heating FORD MUSTANG 2003 Owner's Manual

REMOVAL AND INSTALLATION
Flywheel Ring Gear
Removal
1. Remove the flywheel. For additional information, refer to Section 303 - 01A ,
Section 303 - 01B or
Section 303 - 01C .
2. WARNING: This procedure should be carried out only by a correctly equipped and
experienced acetylene torch operator. Tongs must be used or asbestos gloves worn
when handling the heated flywheel ring gear. Failure to follow these instructions can
result in personal injury.
CAUTION: Tap the flywheel ring gear evenly to prevent binding.
Remove the flywheel ring gear from the flywheel. zEvenly heat the flywheel ring gear with an acetylene torch and use a brass drift to drive
the flywheel ring gear off the flywheel.
Installation
1. WARNING: This procedure should be carried out only by a properly equipped and
experienced acetylene torch operator. Tongs must be used or asbestos gloves worn
when handling the heated flywheel ring gear. Failure to follow these instructions can
result in personal injury.
CAUTION: Do not heat the flywheel ring gear beyond 261°C (500°F). Use heat-
indicating crayons to prevent overheating.
CAUTION: Keep the torch moving to prevent hot spots.
Evenly heat the flywheel ring gear with an acetylene torch. zInstall the flywheel ring gear with the bevel on the flywheel ring gear facing the rear of the
flywheel.
z Use a brass drift to tap the flywheel ring gear into position, reheat as necessary.
2. Install the flywheel. For additional information, refer to Section 303 - 01A ,
Section 303 - 01B or
Section 303 - 01C . SECTION 308-
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GENERAL PROCEDURES
Bearings —
Inspection
NOTE: If any of the following conditions exist, install a new bearing.
1. Inspect the bearing for a bent cage.
2. Inspect bearings for galling (metal smears on roller ends). zGalling is caused by overheating, poor lubrication or an overload situation.
z If galling is found, install a new bearing and inspect the seals.
3. Inspect the bearing for brinelling (surface indentations in the raceway).
4. Inspect bearing for cracked inner race.
SECTION 308-
03B: Manual Transaxle/Transmission — TR3650 2003 Mustang Workshop Manual Klj . 1 ba
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z
Refrigerant R- 134a must not be mixed with air for leak testing or used with air for any
other purpose above atmospheric pressure. R- 134a is combustible when mixed with high
concentrations of air and higher pressures.
z A number of manufacturers are producing alternative refrigerant products that are
designed to be used instead of R- 134a refrigerant. The use of any unauthorized
substitute refrigerant can severely damage the A/C components. If repair is required, use
only new or recycled refrigerant R- 134a.
CAUTION: To avoid contamination of the A/C system, always observe the following:
z Keep service tools and the work area clean.
z Never open or loosen a connection before discharging the system.
z When loosening a connection, if any residual pressure is evident, allow it to leak out
before opening the fitting.
z Evacuate a system that has been opened to install a new component or one that has
been discharged through leakage before charging.
z Seal an open fitting with a cap or plug immediately after disconnecting a component
from the system.
z Clean the outside of the fittings thoroughly before disconnecting a component from the
system.
z Do not remove the sealing caps from a new component until ready to install.
z Refrigerant oil will absorb moisture from the atmosphere if left uncapped. Do not open
an oil container until ready to use, and install the cap immediately after using. Store the
oil in a clean, moisture- free container.
z Install a new O- ring seal before connecting an open fitting. Coat the fitting and the O- ring
seal with refrigerant oil before connecting.
z When installing a refrigerant line, avoid sharp bends. Position the line away from the
exhaust or any sharp edges that can chafe the line.
z Do not open a refrigerant system or uncap a new component unless it is as close as
possible to room temperature. This will prevent condensation from forming inside a
component that is cooler than the surrounding air.
The manual climate control system heats or cools the vehicle depending on the function selector
switch position and the temperature selected.
zThe function selector switch position determines heating or cooling and air distribution.
z The temperature control setting determines the air temperature.
z The heater blower motor switch (18578) varies the blower motor speed.
Principles of Operation
There are four main principles involved with the basic theory of operation:
zheat transfer
z latent heat of vaporization
z relative humidity
z effects of pressure Heat Transfer Klj . 2 ba
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GENERAL PROCEDURES
Air Conditioning (A/C) System Check —
Retail Procedure
NOTE: This Retail Procedure is not eligible for claiming on Ford paid repairs (warranty and ESP).
NOTE: The engine should be run at idle for 10 minutes with the air conditioning on and set to MAX A/C
before carrying out this retail procedure.
NOTE: Read and follow all of the Warnings, Cautions and Notes at the beginning of this section before
continuing.
1. Visual inspection
Open the hood and visually inspect the heating and air conditioning systems for the following:
zCoolant reservoir for correct coolant level
z Heater hoses for deterioration or loose connections
z Radiator and condenser for debris or damaged fins restricting airflow, loose mounting or
connections
z Accessory drive belt(s) and cooling fan(s) for wear or physical damage
z Refrigerant lines and connections for physical damage or loose connections
z Compressor for physical damage or loose connections
z Suction accumulator/drier for physical damage or loose connections
z Wiring and connectors for excessive wear, loose or damaged connections, or incorrect
routing
2. A/C refrigerant analysis
zCarry out air conditioning refrigerant analysis. For additional information, refer to
Refrigerant Identification Testing in this section.
z If the refrigerant fails the analysis, discontinue diagnosis and make recommendations for
repairs.
z If the refrigerant passes the analysis, carry out the air conditioning system check.
3. Air conditioning system check
zConnect manifold gauge set or charging station with gauges to refrigerant system.
z With the vehicle in park, parking brake set, thermometer installed in center panel vent,
and air conditioning system on and set to MAX A/C, start the engine.
z Record air refrigerant system pressures while running the engine at 1,500 rpm and allow
engine to return to idle.
z Operate the blower motor in all control positions and check for correct blower speed
changes.
z With the blower motor on HI, operate air discharge mode selector in all positions and
check for correct airflow in each position.
z Operate the temperature blend selector in all positions and check for correct change in
discharge temperature. Check the air discharge temperature with the selector in the
coolest position and the air conditioning on and set to MAX A/C to determine if the air
discharge temperature is acceptable for the current ambient air temperature.
z Carry out the EATC self- test (if applicable).
If the refrigerant system pressures were low, carry out the refrigerant system leak test.
SECTION 412-
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SPECIFICATIONS
SECTION 412-
02: Heating and Ventilation 2003 Mustang Workshop Manual General Specifications
Item Specification
Lubricant
MERPOL® ESE-
M99B144-
B PAG Refrigerant Compressor Oil (R-134a Systems) F7AZ-19589-
DA (Motorcraft
YN- 12-C) WSH-
M1C231- B
Torque Specifications Description Nm lb-
in Interior evaporator core housing bracket nut and bolts 8 71 Klj . 1 ba
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DESCRIPTION AND OPERATION
Heating and Defrosting
The heating and defrosting system has the following features:
zControls the temperature and, during A/C operation, reduces the relative humidity of the air
inside the vehicle.
z Delivers heated or cooled air to maintain the vehicle interior temperature and comfort level.
z Controls the A/C blower motor speed.
z Cooling or heating can be adjusted to maintain the desired temperature.
z System uses a reheat method to provide conditioned air to the passenger compartment.
z The blower motor (19805) draws outside air through the air inlet duct from just below the
windshield during all system operations except for MAX A/C cooling (when recirculated air is
used).
z All airflow from the blower motor passes through the A/C evaporator core (19860).
z The temperature is then regulated by reheating a portion of the air and blending it with the
remaining cool air to the desired temperature.
z The temperature blending is varied by the air temperature control door, which regulates the
amount of air that flows through and around the heater core (18476), where it is then mixed and
distributed.
Heater Core
The heater core (18476) consists of fins and tubes arranged to extract heat from the engine coolant
and transfer it to air passing through the heater core. Blower Motor SECTION 412-
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DIAGNOSIS AND TESTING
Heating and Defrosting
Refer to
Section 412 - 00 .
SECTION 412-
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REMOVAL AND INSTALLATION
Blower Motor
Removal
1. Disconnect the jumper wire.
2. Disconnect the main harness.
3. Remove the screws. 4. Separate the cover from the motor. SECTION 412-
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REMOVAL AND INSTALLATION
Evaporator Core Housing
Removal
NOTE:
The evaporator core is not separately serviceable, it is serviced only with the evaporator core
housing assembly.
1. Disconnect the battery ground cable.
2. Recover the refrigerant. For additional information, refer to Section 412 - 00 .
3. Drain the cooling system. For additional information, refer to Section 303 - 03A or
Section 303 -
03B .
4. Remove the instrument panel. For additional information, refer to Section 501 - 12 .
5. Disconnect the heater hose couplings from the heater core. For additional information, refer to Section 412 - 00 .
6. Disconnect the vacuum connector. SECTION 412-
02: Heating and Ventilation 2003 Mustang Workshop Manual Material
Item Specification
PAG Compressor Oil (R-134a
Systems)
F7AZ- 19589- DA (Motorcraft
YN- 12-C) WSH-
M1C231-
B MERPOL®
NA ESE-
M99B144-
B Klj . 1 ba
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REMOVAL AND INSTALLATION
Heater Core
Removal
NOTE:
If a heater core leak is suspected, the heater core must be pressure leak tested before it is
removed from the vehicle. For additional information, refer to Section 412 - 00 .
1. Remove the evaporator core housing. For additional information, refer to Evaporator Core Housing in this section.
2. Remove the foam weather seal.
3. Remove the screws and remove the heater core cover.
4. Remove the heater core.
Installation 1. NOTE: Be sure to install a new oval foam weather seal around the heater core inlet and outlet
tubes.
To install, reverse the removal procedure.
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