lock FORD MUSTANG 2003 Workshop Manual

z
Pressurize the EVAP system to 3.48 kPa (14 inches
H
2 O).
z Does the pressure drop immediately? the evaporative emission repair
verification drive cycle. REFER to
Evaporative Emission Repair
Verification Drive Cycle in this
section.
No
GO to F6 .
F6 TEST FOR BLOCKAGE IN CANISTER VENT
SOLENOID HOSE z
Disconnect the canister vent solenoid hose from the
canister vent solenoid.
z Pressurize the EVAP system to 3.48 kPa (14 inches
H
2 O).
z Does the pressure drop immediately? Yes
INSTALL a new canister vent
solenoid hose. CARRY OUT a leak
test. REFER to
Evaporative Emission System Leak Test in this
section. If the system passes the
leak test, CARRY OUT the
evaporative emission repair
verification drive cycle. REFER to
Evaporative Emission Repair Verification Drive Cycle in this
section.
No
GO to F7 .
F7 TEST FOR BLOCKAGE IN CANISTER VENT
SOLENOID z
Disconnect the canister vent solenoid from the
evaporative emissions canister. Refer to
Evaporative Emission Canister Vent Solenoid in this
section.
z Pressurize the EVAP system to 3.48 kPa (14 inches
H
2 O).
z Does the pressure drop immediately? Yes
INSTALL a new canister vent
solenoid. REFER to
Evaporative Emission Canister Vent Solenoid in
this section. CARRY OUT a leak
test. REFER to Evaporative Emission System Leak Test in this
section. If the system passes the
leak test, CARRY OUT the
evaporative emission repair
verification drive cycle. REFER to
Evaporative Emission Repair Verification Drive Cycle in this
section.
No
GO to F8 .
F8 TEST FOR BLOCKAGE IN EVAPORATIVE
EMISSIONS CANISTER z
Disconnect the evaporative emissions canister inlet
elbow from the evaporative emissions canister. Yes
INSTALL a new evaporative
emissions canister. REFER to Klj . 23 ba
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z
Pressurize the EVAP system to 3.48 kPa (14 inches
H
2 O).
z Does the pressure drop immediately? Evaporative Emission Canister in
this section. CARRY OUT a leak
test. REFER to Evaporative Emission System Leak Test in this
section. If the system passes the
leak test, CARRY OUT the
evaporative emission repair
verification drive cycle. REFER to
Evaporative Emission Repair Verification Drive Cycle in this
section.
No
GO to F9 .
F9 TEST FOR BLOCKAGE IN CANISTER INLET
ELBOW z
Disconnect the fuel vapor control valve tube
assembly from the evaporative emissions canister
inlet elbow.
z Pressurize the EVAP system to 3.48 kPa (14 inches
H
2 O).
z Does the pressure drop immediately? Yes
INSTALL a new evaporative
emissions canister inlet elbow.
CARRY OUT a leak test. REFER to
Evaporative Emission System Leak
Test in this section. If the system
passes the leak test, CARRY OUT
the evaporative emission repair
verification drive cycle. REFER to
Evaporative Emission Repair Verification Drive Cycle in this
section.
No
GO to F10 .
F10 TEST FOR PINCHED FUEL VAPOR CONTROL
VALVE TUBE z
Lower the fuel tank 19.05 mm (3/4 inch).
z Connect the Evaporative Emission System Leak
Tester to the fuel filler pipe.
z Close the canister vent solenoid. Refer to Canister Vent Solenoid Closing Procedure in this section.
z Pressurize the EVAP system to 3.48 kPa (14 inches
H
2 O).
z Is the FTP (FTP V) PID reading 3.11 kPa to 3.86
kPa (12.5 to 15.5 inches H
2 O) (4.22 to 4.90
volts)? Yes
INSTALL a new fuel vapor control
valve tube assembly. REFER to
Fuel Vapor Control Tube Assembly
Valve in this section. CARRY OUT a
leak test. REFER to Evaporative Emission System Leak Test in this
section. If the system passes the
leak test, CARRY OUT the
evaporative emission repair
verification drive cycle. REFER to
Evaporative Emission Repair Verification Drive Cycle in this
section.
No
GO to F11 .
F11 TEST FOR BLOCKAGE IN FUEL FILLER TUBE
ASSEMBLY z
Disconnect the tank vapor recirculation tube from
the fuel filler pipe and plug both openings. Yes
INSTALL a new fuel vapor control
valve tube assembly. REFER to Klj . 24 ba
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SPECIFICATIONS
SECTION 303-
14: Electronic Engine Controls 2003 Mustang Workshop Manual General Specifications
Item Specification
Lubricants
Super premium SAE 5W-
20 Engine Oil XO-5W20-DSP WSS-
M2C914- A Penetrating and Lock Lubricant E8AZ-19A501-
B N/A
Pipe Sealant with Teflon D8AZ-19554-
A WSK-
M26350- A2
Torque Specifications Description Nm lb-
ft lb-
in Cylinder head temperature (CHT) sensor —
3.8L 10 — 89
Engine coolant temperature (ECT) sensor —
4.6L (2V) 20 — 15
Engine coolant temperature (ECT) sensor —
4.6L (4V) 24 18 —
Heated oxygen sensors (HO2S) 41 30 —
Catalyst monitor sensors 41 30 —
Crankshaft position (CKP) sensor bolts —
3.8L 6 — 53
Crankshaft position (CKP) sensor bolts —
4.6L 10 — 89
Power steering reservoir bolts 10 — 89
Camshaft position (CMP) sensor bolt —
4.6L 10 — 89
PCM connector to module bolt 6 — 53
Idle air control (IAC) valve bolts 10 — 89
Camshaft synchronizer housing bolt 25 18 —
Throttle position (TP) sensor screws 3 — 27
Fuel pressure sensor bolts 4 — 35
Air intake scoop bolts 25 18 —
Air intake scoop bracket bolt 25 18 —
Air intake scoop bracket nuts 25 18 —
Air intake scoop bracket throttle body nut 9 — 80
Exhaust gas recirculation (EGR) vacuum regulator solenoid bolts 10 — 89 Klj . 1 ba
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REMOVAL AND INSTALLATION
Heated Oxygen Sensor (HO2S)
Removal and Installation
1. Disconnect the battery ground cable. For additional information, refer to Section 414 - 01 .
2. Raise and support the vehicle. For additional information, refer to Section 100 - 02 .
3. NOTE: Two heated oxygen sensors (HO2S) are used for the engine control system. They are
located in the dual converter Y pipe. The left side (HO2S) is shown, the right side is similar.
Disconnect the HO2S electrical connector.
4. NOTE: If necessary, lubricate the heated oxygen sensors with penetrating and lock lubricant to
assist in removal.
Using the special tool, remove the HO2S from the dual converter Y pipe.
5. To install, reverse the removal procedure.
SECTION 303-
14: Electronic Engine Controls 2003 Mustang Workshop Manual Special Tool(s)
Socket, Exhaust Gas Oxygen
Sensor
303-
476 (T94P-9472- A)
Material Item Specification
Penetrating and Lock Lubricant
or equivalent E8AZ-
19A501-
B Klj . 1 ba
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REMOVAL AND INSTALLATION
Catalyst Monitor Sensor
Removal and Installation
1. Disconnect the battery ground cable. For additional information, refer to Section 414 - 01 .
2. Raise and support the vehicle. For additional information, refer to Section 100 - 02 .
3. NOTE: Two catalyst monitor sensors are used for the engine control system. They are located
in the dual converter Y pipe downstream from the catalyst. The left side catalyst monitor sensor
is shown, the right side is similar.
Disconnect the connector.
4. NOTE: If necessary, lubricate the sensors with penetrating and lock lubricant to assist in
removal.
Using the special tool, remove the catalyst monitor sensors from the dual converter Y pipe.
SECTION 303-
14: Electronic Engine Controls 2003 Mustang Workshop Manual Special Tool(s)
Socket, Exhaust Gas Oxygen
Sensor
303-
476 (T94P-9472- A)
Material Item Specification
Penetrating and Lock Lubricant
or equivalent E8AZ-
19A501-
B Klj . 1 ba
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DESCRIPTION AND OPERATION
Identification Tags
All vehicles are equipped with a Vehicle Certification Label, located on the driver side door lock post.
For correct transmission identification, refer to the code in the space marked TR.
For model, service ID level or build date information, refer to the transmission service ID tag located on
the transmission case.
Identification Tag
SECTION 307-
01: Automatic Transaxle/Transmission 2003 Mustang Workshop Manual Item Part Number Description
1 — Model number
2 — Assembly number
3 — Serial number
4 — Model and serial number Klj . 1 ba
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DESCRIPTION AND OPERATION
Range Selection
The transmission has six range positions: P, R, N, (D), 2 and 1.
Park
In the PARK position:
zthere is no powerflow through the transmission.
z the parking pawl locks the output shaft to the case.
z the engine can be started.
z the ignition key can be removed.
Reverse
In the REVERSE position:
zthe vehicle can be operated in a rearward direction, at a reduced gear ratio.
z engine braking will occur.
Neutral
In the NEUTRAL position:
zthere is no powerflow through the transmission.
z the output shaft is not held and is free to turn.
z the engine can be started.
Overdrive
Overdrive is the normal position for most forward driving.
The OVERDRIVE position provides:
zAutomatic shifts.
SECTION 307-
01: Automatic Transaxle/Transmission 2003 Mustang Workshop Manual Klj . 1 ba
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The TCC solenoid is used to control the apply and release of the TCC.
Shift Solenoid —
SSA, SSB
Two on/off shift solenoids provide gear selection of first through fourth gears by controlling the
pressure to the three shift valves. One unit containing the two shift solenoids is located in the main
control valve body. The shift solenoids are two- way, normally open style.
a When a manual pull- in occurs above a calibrated speed, the transmission will not downshift from the
higher gear until the vehicle speed drops below this calibrated speed.
EC = Electronically Controlled
HD = Hydraulically Disabled
Transmission Fluid Temperature (TFT) Sensor
The transmission fluid temperature (TFT) sensor is located on the lead frame assembly near the shift
solenoids on the main control valve body. It is a temperature- sensitive device called a thermistor. It
sends a voltage signal to the PCM. The voltage signal varies with transmission fluid temperature. The
PCM uses this signal to determine whether a cold start shift schedule is necessary. The shift schedule
is compensated when the transmission fluid temperature is cold. The PCM also inhibits (TCC)
operation at low transmission fluid temperatures and corrects electronic pressure control.
Vehicle Speed (VSS) Sensor
The source of vehicle speed (VSS) is model dependent. Possible sources of vehicle speed input are
anti- lock brake sensor (ABS), a gear- driven vehicle speed sensor (VSS), or an output shaft speed
sensor (OSS). The VSS signal is either an A/C signal whose frequency changes with speed, or an
SCP data message depending on the source. Some applications will have both. The vehicle speed
signal is an input to various vehicle subsystems such as the powertrain control module (PCM),
instrument cluster (speedometer and odometer), speed control system, etc. The vehicle speed source
must be operational to enter output state control (OSC) mode for diagnostics.
Regardless of the type of vehicle speed system, the PCM always uses the OSS for transmission and Solenoid Operation Chart Selector Lever Position PCM Commanded Gear Solenoids
SSA SSB TCC
P/R/N 1 ON OFF HD
(D) 1 ON OFF HD
(D) 2 OFF OFF EC
(D) 3 OFF ON EC
(D) 4 ON ON EC
w/OD OFF
1 1 ON OFF HD
2 2 OFF OFF EC
3 3 OFF ON EC
Manual 2 2 OFF OFF EC
Manual 1 1 ON OFF HD
1
a 2 OFF OFF EC Klj . 3 ba
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DIAGNOSIS AND TESTING
Output State Control (OSC) Mode
Output State Control (OSC) allows the technician to take control of certain parameters to function the
transmission. For example, OSC allows the technician to shift the transmission only when he/she
commands a gear change. If the technician commands 1st gear in OSC, the transmission will remain
in 1st gear until the technician commands the next gear. Another example, the technician can
command a shift solenoid to turn on or off when carrying out an electrical circuit check. OSC has two
modes of operation for transmission, the BENCH MODE and the DRIVE MODE. Each
mode/parameter has a unique set of vehicle operating requirements that the technician is required to
meet before being allowed to operate OSC.
NOTE:
To operate OSC the digital transmission range (TR) sensor must be operational. No Diagnostic
Trouble Codes (DTCs) related to the digital TR sensor can be present.
To operate OSC the vehicle speed source must be operational. No diagnostic codes (DTCs) related to
this source can be present. The vehicle speed source can vary depending on vehicle configuration.
Technicians should verify which input source is applicable for their vehicle application. The following
are potential vehicle speed sources:
„anti- lock braking system (ABS)
„ output shaft speed (OSS) sensor
„ vehicle speed sensor
z The vehicle requirements MUST BE MET when SENDING the OSC value. Refer to individual
test modes for vehicle requirements.
z If the vehicle requirements are NOT MET when SENDING the OSC value, an ERROR
MESSAGE will appear. When the ERROR MESSAGE is received, OSC is aborted and must be
restarted.
z If AFTER SENDING an OSC value, and the vehicle requirements are no longer met, the PCM
will cancel the OSC value and NO ERROR message will appear. Once the vehicle requirements
are met again, the PCM will automatically SEND the previous OSC value without any additional
actions required by the service technician.
z The OSC value XXX may be sent anytime to cancel OSC.
Output State Control (OSC) Procedures
zCarry out visual inspection and vehicle preparation as required.
z Select "Vehicle and Engine Selection" menu.
z Select appropriate vehicle and engine.
z Select "Diagnostic Data Link."
z Select "Powertrain Control Module."
z Select "Output Test Mode."
z Select "KOEO On- Demand Self Test and KOER On- Demand Self Tests."
z Carry out test and record DTCs.
z Repair all NON- Transmission DTCs.
z Repair all digital TR Sensor DTCs.
SECTION 307-
01: Automatic Transaxle/Transmission 2003 Mustang Workshop Manual Klj . 1 ba
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following areas of possible leakage should also be checked to determine if engine oil leakage is
causing the concern.
a. Leakage at the engine valve cover gasket may allow oil to flow over the torque converter housing or seep down between the torque converter housing and cylinder block causing oil to
be present in or at the bottom of the torque converter housing.
b. Oil galley plug leaks will allow oil to flow down the rear face of the cylinder block to the bottom of the torque converter housing.
c. Leakage at the crankshaft rear oil seal will work back to the flexplate, and then into the torque converter housing.
d. Leakage at engine oil pressure sensor.
Leak Check Test 1. Remove the fluid level indicator and note the color of the fluid. Original factory fill fluid is dyed red to aid in determining if leakage is from the engine or transmission. Unless a considerable
amount of makeup fluid has been added or the fluid has been changed, the red color should
assist in pinpointing the leak.
2. Remove the torque converter housing cover. Clean off any fluid from the top and bottom of the torque converter housing, front of the case and rear face of the engine and oil pan. Clean the
torque converter area by washing with a suitable nonflammable solvent and blow dry with
compressed air.
3. Wash out the torque converter housing, the front of the flexplate and the converter drain plugs. The torque converter housing may be washed out using cleaning solvent and a squirt- type oil
can. Blow all washed areas dry with compressed air.
4. Start and run the engine until the transmission reaches its normal operating temperature. Observe the back of the cylinder block and top of the torque converter housing for evidence of
fluid leakage. Raise the vehicle on a hoist; refer to Section 100 - 02 and run the engine at fast
idle, then at engine idle, occasionally shifting to the Overdrive and Reverse ranges to increase
pressure within the transmission. Observe the front of the flexplate, back of the cylinder block
(in as far as possible), and inside the torque converter housing and front of the case. Run the
engine until fluid leakage is evident and the probable source of leakage can be determined.
Leak Check Test With Black Light Used With 12 Volt Master UV Diagnostic Inspection Kit
Oil soluble aniline or fluorescent dyes premixed at the rate of 2.5ml (1/2 teaspoon) of dye powder to
0.235L (1/2 pint) of transmission fluid have proved helpful in locating the source of fluid leakage. Such
dyes may be used to determine whether an engine oil or transmission fluid leak is present, or if the
fluid in the fluid cooler leaks into the engine cooling system. A black light must be used with the
fluorescent dye solution. Klj . 4 ba
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