radiator cap FORD MUSTANG 2003 Owner's Manual

operating. Failure to follow these instructions could result in damage to the cooling system or
engine and/or personal injury. To avoid having scalding hot coolant or steam blow out of the
cooling system, use extreme care when removing the pressure relief cap from a hot degas
bottle. Wait until the engine has cooled, then wrap a thick cloth around the pressure relief cap
and turn it slowly one turn (counterclockwise). Step back while the pressure is released from
the cooling system. When certain all the pressure has been released, remove pressure relief
cap (still with a cloth).
1. Immerse the pressure relief cap in water and install it on the shallow filler neck of Radiator/Heater Core Pressure Tester and Radiator Cap Adapter, part of Radiator/Heater Core
Pressure Tester.
2. Immerse the filler neck seal in water and install it in the filler neck adapter.
3. Install the filler neck adapter with the filler neck seal to the Radiator Cap Adapter.
4. Connect the female quick- connect fitting of the pressure test pump to the male quick- connect
fitting of the filler neck adapter.
5. NOTE: If the plunger of the pump is depressed too fast, an erroneous pressure reading will
result.
Slowly depress the plunger of the pressure test pump until the pressure gauge reading stops
increasing and note the highest pressure reading obtained.
6. Release the pressure by turning the relief screw counterclockwise. Then tighten the pressure relief screw and repeat Step 6 (at least twice) to make sure the reading is repeatable within the
specifications of the pressure relief cap.
7. If the pressure test gauge readings are not within specifications, install a new pressure relief cap. If the pressure test gauge readings are within specifications, carry out the cooling system
pressure test.
Radiator Leak Test, Removed From the Vehicle CAUTION: Never leak test an aluminum radiator or intercooler in the same water that
copper/brass radiators are tested in. Flux and caustic cleaners may be present in the cleaning
tank and they will damage aluminum radiators and intercoolers.
NOTE: Clean the radiator or intercooler before leak testing to avoid contamination of tank.
1. Leak test the radiator or intercooler in clean water with 138 kPa (20 psi) air pressure. Klj . 6 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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DIAGNOSIS AND TESTING
Leakage Inspection
CAUTION: Do not try to stop the fluid leak by increasing the torque beyond specifications.
This may cause damage to the case threads.
Check the fluid filler tube connection at the transmission case. If leakage is found here, install a new
grommet.
Check the VSS plug or VSS sensor O-ring (model dependent). If leakage is found install a new O- ring.
Check fluid lines and fittings between the transmission and the cooler in the radiator tank for
looseness, wear, or damage. If leakage cannot be stopped by tightening a fluid tube nut, install new
parts. When fluid is found leaking between the case and cooler line fitting, check for missing or
damaged O- ring, then tighten the fitting to maximum specification.
If the leak continues, install a new cooler line fitting and tighten to specification. The same procedure
should be followed for fluid leaks between the radiator cooler and the cooler line fittings in this section;
refer to Section 307 - 02 .
Check the engine coolant in the radiator. If transmission fluid is present in the coolant, the cooler in the
radiator is probably leaking.
The cooler can be further checked for leaks by disconnecting the lines for the cooler fittings and
applying no more than 345 kPa (50 psi) air pressure to the fittings. Remove the radiator cap to relieve
the pressure buildup at the exterior of the oil cooler tank. If the cooler is leaking and or will not hold
pressure, install a new cooler.
If leakage is found at the transmission range selector lever, install a new seal.
If leakage is found at the transmission internal harness connector, install a new O- ring. 4R70W External Sealing SECTION 307-
01: Automatic Transaxle/Transmission 2003 Mustang Workshop Manual Klj . 1 ba
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DIAGNOSIS AND TESTING
Transmission Cooling
Inspection and Verification
WARNING: Never remove the radiator cap under any conditions while the engine is
operating. Failure to follow these instructions could result in personal injury and/or damage to
the cooling system or engine. To avoid having scalding hot coolant or steam blow out of the
radiator, use extreme care when removing the radiator cap from a hot radiator. Wait until the
engine has cooled, then wrap a thick cloth around the radiator cap and turn it slowly to the first
stop. Step back while the pressure is released from the cooling system. When you are certain
all the pressure has been released, press down on the radiator cap (with a cloth), turn and
remove.
The transmission fluid cooler is integral to the radiator (8005). Whenever leaks or damage to the
radiator are found, install an entire new radiator. For additional information, refer to Section 303 - 03A or
Section 303 - 03B .
Symptom Chart SECTION 307-
02: Transaxle/Transmission Cooling 2003 Mustang Workshop Manual SYMPTOM CHART
Condition
Possible Sources Action
z Transmission
Overheating z
Damaged radiator. zREPAIR or install a new
radiator. For additional
information, REFER to
Section 303 - 03A or
Section 303 - 03B .
z System leaks. zINSPECT for leaks. REPAIR
as necessary.
z Incorrect fluid level. zADJUST to proper level.
z Fluid condition. zINSPECT according to
instructions under Fluid
Condition Check. REFER to
Section 307 - 01 .
z Damaged, blocked,
reversed, leaking or
restricted cooler lines
or cooler tubes. z
INSPECT cooler lines and
tubes. REPAIR or flush as
necessary.
z Engine concerns
causing transmission
to overheat. z
INSPECT engine cooling
system. For additional
information, REFER to
Section 303 - 03A or
Section 303 - 03B .
z Excessive towing
loads. z
CHECK gross vehicle weight.
z Incorrect idle or
performance. z
REFER to the Powertrain
Control/Emissions Diagnosis
(PC/ED) manual. Klj . 1 ba
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PINPOINT TEST C: THE A/C DOES NOT OPERATE/DOES NOT
OPERATE CORRECTLY z
Is the heater core inlet hose too hot to handle? B3 CHECK THE ENGINE COOLING SYSTEM INCLUDING
RADIATOR CAP FOR LEAKS z
Fill the engine cooling system to specified level.
z NOTE: It is not necessary to check the components
separately at this time.
z Pressure check the engine cooling system. Refer to Section 303 - 03A or
Section 303 - 03B .
z Does the engine cooling system, including the radiator
cap, hold pressure? Yes
GO to
B4 .
No
Pressure test the heater
core. REFER to
Component Tests, Heater
Core — Pressure Test. B4 CHECK THE HEATER CORE OUTLET HOSE FOR HOT
WATER z
Feel the heater core outlet hose.
z Is the heater core outlet hose cool or cold? Yes
TEST the heater core for a
plugged or partially
plugged condition. REFER
to
Section 303 - 03A or
Section 303 - 03B .
No
GO to Pinpoint Test E .
Test Step Result / Action to Take
C1 CHECK THE PCM PID WACF
z
Connect the diagnostic tool.
z Turn the function selector to the OFF position.
z Key in ON position.
z Enter the following diagnostic mode on the diagnostic
tool:
z Monitor the PCM PID WACF while turning the function
selector.
z Does the PCM PID WACF read YES? Yes
REFER to the Powertrain
Control/Emissions Diagnosis
(PC/ED) manual.
No
GO to
C2 .
C2 CHECK THE PCM PID WACF WITH THE A/C ON
z
Turn the function selector switch to the A/C position.
z Enter the following diagnostic mode on the diagnostic Yes
REFER to the Powertrain Klj . 15 ba
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SPECIFICATIONS
SECTION 414-
01: Battery, Mounting and Cables 2003 Mustang Workshop Manual General Specifications
Item Specification
Manufacturer Motorcraft
Voltage 12 volt
Amps at -
17.7°C (0°F) cold crank 540
Minutes—
reserve capacity 100
Amps/hrs.—20 hour rate 55
Location Left front of engine compartment
Torque Specifications Description Nm lb-
ft lb-
in Battery cable harness front support bracket nut 25 18 —
Battery cable terminal bolts 7 — 62
Battery hold-
down bolt 10 — 89
Battery junction box nut 20 15 —
Battery tray bolts 11 8 —
Front lower cable harness bracket nuts 11 8 —
Generator B+ cable nut 8 — 71
Battery cable bracket nut (left upper) 25 18 —
Battery ground cable nut (engine block) 25 18 —
Battery ground cable at the radiator support bolt 12 9 —
Positive battery cable nut (starter solenoid) 12 9 —
Positive battery wire nut (starter solenoid) 6 — 53
Right engine mount cable harness bracket nut 25 18 — Klj . 1 ba
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