FORD MUSTANG 2003 Workshop Manual

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-
00: Climate Control System - General Information 2003 Mustang Workshop Manual Klj . 1 ba
22003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_2308/S3B~us~en~ ...

4.
Refrigerant system leak test
zUse either an ultraviolet (UV) or an electronic leak detector to check for leaks at all
refrigerant lines, connections, and components.
After all tests have been completed, report all findings and recommended repairs to your
service advisor before carrying out further diagnostic procedures. Klj . 2 ba
22003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_2308/S3B~us~en~ ...

GENERAL PROCEDURES
Spring Lock Coupling
Disconnect
1. Remove the A/C tube lock coupling clip (19E746), if equipped.
2. Fit the special tool to the spring lock coupling.
3. Push the tool into the cage opening to release the female fitting from the A/C tube lock coupling spring (19E576).
SECTION 412-
00: Climate Control System - General Information 2003 Mustang Workshop Manual Special Tool(s)
Remover, Refrigerant Coupling
Set
412-
039 (T84L-19623- B) Klj . 1 ba
62003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_2308/S3B~us~en~ ...

4. Pull the spring lock coupling fittings apart.
5.
CAUTION: Do not use metal tools to remove the O- ring seals. They can cause axial
scratches across the O- ring seal grooves, resulting in refrigerant leaks.
Remove the O- ring seals with a non- metallic tool.
6. CAUTION: Do not use a screwdriver or similar tool to remove the A/C tube lock
coupling spring; this can cause axial scratches across the O- ring seal grooves resulting
in refrigerant leaks.
Remove the A/C tube lock coupling spring with a small hooked wire. Klj . 2 ba
62003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_2308/S3B~us~en~ ...

Cleaning
1. Fabricate a cleaning tool from a 1/8 inch diameter brazing rod.
2. Cut an abrasive pad from maroon colored 3M Scotch Brite® with the dimensions corresponding to the coupling size.
3. Assemble the pad to the tool.
4. Coat the abrasive pad with PAG Refrigerant Compressor Oil (R- 134a Systems) or equivalent.
5. Roll the pad on the tool and install it in a variable speed drill motor.
6. CAUTION: Maintain low speed drill rotation when inserting or removing the cleaning Coupling Size Pad Size
3/8 inch 25 x 50 mm (1 x 2 inch)
1/2 inch 25 x 50 mm (1 x 2 inch)
5/8 inch 25 x 76 mm (1 x 3 inch)
3/4 inch 25 x 102 mm (1 x 4 inch) Klj . 3 ba
62003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_2308/S3B~us~en~ ...

tool to prevent axial scratches which may cause future leaks.
Polish for one minute at moderate speed (less than 1,500 rpm) or until the surface is clean and
free of scratches or foreign material.
7. Clean the fitting with a lint- free cloth.
8. Inspect the surface for grooves or scratches. If grooves and scratches are still present, install a new component.
9. Clean the O- ring seal grooves with a 300 mm (12 inch) length of natural fiber string.
z Loop the string around the grooves and pull the string back and forth.
10. Remove any foreign material from the grooves with a lint- free cloth.
Connect 1. Install the A/C tube lock coupling spring.
2. Lubricate the inside of the coupling with PAG Refrigerant Compressor Oil (R- 134a Systems) or
equivalent. Klj . 4 ba
62003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_2308/S3B~us~en~ ...

3.
CAUTION: Use only the new O- ring seals. The use of any O-ring seals other than
those specified in the Ford Master Parts Catalog may result in intermittent leakage
during vehicle operation.
Install the O- ring seals.
z Lubricate the O- ring seals with PAG Refrigerant Compressor Oil (R- 134a Systems) or
equivalent.
4. Connect the spring lock coupling fittings with a twisting motion until the A/C tube lock coupling spring snaps over the flared end of the female fitting.
5. Install the A/C tube lock coupling clip. Klj . 5 ba
62003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_2308/S3B~us~en~ ...

Klj . 6 ba
62003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_2308/S3B~us~en~ ...

GENERAL PROCEDURES
Heater Hose Coupling
Disconnect
CAUTION: Do not attempt to install a new bushing, spacer or O- rings in the heater hose
coupling; damage to the heater hose coupling can result. If the heater hose coupling is the
cause of a coolant leak, the affected heater hose must be replaced as an assembly.
1. WARNING: The engine must be off, fully cool and the cooling system fully
depressurized before attempting to disconnect any heater water hoses. Failure to comply
with this warning can result in serious injury or burns from hot liquid escaping out of the
engine cooling system.
Depressurize the engine cooling system.
2. Push the heater hose toward the tube to fully expose the locking tabs.
3. NOTE: When compressing the white coupling retainer with the special tool, the special tool
must be perpendicular to and on the highest point of the coupling.
NOTE: If the heater hose coupling is accessible, the retainer tabs can be compressed by hand
to disconnect the heater hose.
Push the special tool over the coupling retainer windows to compress the retainer locking tabs.
SECTION 412-
00: Climate Control System - General Information 2003 Mustang Workshop Manual Special Tool(s)
Remover, Heater Hose Inlet
Tube
412-
042 (T85T-18539- AH) Disconnect Tool, Heater Hose
412-
127
Material Item Specification
MERPOL®
—
ESE-
M99B144- B Klj . 1 ba
32003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_2308/S3B~us~en~ ...

4.
NOTE: A slight twisting motion while pulling on the heater water hose may be necessary to
assist in the removal.
Pull the heater hose away from the heater core tube.
5. Spread the retainer tabs apart and slide the retainer off the tube. zDiscard the retainer.
Connect 1. Clean the tubes and lubricate with coolant hose lubricant or plain water.
2. Install a new coupling retainer (18D434) into the heater hose coupling housing. Klj . 2 ba
32003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_2308/S3B~us~en~ ...