AC system FORD MUSTANG 2003 Workshop Manual

REMOVAL AND INSTALLATION
Degas Bottle
Removal and Installation
1. Drain the coolant. For additional information, refer to Supercharger Cooling System Draining, Filling and Bleeding in this section.
2. Disconnect the coolant hoses.
3. Remove the bolts and the degas bottle.
4. To install, reverse the removal procedure.
SECTION 303-
03B: Supercharger Cooling 2003 Mustang Workshop Manual Klj . 1 ba
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REMOVAL AND INSTALLATION
Fuel Injectors
Removal and Installation
WARNING: Do not smoke or carry lighted tobacco or open flame of any type when
working on or near any fuel related components. Highly flammable mixtures are always present
and may ignite. Failure to follow these instructions may result in personal injury.
WARNING: Fuel in the fuel system remains under high pressure even when the engine is
not running. Before working on or disconnecting any of the fuel lines or fuel system
components, the fuel pressure must be relieved. Failure to follow these instructions may result
in personal injury
1. Remove the supply manifold. For additional information, refer to Supply Manifold in this section.
2. Remove the six fuel injectors from the supply manifold.
3. CAUTION: The retaining clip must be in the upper groove on the injector or the
injector may become loose.
NOTE: Inspect the two O- rings from each fuel injector. Install new O- rings as needed.
NOTE: Lubricate the new O- rings with clean engine oil to aid installation.
To install, reverse the removal procedure.
SECTION 303-
04A: Fuel Charging and Controls — 3.8L 2003 Mustang Workshop Manual Material
Item Specification
SAE 5W-
20 Premium Synthetic
Blend Motor Oil
XO- 5W20-QSP or equivalent WSS-
M2C153-
H Klj . 1 ba
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REMOVAL AND INSTALLATION
Supply Manifold
Removal and Installation
WARNING: Do not smoke or carry lighted tobacco or open flame of any type when
working on or near any fuel related components. Highly flammable mixtures are always present
and may ignite. Failure to follow these instructions may result in personal injury.
WARNING: Fuel in the fuel system remains under high pressure even when the engine is
not running. Before working on or disconnecting any of the fuel lines or fuel system
components, the fuel system pressure must be relieved. Failure to follow these instructions
may result in personal injury.
1. Disconnect the battery ground cable.
2. Remove the upper intake manifold. For additional information, refer to Section 303 - 01A .
3. Relieve the fuel pressure. For additional information, refer to Section 310 - 00 .
4. Disconnect the fuel line. For additional information, refer to Section 310 - 00 .
5. Separate the wiring harness from the supply manifold.
6. NOTE: Right side shown, left side similar.
Disconnect the six fuel injector electrical connectors. 7. Disconnect the fuel pressure sensor. SECTION 303-
04A: Fuel Charging and Controls — 3.8L 2003 Mustang Workshop Manual Klj . 1 ba
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REMOVAL AND INSTALLATION
Fuel Injectors
Removal
WARNING: Do not smoke or carry lighted tobacco or open flame of any type when
working on or near any fuel related components. Highly flammable mixtures are always present
and may be ignited. Failure to follow these instructions may result in personal injury.
WARNING: Fuel in the fuel system remains under high pressure even when the engine is
not running. Before working on or disconnecting any of the fuel lines or fuel system
components, the fuel pressure must be relieved. Failure to follow these instructions may result
in personal injury.
1. Relieve the fuel pressure. For additional information, refer to Section 310 - 00 .
2. Remove the supply manifold. For additional information, refer to Fuel Injection Supply Manifold in this section.
3. Remove the fuel injectors from the supply manifold.
Installation 1. NOTE: Lubricate the new O- rings with Super Premium SAE 10W-30, XO-10W30- DSP or
equivalent meeting Ford specification WSS- M2C153-G, to aid installation.
Inspect the two O- rings on each fuel injector. Install new O- rings if necessary.
2. Install the fuel injectors onto the supply manifold.
SECTION 303-
04B: Fuel Charging and Controls — 4.6L (2V) 2003 Mustang Workshop Manual Klj . 1 ba
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REMOVAL AND INSTALLATION
Fuel Injection Supply Manifold
Removal
WARNING: Do not smoke or carry lighted tobacco or open flame of any type when
working on or near any fuel related components. Highly flammable mixtures are always present
and may be ignited. Failure to follow these instructions may result in personal injury.
WARNING: Fuel in the fuel system remains under high pressure even when the engine is
not running. Before working on or disconnecting any of the fuel lines or fuel system
components, the fuel pressure must be relieved. Failure to follow these instructions may result
in personal injury.
1. Disconnect the battery ground cable (14301). For additional information, refer to Section 414 -
01 .
2. Disconnect the air cleaner outlet tube. For additional information, refer to Section 303 - 12 .
3. Relieve the fuel pressure. For additional information, refer to Section 310 - 00 .
4. Disconnect the fuel line. For additional information, refer to Section 310 - 00 .
5. Remove the throttle body (9E926). For additional information, refer to Throttle Body in this
section.
6. Remove the idle air control (IAC) hose and position it out of the way.
7. Remove the positive crankshaft ventilation (PCV) hose.
SECTION 303-
04B: Fuel Charging and Controls — 4.6L (2V) 2003 Mustang Workshop Manual Klj . 1 ba
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REMOVAL AND INSTALLATION
Fuel Injection Supply Manifold and Fuel Injector
Removal and Installation
WARNING: Do not smoke or carry lighted tobacco or open flame of any type when
working on or near any fuel related components. Highly flammable mixtures are always present
and can ignite. Failure to follow these instructions can result in personal injury.
WARNING: Fuel in the fuel system remains under high pressure even when the engine is
not running. Before working on or disconnecting any of the fuel lines or fuel system
components, the fuel system pressure must be relieved. Failure to follow these instructions
can result in personal injury.
1. Disconnect the battery ground cable.
2. Remove the air cleaner outlet tube. For additional information, refer to Section 303 - 12 .
3. Release the fuel pressure. For additional information, refer to Section 310 - 00 .
4. Disconnect the fuel supply hose spring lock coupling. For additional information, refer to Section 310 - 00 .
5. Remove the exhaust gas recirculation (EGR) valve and the exhaust manifold- to-EGR valve
tube. For additional information, refer to Section 303 - 08 .
6. Remove the throttle body and spacer assembly.
7. Disconnect the vacuum hose.
SECTION 303-
04C: Fuel Charging and Controls — Cobra 4.6L (4V) 2003 Mustang Workshop Manual Material
Item Specification
SAE 5W-
20 Premium Synthetic
Blend Motor Oil
XO- 5W20- QSP WSS-
M2C153-
H Klj . 1 ba
42003 Mustang Workshop Manual
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REMOVAL AND INSTALLATION
Fuel Injectors
Removal
WARNING: Do not smoke or carry lighted tobacco or open flame of any type when
working on or near any fuel related components. Highly flammable mixtures are always present
and can ignite. Failure to follow these instructions can result in personal injury.
WARNING: Fuel in the fuel system remains under high pressure even when the engine is
not running. Before working on or disconnecting any of the fuel lines or fuel system
components, the fuel system pressure must be relieved. Failure to follow these instructions
can result in personal injury.
1. Remove the supply manifold. For additional information, refer to Supply Manifold in this section.
2. Remove the eight fuel injectors from the supply manifold.
Installation CAUTION: The retaining clip must be in the upper groove on the injector or the injector
can become loose.
1. NOTE: Inspect the two O- rings from each fuel injector. Install new O- rings as needed.
NOTE: Lubricate the new O- rings with clean engine oil.
To install, reverse the removal procedure.
SECTION 303-
04D: Fuel Charging and Controls — Mach I 4.6L (4V) 2003 Mustang Workshop Manual Klj . 1 ba
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REMOVAL AND INSTALLATION
Supply Manifold
Removal
WARNING: Do not smoke or carry lighted tobacco or open flame of any type when
working on or near any fuel related components. Highly flammable mixtures are always present
and can ignite. Failure to follow these instructions can result in personal injury.
WARNING: Fuel in the fuel system remains under high pressure even when the engine is
not running. Before working on or disconnecting any of the fuel lines or fuel system
components, the fuel system pressure must be relieved. Failure to follow these instructions
can result in personal injury.
1. Disconnect the battery ground cable. For additional information, refer to Section 414 - 01 .
2. Remove the upper intake manifold. For additional information, refer to Section 303 - 01D .
3. Relieve the fuel pressure. For additional information, refer to Section 310 - 00 .
4. Disconnect the fuel line. For additional information, refer to Section 310 - 00 .
5. Position the wiring harness aside. zDisconnect the RH fuel injector electrical connectors.
z Separate the harness from the RH fuel supply manifold stud bolt.
6. Disconnect the fuel pressure sensor. zDisconnect the electrical connector.
z Disconnect the vacuum hose.
SECTION 303-
04D: Fuel Charging and Controls — Mach I 4.6L (4V) 2003 Mustang Workshop Manual Klj . 1 ba
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Component Tests
Drive Belt Noise/Flutter
Drive belt chirp occurs due to pulley misalignment or excessive pulley runout. It can be the result of a
damaged pulley or an incorrectly aligned pulley.
To correct, determine the area where the noise comes from. Check each of the pulleys in that area
with a straightedge to the crankshaft pulley, looking for accessory pulleys out of position in the fore/aft
direction or at an angle to the straightedge.
Drive belt squeal is an intermittent noise that occurs when the drive belt slips on a pulley during certain
conditions, such as: engine start up, rapid engine acceleration, or A/C clutch engagement.
Drive belt squeal can occur:
zif any of the accessories are damaged, have a worn or damaged bearing, internal torsional
resistance above normal. All accessories should be rotatable by hand in the unloaded condition.
If not, inspect the accessory.
z if fluid gets on the drive belt. This includes power steering fluid, engine coolant, engine oil or air
conditioning system lubricant. If fluid does get on the drive belt during service, clean the drive
belt with soap and water and thoroughly rinse with clean water.
z NOTE: The drive belt tensioner arm should rotate freely without binding.
if the drive belt is too long. A drive belt that is too long will allow the drive belt tensioner arm to
go all the way to the arm travel stop under certain load conditions, which will release tension to
the drive belt. If the drive belt tensioner indicator is outside the installation wear range window,
install a new drive belt.
z if the drive belt tensioner is worn or damaged.
Belt Tension
NOTE: Drive belt tension is not adjustable.
The drive belt tensioner automatically adjusts drive belt tension. Symptom Chart Condition
Possible Sources Action
z Drive belt
noise, chirping,
flutter z
Defective/worn drive
belt.
z Misaligned pulley.
z Pulley runout.
z Damaged
accessories.
z Fluid contamination
of drive belt. z
GO to Component Tests, Drive
Belt, Noise/Flutter.
z Damaged or worn
drive belt tensioner. z
GO to Component Tests, Belt
Tensioner, Automatic.
z Premature
drive belt wear z
Defective drive belt.
z Misaligned pulley.
z Pulley runout.
z Damaged
accessories.
z Incorrectly installed
drive belt. z
GO to Component Tests, Drive
Belt Noise/Flutter and Drive
Belt Misalignment diagnosis. Klj . 2 ba
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SPECIFICATIONS
SECTION 303-
06: Starting System 2003 Mustang Workshop Manual General Specifications
Item Specification
Normal engine cranking speed rpm 100-
140 rpm Starter motor no load current draw amperes 60-
80 amps Starter motor normal load current draw 130 amps
Starter motor maximum load current draw amperes 400 amps
Maximum starting circuit voltage drop (engine at normal engine temperature) 0.5 volt
Torque Specifications Description Nm lb-
ft lb-
in Starter motor bolts 25 18 —
Starter motor ground cable nut 25 18 —
Starter motor solenoid S terminal nut 6 — 53
Starter motor solenoid B terminal nut 12 9 — Klj . 1 ba
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