coolant level FORD MUSTANG 2003 Owner's Guide

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
22003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_4464/S3B~us~en~ ...

CAUTION: The use of any other type of transmission fluid than specified could result in
transmission failure.
If fluid needs to be added, add fluid in 0.25L (1/2 pint) increments through the filler tube. Do not overfill
the fluid. For fluid type, refer to the specification chart.
Fluid Condition Check
1. Check the fluid level.
2. Observe the color and the odor. The color under normal circumstances should be dark reddish, not brown or black or have a burnt odor.
3. Hold the fluid level indicator over a white facial tissue and allow the fluid to drip onto the facial tissue and examine the stain.
4. If evidence of solid material is found, the transmission fluid pan should be removed for further inspection.
5. If the stain is a foamy pink color this may indicate coolant in the transmission. The engine cooling system should also be inspected at this time.
6. If fluid contamination or transmission failure is confirmed by the sediment in the bottom of the fluid pan, the transmission must be disassembled and completely cleaned. This includes the
torque converter and cooler tubes. The oil- to-air cooler will need to be installed.
7. Carry out diagnostic checks and adjustments. Refer to Diagnosis By Symptom in this section. Klj . 3 ba
32003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_2748/S3B~us~en~ ...

Stall Speed Test
WARNING: Apply the parking brake firmly while carrying out each stall test.
CAUTION: Carry out line pressure test prior to carrying out stall test. If the line pressure is
low at stall, do not carry out stall test or further transmission damage will occur.
The stall speed test checks:
zthe torque converter clutch operation and installation.
z the holding ability of the forward clutch.
z the reverse clutch (the low- reverse bands).
z the planetary one- way clutch.
z the engine driveability.
Conduct this test with the engine coolant and transmission fluid at correct levels and at normal
operating temperature.
Apply the parking brake firmly for each stall speed test. 1. Find the specified stall rpm for the vehicle; see the stall speed diagnosis chart. Use a grease pencil to mark the rpm on the dial of a tachometer.
2. Connect a tachometer to the engine.
3. NOTE: If the rpm recorded by the tachometer exceeds the maximum limits, release the
accelerator pedal immediately because clutch or band slippage is indicated.
In each of the following ranges (D), 2, 1, R, press the accelerator pedal to the floor and hold it ·
Reverse Clutch Low In Neutral Only ·
Valve Body Low In Overdrive Only ·
Forward Clutch ·
Valve Body Low In 1st Position Only ·
Forward Clutch ·
Valve Body ·
Low/Reverse Servo Low In 2nd Only ·
Intermediate Clutch ·
Valve Bodies ·
Forward Clutch Stall Speed
Application Min. Max.
3.8L engine 2,240 2,619
4.6L 2V engine 2,339 2,738
4.6L 4V MACH 1 engine 2,375 2,767 Klj . 4 ba
72003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_2748/S3B~us~en~ ...

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
22003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_2748/S3B~us~en~ ...

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
412003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_2308/S3B~us~en~ ...

PINPOINT TEST B: INSUFFICIENT, ERRATIC, OR NO HEAT z
Does the vacuum control motor hold a vacuum? A20 CHECK THE VACUUM CONTROL MOTOR INSTALLATION
z
Key in OFF position.
z Check the attachment of the vacuum control motor arm to
damper door.
z Is the vacuum control motor arm attached to the door or
door crank arm? Yes
REPAIR or INSTALL a
new damper door.
TEST the system for
normal operation.
No
CONNECT the vacuum
control motor arm to
the door and check
operation. TEST the
system for normal
operation.
Test Step Result / Action to Take
B1 CHECK FOR CORRECT ENGINE COOLANT LEVEL
z
Key in OFF position.
z Check the engine coolant level when hot and cold.
z Is the engine coolant at the correct level (hot/cold) as
indicated on the engine coolant recovery reservoir? Yes
GO to
B2 .
No
GO to B3 .
B2 CHECK FOR HOT WATER TO THE HEATER CORE INLET
HOSE WARNING: The heater core inlet hose will become
too hot to handle and may cause serious burns if the
system is working correctly.
z Key in START position.
z Allow the engine to reach normal operating temperature.
z Feel the heater core inlet hose. Yes
GO to
B4 .
No
TEST the engine cooling
system for correct
operation. REFER to
Section 303 - 03A or
Section 303 - 03B . Klj . 14 ba
412003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_2308/S3B~us~en~ ...

Heater Core
WARNING: Carbon monoxide gas is colorless, odorless and dangerous. If it is necessary
to operate the engine with the vehicle in a closed area such as a garage, always use an exhaust
collector to vent the exhaust gases outside the closed area. Failure to follow these instructions
may result in personal injury.
1. NOTE: Testing of returned heater cores reveals that a large percentage of heater cores are
good and did not require installation of a new heater core. If a heater core leak is suspected, the
heater core must be tested by following the Plugged Heater Core Component Test before the
Heater Core Pressure Test. Carry out a system inspection by checking the heater system
thoroughly as follows:
Inspect for evidence of coolant leakage at the heater water hose to heater core attachments. A
coolant leak in the heater water hose could follow the heater core tube to the heater core and
appear as a leak in the heater core.
CAUTION: Spring- type clamps are installed as original equipment. Installation and
overtightening of non- specification clamps can cause leakage at the heater water hose
connection and damage the heater core.
2. Check the integrity of the heater water hose clamps.
Heater Core— Plugged
WARNING: The heater core inlet hose will become too hot to handle if the system is
working correctly.
1. Check to see that the engine coolant is at the correct level.
2. Start the engine and turn on the heater.
3. When the engine coolant reaches operating temperature, feel the heater core outlet hose to see if it is hot.
If it is not hot:
zthe heater core may have an air pocket.
z the heater core may be plugged.
z the thermostat is not working correctly.
Heater Core— Pressure Test
Use the radiator/heater core pressure tester to carry out the pressure test. 1. NOTE: Due to space limitations, a bench test may be necessary for pressure testing.
Drain the coolant from the cooling system. For additional information, refer to Section 303 - 03A
or
Section 303 - 03B .
2. Disconnect the heater water hoses from the heater core. For additional information, refer to Klj . 37 ba
412003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_2308/S3B~us~en~ ...

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~ ...

DESCRIPTION AND OPERATION
Heating and Defrosting
The heating and defrosting system has the following features:
zControls the temperature and, during A/C operation, reduces the relative humidity of the air
inside the vehicle.
z Delivers heated or cooled air to maintain the vehicle interior temperature and comfort level.
z Controls the A/C blower motor speed.
z Cooling or heating can be adjusted to maintain the desired temperature.
z System uses a reheat method to provide conditioned air to the passenger compartment.
z The blower motor (19805) draws outside air through the air inlet duct from just below the
windshield during all system operations except for MAX A/C cooling (when recirculated air is
used).
z All airflow from the blower motor passes through the A/C evaporator core (19860).
z The temperature is then regulated by reheating a portion of the air and blending it with the
remaining cool air to the desired temperature.
z The temperature blending is varied by the air temperature control door, which regulates the
amount of air that flows through and around the heater core (18476), where it is then mixed and
distributed.
Heater Core
The heater core (18476) consists of fins and tubes arranged to extract heat from the engine coolant
and transfer it to air passing through the heater core. Blower Motor SECTION 412-
02: Heating and Ventilation 2003 Mustang Workshop Manual Klj . 1 ba
22003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_2308/S3B~us~en~ ...

Instrument Cluster—
Base 4.6L Engine transmission)
16 — LOW FUEL level indicator
17 — SERVICE ENGINE SOON indicator
18 — THEFT indicator
19 — AIR BAG warning indicator
20 — Charging system indicator
21 — Safety belt warning indicator
Item Part
Number Description
1 — Fuel gauge
2 — Engine coolant temperature gauge
3 — Speedometer
4 — Turn signal/hazard indicator
5 — High beam indicator
6 — Tachometer
7 — Odometer
8 — Trip odometer reset button
9 — Voltmeter gauge
10 — Oil pressure gauge
11 — CHECK FUEL CAP indicator
12 — BRAKE warning indicator
13 — ABS warning indicator Klj . 2 ba
42003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_5108/S3B~us~en~ ...