or
damaged air intake
system. z
Refer to the appropriate section
in Group 303 for the procedure.
REFER to the Powertrain
Control/Emissions Diagnosis
(PC/ED) manual.
z Damaged or
plugged exhaust
system. z
INSPECT exhaust system.
z Incorrect tire size. zREFER to Section 204 - 04 .
z Dragging brakes. zREFER to Section 206 - 00 . Klj . 5 ba
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1. If compression improves considerably, piston rings are faulty.
2. If compression does not improve, valves are sticking or seating incorrectly.
3. If two adjacent cylinders indicate low compression pressures and squirting oil on each piston
does not increase compression, the head gasket may be leaking between cylinders. Engine oil
or coolant in cylinders could result from this condition.
Use the Compression Pressure Limit Chart when checking cylinder compression so that the
lowest reading is within 75 percent of the highest reading.
Cylinder Leakage Detection
When a cylinder produces a low reading, use of the Engine Cylinder Leak Detection/Air Pressurization
Kit will be helpful in pinpointing the exact cause.
The leakage detector is inserted in the spark plug hole, the piston is brought up to dead center on the
compression stroke, and compressed air is admitted.
Once the combustion chamber is pressurized, a special gauge included in the kit will read the
percentage of leakage. Leakage exceeding 20 percent is excessive.
While the air pressure is retained in the cylinder, listen for the hiss of escaping air. A leak at the intake
valve (6507) will be heard in the throttle body (9E926). A leak at the exhaust valve (6505) can be
heard at the tail pipe. Leakage past the piston rings will be audible at the positive crankcase ventilation
(PCV) connection. If air is passing through a blown head gasket to an adjacent cylinder, the noise will
be evident at the spark plug hole of the cylinder into which the air is leaking. Cracks in the cylinder
block or gasket leakage into the cooling system may be detected by a stream of bubbles in the radiator
(8005).
Oil Consumption Test
The following diagnostic procedure is used to determine the source of excessive internal oil
consumption. 1. NOTE: Oil use is normally greater during the first 16,100 km (10,000 miles) of service. As
mileage increases, oil use generally decreases. Vehicles in normal service should get at least
1,450 km per liter (900 miles per quart) after 16,000 km (10,000 miles) of service. High speed
driving, towing, high ambient temperature and other factors may result in greater oil use.
Define excessive oil consumption, such as the number of miles driven per liter (quart) of oil
used. Also determine customer's driving habits, such as sustained high speed operation,
towing, extended idle and other considerations.
2. Verify that the engine has no external oil leak as described under Engine Oil Leaks in the Diagnosis and Testing portion of this section.
3. Verify that the engine has the correct oil level dipstick (6750).
4. Verify that the engine is not being run in an overfilled condition. Check the oil level at least five minutes after a hot shutdown with the vehicle parked on a level surface. In no case should the
level be above MAX or the letter F in FULL. If significantly overfilled, carry out Steps 6a through
6d.
5. Verify the spark plugs are not oil saturated. If the spark plugs are oil saturated and compression is good it can be assumed the valve seals or valve guides are at fault. Klj . 9 ba
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6. Carry out an oil consumption test:
a. Drain the engine oil, remove the oil bypass filter (6714) and refill with one liter (quart) less than
the recommended amount.
b. Run the engine for three minutes (10 minutes if cold), and allow the oil to drain back for at least five minutes with the vehicle on a level surface.
c. Remove oil level dipstick and wipe clean. (Do not wipe with anything contaminated with silicone compounds.) Reinstall the oil level dipstick, being sure to seat it firmly in the oil level indicator
tube (6754). Remove the oil level dipstick and draw a mark on the back (unmarked) surface at
the indicated oil level. This level should be about the same as the MIN or ADD mark on the face
of the oil level dipstick.
d. Add one liter (quart) of oil. Restart the engine and allow to idle for at least two minutes. Shut off the engine and allow the oil to drain back for at least five minutes. Mark the oil level dipstick,
using the procedure above.
e. Record the vehicle mileage. f. Instruct the customer to drive the vehicle as usual and perform the following:
„Check the oil level regularly at intervals of 160 to 240 km (100- 150 miles).
„ Return to the service point when the oil level drops below the lower (MIN or ADD) mark
on the oil level dipstick.
„ Add only full liters (quarts) of the same oil in an emergency. Note the mileage at which
the oil is added.
g. Check the oil level under the same conditions and at the same location as in Steps 6c and 6d.
„Measure the distance from the oil level to the UPPER mark on the oil level dipstick and
record.
„ Measure the distance between the two scribe marks and record.
„ Divide the first measurement by the second.
„ Divide the distance driven during the oil test by the result. This quantity is the
approximate oil consumption rate in kilometers per liter or in miles per quart.
h. If the oil consumption rate is unacceptable, go to Step 7.
7. Check the positive crankcase ventilation (PCV) system. Make sure the system is not plugged.
8. Check for plugged oil drain- back holes in the cylinder heads and cylinder block.
9. If the condition still exists after performing the above steps, go to Step 10.
10. Perform a cylinder compression test or perform a cylinder leak detection test with Engine Cylinder Leak Detection/Air Pressurization Kit. This can help determine the source of oil
consumption such as valves, piston rings or other areas.
11. NOTE: After determining if new parts should be installed, make sure correct parts are used.
Check valve guides for excessive guide clearance. Install new all valve stem seals (6571) after
verifying valve guide clearance.
12. Worn or damaged internal engine components can cause excessive oil consumption. Small deposits of oil on the tips of spark plugs can be a clue to internal oil consumption. If internal oil
consumption still persists, proceed as follows:
a. Remove the engine from the vehicle and place it on an engine work stand. Remove the intake manifolds (9424), cylinder heads, oil pan (6675) and oil pump (6600).
b. Check piston ring clearance, ring gap and ring orientation. Repair as necessary.
c. Check for excessive bearing clearance. Repair as necessary.
13. Repeat the oil consumption test (Step 6) to confirm the oil consumption concern has been resolved. Klj . 10 ba
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4. WORN RINGS OR DILUTED OIL: When the engine is accelerated (dotted needle), the needle
drops to 0 kPa (0 in- Hg). Upon deceleration, the needle runs slightly above 74 kPa (22 in- Hg).
5. STICKING VALVES: When the needle (dotted) remains steady at a normal vacuum but occasionally flicks (sharp, fast movement) down and back about 13 kPa (4 in- Hg), one or more
valves may be sticking.
6. BURNED OR WARPED VALVES: A regular, evenly- spaced, downscale flicking of the needle
indicates one or more burned or warped valves. Insufficient hydraulic lash adjuster or hydraulic
lash adjuster (HLA) clearance will also cause this reaction.
7. POOR VALVE SEATING: A small but regular downscale flicking can mean one or more valves are not seating.
8. WORN VALVE GUIDES: When the needle oscillates over about a 13 kPa (4 in- Hg) range at idle
speed, the valve guides could be worn. As engine speed increases, the needle will become
steady if guides are responsible.
9. WEAK VALVE SPRINGS: When the needle oscillation becomes more violent as engine rpm is increased, weak valve springs are indicated. The reading at idle could be relatively steady.
10. LATE VALVE TIMING: A steady but low reading could be caused by late valve timing.
11. IGNITION TIMING RETARDING: Retarded ignition timing will produce a steady but somewhat low reading.
12. INSUFFICIENT SPARK PLUG GAP: When spark plugs are gapped too close, a regular, small pulsation of the needle can occur.
13. INTAKE LEAK: A low, steady reading can be caused by an intake manifold or throttle body gasket leak.
14. BLOWN HEAD GASKET: A regular drop of fair magnitude can be caused by a blown head gasket or warped cylinder head- to-cylinder block surface.
15. RESTRICTED EXHAUST SYSTEM: When the engine is first started and is idled, the reading may be normal, but as the engine rpm is increased, the back pressure caused by a clogged
muffler (5230), kinked tail pipe or other concerns will cause the needle to slowly drop to 0 kPa
(0 in-Hg). The needle then may slowly rise. Excessive exhaust clogging will cause the needle to
drop to a low point even if the engine is only idling.
16. When vacuum leaks are indicated, search out and correct the cause. Excess air leaking into the system will upset the fuel mixture and cause concerns such as rough idle, missing on
acceleration or burned valves. If the leak exists in an accessory unit such as the power brake
booster (2005), the unit will not function correctly. Always fix vacuum leaks.
Excessive Engine Oil Consumption
The amount of oil an engine uses will vary with the way the vehicle is driven in addition to normal
engine- to-engine variation. This is especially true during the first 16,100 km (10,000 miles) when a new
engine is being broken in or until certain internal engine components become conditioned. Vehicles
used in heavy- duty operation may use more oil. The following are examples of heavy- duty operation:
z trailer towing applications
z severe loading applications
z sustained high speed operation Klj . 12 ba
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z
incorrectly functioning valve tappet
z air in lubrication system
z excessive valve guide wear
z low oil pressure
Excessive collapsed valve tappet gap can be caused by loose rocker arm seat bolts/nuts, incorrect
initial adjustment or wear of valve tappet face, or worn roller valve tappets, push rod (6565), rocker
arm (6564), rocker arm seat or valve tip. With valve tappet collapsed, check gap between the valve tip
and the rocker arm to determine if any other valve train parts are damaged, worn or out of adjustment.
An incorrectly functioning valve tappet can be sticking, caused by contaminants or varnish inside the
tappet. The tappet can have a check valve that is not functioning correctly, which can be caused by an
obstruction, such as dirt or chips that prevent the check valve from closing, or a broken check valve
spring. A tappet with a leakdown time out of specification can cause tappet noise. If no other cause for
noisy valve tappets can be found, the leakdown rate should be checked and new valve tappets
installed if found to be out of specification.
Assembled valve tappets can be tested with Hydraulic Tappet Leakdown Tester to check the leakdown
rate. The leakdown rate specification is the time in seconds for the plunger to move a specified
distance while under a 22.7 kg (50 lb) load.
Air bubbles in the lubrication system will prevent the valve tappet from supporting the valve spring
load. This can be caused by too high or too low an oil level in the oil pan or by air being drawn into the
system through a hole, crack or leaking gasket on the oil pump screen cover and tube. Klj . 17 ba
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GENERAL PROCEDURES
Sprockets
1. 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 blade has been examined for
possible cracks and separation.
NOTE: Specifications show the expected minimum or maximum condition. Refer to the
appropriate section in Group 303 for the procedure.
NOTE: If a component fails to meet the specifications, it is necessary to install a new
component or refinish. If the component can be refinished, wear limits are provided as an aid to
making a decision. A new component must be installed for any component that fails to meet
specifications and cannot be refinished.
Inspect the timing chain/belt and the sprockets.
zInstall new components as necessary. Refer to the appropriate section in Group 303 for
the procedure.
SECTION 303-
00: Engine System — General Information 2003 Mustang Workshop Manual Klj . 1 ba
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GENERAL PROCEDURES
Rocker Arms —
Cleaning
1. Clean all parts thoroughly. Make sure all oil passages are open.
2. Make sure oil passage in the push rod/valve tappet end of the rocker arm (6564) is open.
SECTION 303-
00: Engine System — General Information 2003 Mustang Workshop Manual Klj . 1 ba
12003 Mustang Workshop Manual
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