clutch FORD MUSTANG 2003 Workshop Manual

DESCRIPTION AND OPERATION
Speed Control
The speed control system consists of the following components:
zspeed control actuator cable (9A825)
z deactivator switch
z output shaft sensor (OSS)
z speed control actuator switches (9C888)
z brake pedal position (BPP) switch (13480)
z speed control servo (9C735)
z clutch pedal position switch (manual transmission only)
SECTION 310-
03: Speed Control 2003 Mustang Workshop Manual Klj . 1 ba
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z
speed control actuator switches.
z brake pedal position (BPP) switch.
z clutch pedal position (CPP) switch.
z deactivator switch.
The output of the speed control servo is the:
zspeed control actuator cable controlling the throttle position.
Inspection and Verification
NOTE: If any concerns are noted with the speedometer, stoplamps, or horn, address those concerns
by referring to their associated sections before continuing speed control diagnosis.
1. Verify the customer concern by operating the speed control system.
2. Visually inspect for obvious signs of mechanical and electrical damage.
3. If the fault is not visually evident, verify the symptom and GO to the Symptom chart.
Symptom Chart
NOTE: New speed control diagnostic software is available in Version 12 or higher for the diagnostic
tool. When using this software, it is necessary to use Next Generation Speed Control Adapter 007-
00586 with the diagnostic tool.
NOTE: Refer to the Wiring Diagrams for connector numbers stated in the Pinpoint Test.
Visual Inspection Chart Mechanical Electrical
z
Deactivator switch
z Speed control actuator cable not attached to throttle
z Speed control actuator cable not fully seated to the
engine bracket z
Central junction box (CJB)
Fuse:
„15 (15A)
„ 33 (15A)
„ 35 (15A)
z Battery junction box (BJB)
fuse:
„HORN (20A)
z Wiring harness
z Loose or corroded
connections
z Speed control actuator
switches
Symptom Chart Condition
Possible Sources Action
z The speed control is zCentral junction zGo To Pinpoint Test A . Klj . 2 ba
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inoperative
box (CJB) fuse
17 (15A), 33
(15A).
z Battery junction
box (BJB) fuse
HORN (20A).
z Circuitry.
z Deactivator
switch.
z Clutch pedal
position (CPP)
switch.
z Speed control
actuator switch.
z Speed control
servo.
z Powertrain
control module
(PCM).
z The set speed
fluctuates z
Circuitry.
z Speed control
servo.
z Powertrain
control module
(PCM). z
Go To Pinpoint Test B .
z Engine. zREFER to the Powertrain
Control/Emissions
Diagnosis (PC/ED)
manual.
z The speed control
does not disengage
when the brakes are
applied z
Central junction
box (CJB) fuse
33 (15A).
z Circuitry.
z Brake pedal
position (BPP)
switch.
z Speed control
servo. z
Go To Pinpoint Test C .
z The speed control
does not disengage
when the clutch is
applied z
Cluch pedal
position (CPP)
switch.
z Speed control
servo. z
Go To Pinpoint Test D .
z The speed control
switch is
inoperative— COAST z
Speed control
actuator switch.
z Speed control
servo. z
Go To Pinpoint Test E .
z The speed control
switch is
inoperative—
SET/ACCEL z
Speed control
actuator switch.
z Speed control
servo. z
Go To Pinpoint Test F .
z The speed control
switch is
inoperative—
RESUME z
Speed control
actuator switch.
z Speed control
servo. z
Go To Pinpoint Test G .
z The speed control
switch is
inoperative— OFF z
Speed control
actuator switch.
z Speed control
servo. z
Go To Pinpoint Test H . Klj . 3 ba
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PINPOINT TEST C: THE SPEED CONTROL DOES NOT DISENGAGE
WHEN THE BRAKES ARE APPLIED
PINPOINT TEST D: THE SPEED CONTROL DOES NOT DISENGAGE
WHEN THE CLUTCH IS APPLIED B2 CHECK THE SPEED CONTROL
ACTUATOR CABLE z
NOTE: The speed control actuator cable
must be disconnected at both ends while
carrying out this test.
z Check the speed control actuator cable
for sticking or binding at the speed
control servo and throttle body.
z Is the speed control actuator cable
OK? Yes
GO to
B3 .
No
INSTALL a new speed control actuator cable;
REFER to Actuator Cable — Speed Control .
TEST the system for normal operation. B3 CHECK THE SPEED CONTROL SERVO
z
INSTALL a known good speed control
servo.
z Test drive the vehicle for correct
operation.
z Does the speed control operate
correctly? Yes
INSTALL a new speed control servo; REFER
to
Actuator — Speed Control Servo . TEST the
system for normal operation.
No
INSTALL a new PCM; REFER to Section 303 -
14 . TEST the system for normal operation.
Test Step Result / Action to Take
C1 CHECK THE BPP SWITCH CIRCUITRY
z
Key in OFF position.
z Disconnect: Speed Control Servo C122 .
z Measure the voltage between speed control servo C122 Pin 4,
Circuit 511 (LG), harness side and speed control servo C122
Pin 10, Circuit 1205 (BK), harness side, while depressing the
brake pedal.
z Is the voltage greater than 10 volts? Yes
INSTALL a new speed
control servo; REFER to
Actuator
— Speed
Control Servo . TEST
the system for normal
operation.
No
REPAIR Circuit 810
(RD/LG) and Circuit 511
(LG) as necessary.
TEST the system for
normal operation. Test Step Result / Action to Take
D1 CHECK THE CLUTCH PEDAL POSITION (CPP) SWITCH
z
Key in OFF position.
z Disconnect: CPP Switch C2072.
z Measure the resistance between CPP switch pin 2
(component side) and CPP switch pin 1 (component side), Yes
INSTALL a new speed
control servo; REFER to
Actuator
— Speed Control Klj . 10 ba
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PINPOINT TEST E: THE SPEED CONTROL SWITCH IS
INOPERATIVE—
COAST
PINPOINT TEST F: THE SPEED CONTROL SWITCH IS
INOPERATIVE— SET/ACCEL while depressing and releasing clutch pedal.
z Is the resistance greater than 10,000 ohms with the
clutch pedal depressed and less than 5 ohms with the
clutch pedal released? Servo . TEST the system
for normal operation.
No
INSTALL a new CPP
switch. TEST the system
for normal operation. Test Step Result / Action to
Take E1 CHECK THE SPEED CONTROL ACTUATOR SWITCH
z
Key in OFF position.
z Disconnect: Speed Control Servo C122.
z Measure the resistance between speed control servo C122 Pin
5, Circuit 151 (LB/BK), harness side and speed control servo
C122 Pin 6, Circuit 848 (DG/OG), harness side, while pressing
the speed control actuator switch COAST.
z Is the resistance between 108 and 132 ohms? Yes
INSTALL a new speed
control servo; REFER
to
Actuator — Speed
Control Servo . TEST
the system for normal
operation.
No
INSTALL a new speed
control actuator switch;
REFER to Switch —
Speed Control
Actuator . TEST the
system for normal
operation. Test Step Result / Action to
Take F1 CHECK THE SPEED CONTROL ACTUATOR SWITCH
z
Key in OFF position.
z Disconnect: Speed Control Servo C122.
z Measure the resistance between speed control servo C122 Pin 5,
Circuit 151 (LB/BK), harness side and speed control servo C122
Pin 6, Circuit 848 (DG/OG), harness side, while pressing the
speed control actuator switch SET/ACCEL. Yes
INSTALL a new speed
control servo; REFER
to
Actuator — Speed
Control Servo . TEST
the system for normal
operation. Klj . 11 ba
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SPECIFICATIONS
a
Manifold gauge set pressures may vary slightly depending on the distance between the service
SECTION 412-
00: Climate Control System - General Information 2003 Mustang Workshop Manual General Specifications
Item Specification
A/C Compressor
Type FS-
10 swashplate, 5 double- acting pistons Displacement 170 cc (10.4 cu in)
Rotation Clockwise
A/C Pressure Relief Valve
a Open pressures 3,792-
4,137 kPa (550- 600 psi) A/C Pressure Sensor Refer to the Powertrain Control/Emissions
Diagnosis (PC/ED) manual.
Coolant Hose Lubricant
MERPOL® ESE-
M99B144- B Evaporator Core Orifice
Color Orange
Diameter 1.45 mm (0.057 in)
Magnetic Clutch
Air gap clearance 0.35-
0.75 mm (0.014- 0.030 in) Dual Function Pressure Switch (V8)
a Fan on/open 2,137-
2,344 kPa (310- 340 psi) Fan off/close 1,655-
2,137 kPa (240- 310 psi) Clutch off/open 2,999-
3,275 kPa (435- 475 psi) Clutch on/closed 1,517-
1,931 kPa (220- 280 psi) Pressure Cutoff Switch (V6)
a Open 2,999-
3,275 kPa (435- 475 psi) Close 1,586-
1,999 kPa (230- 290 psi) A/C Cycling Switch Open and Closed Pressures
a Open pressure 145-
159 kPa (21- 23 psi) Close pressure 290 kPa (42 psi)
Refrigerant Lubricant and Capacity
PAG Refrigerant Compressor Oil (R-134a Systems)
F7AZ- 19589- DA (Motorcraft YN-12- C) WSH-
M1C231- B Capacity 254 ml (8.6 oz)
Refrigerant and Capacity
R134a Refrigerant YN-
19 WSH-
M17B19- A Capacity .96 kg (34 oz)
Refrigerant System Cleaner
A/C Systems Flushing Solvent F4AZ-19579-
A — Klj . 1 ba
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evaporator core, it absorbs heat from the passenger compartment airflow passing over the plate/fin
sections of the A/C evaporator core. This addition of heat causes the refrigerant to boil (convert to a
gas). The now cooler passenger compartment air can no longer support the same humidity level of the
warmer air and this excess moisture condenses on the exterior of the evaporator coils and fins and
drains outside the vehicle.
The suction accumulator/drier (19C836) is designed to remove moisture from the refrigerant and to
prevent any liquid refrigerant that may not have been vaporized in the A/C evaporator core from
reaching the A/C compressor. The A/C compressor is designed to pump refrigerant vapor only, as
liquid refrigerant will not compress and can damage the A/C compressor.
The refrigerant cycle is now repeated with the A/C compressor again increasing the pressure and
temperature of the refrigerant.
The A/C cycling switch (19E561) interrupts compressor operation before the external temperature of
the A/C evaporator core gets low enough to cause the condensed water vapor (excess humidity) to
turn to ice. It does this by monitoring low side line pressure. It is known that a refrigerant pressure of
approximately 210 kPa (30 psi) will yield an operating temperature of 0°C (32°F). The A/C cycling
switch controls system operation in an effort to maintain this temperature.
The high side line pressure is also monitored so that the A/C compressor operation can be interrupted
if system pressure becomes too high.
The A/C compressor pressure relief valve (19D644) will open and vent refrigerant to relieve unusually
high system pressure.
Clutch Cycling Orifice Tube Type Refrigerant System Klj . 4 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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Symptom Chart
Condition
Possible Sources Action
z Incorrect/erratic direction
of airflow from outlet(s) z
No vacuum to A/C heater
function switch selector.
z A/C heater function selector
switch leaks vacuum.
z Kinked/pinched vacuum hose.
z Leaking vacuum control
motor.
z Leaking A/C vacuum check
valve.
z Leaking A/C vacuum reservoir
tank and bracket.
z Vacuum actuator arm not
connected to door crank. z
Go To Pinpoint
Test A .
z Insufficient, erratic, or no
heat z
Low engine coolant level.
z Thermostat stuck open.
z Disengaged/damaged
temperature cable. z
Go To Pinpoint
Test B .
z The A/C does not
operate/does not operate
correctly z
CASS strategy failure.
z Open fuses.
z A/C clutch relay.
z Shorted blend door actuator.
z Powertrain control module.
z Circuitry short/open.
z A/C cycling switch damaged.
z A/C system discharged/low
charge.
z Function selector switch
damaged.
z A/C pressure cut-off switch
damaged.
z A/C compressor clutch
damaged. z
Go To Pinpoint
Test C .
z The A/C is always on zCircuitry short/open.
z A/C cycling switch.
z A/C heater function selector
switch.
z Constant control relay
module.
z Incorrect A/C clutch air gap. z
Go To Pinpoint
Test D .
z Insufficient A/C cooling zRestricted A/C evaporator
core orifice.
z Low refrigerant level. z
Go To Pinpoint
Test E .
z No operation in all the
temperature settings z
Damaged blend door actuator
cable.
z Damaged air temperature
control door. z
Go To Pinpoint
Test F .
z The blower motor does
not operate z
Open fuse.
z Circuitry open/shorted.
z Damaged heater blower
motor switch (18578).
z Damaged heater blower
motor switch resistor (18591).
z Damaged blower motor relay.
z Damaged blower motor. z
Go To Pinpoint
Test G .
z The blower motor
operates continuously in z
Circuitry short/open.
z Damaged heater blower z
Go To Pinpoint Klj . 6 ba
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z
Disconnect: CCRM C1262.
z Measure the resistance of CCRM C1262- 18, circuit 1205
(BK), harness side and ground.
z Is the resistance reading less than 5 ohms? GO to
C21 .
No
REPAIR circuit 1205 (BK) for
an open. TEST the system for
normal operation. C21 CHECK CIRCUIT 20 (WH/LB) AT THE CONSTANT
CONTROL RELAY MODULE z
Key in ON position.
z Measure the voltage at the CCRM C1262- 13, circuit 20
(WH/LB), harness side and ground.
z Is the voltage reading greater than 10 volts? Yes
GO to
C22 .
No
REPAIR circuit 20 (WH/LB) for
an open. TEST the system for
normal operation. C22 CHECK THE POWER TO THE A/C CLUTCH
z
Key in OFF position.
z Connect: CCRM 1262.
z Disconnect: A/C Clutch C100.
z Turn the function selector to the A/C position.
z Measure the voltage at the A/C clutch C100, circuit 347
(BK/YE), harness side and ground. Yes
GO to
C24 .
No
GO to C23 . Klj . 22 ba
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