Test G FORD MUSTANG 2003 Workshop Manual

PINPOINT TEST J: NO OPERATION IN LOWER SPEEDS
Component Tests z
Measure the resistance between C294a- 3, circuit 1205
(BK), harness side and ground.
z Is the resistance less than 10,000 ohms? Yes
REPAIR circuit 1205 (BK) for
an open. TEST the system for
normal operation.
No
INSTALL a new blower motor
switch. REFER to
Section 412 - 04 . TEST the system for
normal operation. Test Step Result / Action to Take
J1 CHECK CIRCUIT 261 (OG/BK) FOR AN OPEN
z
Disconnect: Blower Motor Resistor C294a.
z Key in ON position.
z Turn the function selector switch to the FLOOR position.
z Set the blower motor switch to low.
z Measure the voltage between the blower motor resistor
C2185- 4, circuit 261 (OG/BK), jumper side and ground.
z Is the voltage greater than 10 volts? Yes
GO to
J2 .
No
REPAIR circuit 261 (OG/BK) for
an open circuit between the
blower motor and the blower
motor resistor. TEST the
system for normal operation. J2 CHECK CIRCUIT 1205 (BK) FOR AN OPEN
z
Key in OFF position.
z Measure the resistance between the blower motor
resistor C2185- 1, circuit 1205 (BK), jumper side and
ground.
z Is the resistance less than 5 ohms? Yes
INSTALL a new blower motor
resistor. REFER to
Section 412 -
03 . TEST the system for
normal operation.
No
REPAIR circuit 1205 (BK) for an
open between the blower motor
resistor and ground. TEST the
system for normal operation. Klj . 36 ba
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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
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Section 412 - 02 .
3. Install a short piece of heater water hose, approximately 101 mm (4 inches) long on each heater core tube.
4. Fill the heater core and heater water hoses with water and install Plug BT-7422- B and adapter
BT- 7422- A from the radiator/heater core pressure tester in the heater water hose ends. Secure
the heater water hoses, plug and adapter with hose clamps.
5. Attach the pump and gauge assembly from the radiator/heater core pressure tester to the adapter.
6. Close the bleed valve at the base of the gauge. Pump 241 kPa (35 psi) of air pressure into the heater core.
7. Observe the pressure gauge for a minimum of three minutes.
8. If the pressure drops, check the heater water hose connections to the core tubes for leaks. If the heater water hoses do not leak, remove the heater core from the vehicle and carry out the
bench test.
Heater Core— Bench Test
1. Remove the heater core from the vehicle. For additional information, refer to Section 412 - 02 .
2. Drain all of the coolant from the heater core.
3. Connect the 101 mm (4 inch) test heater water hoses with plug and adapter to the core tubes. Then connect the radiator/heater core pressure tester to the adapter.
4. Apply 241 kPa (35 psi) of air pressure to the heater core. Submerge the heater core in water.
5. If a leak is observed, install a new heater core. Klj . 38 ba
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A/C Evaporator/Condenser Core—
On-Vehicle Leak Test
1. Discharge and recover the refrigerant. For additional information, refer to Air Conditioning (A/C) System Recovery, Evacuation and Charging in this section.
2. NOTE: DO NOT leak test an A/C evaporator core with the suction accumulator/drier (19C836)
attached to the core tubes.
Disconnect the suspect A/C evaporator core or A/C condenser core from the A/C system. For
additional information, refer to Section 412 - 03 .
3. Clean the spring lock couplings. For additional information, refer to Spring Lock Coupling in this
section.
4. Connect the appropriate test fittings from the A/C Test Fitting Set to the evaporator or condenser tube connections.
5. NOTE: The automatic shut- off valves on some gauge set hoses do not open when connected to
the test fittings. If available, use hoses without shut- off valves. If hoses with shut-off valves are
used, make sure the valve opens when attached to the test fittings or install an adapter which
will activate the valve. The test is not valid if the shut- off valve does not open.
Connect the red and blue hoses from the manifold gauge set to the test fittings on the A/C
evaporator core or A/C condenser core. Connect the yellow hose to a known good vacuum
pump.
6. Open both gauge set valves and start the vacuum pump. Allow the vacuum pump to operate for a minimum of 45 minutes after the gauge set low pressure gauge indicates 101 kPa (30 in- Hg).
The 45- minute evacuation is necessary to remove any refrigerant from oil left in the A/C
evaporator core or A/C condenser core. If the refrigerant is not completely removed from the oil,
outgassing will degrade the vacuum and appear as a refrigerant leak.
7. If the low pressure gauge reading will not drop to 101 kPa (30 in- Hg) when the valves on the
gauge and manifold set are open and the vacuum pump is operating, close the gauge set
valves and observe the low pressure gauge. If the pressure rises rapidly to zero, a large leak is
indicated. Recheck the test fitting connections and gauge set connections before installing a
new A/C evaporator core or A/C condenser core.
8. After evacuating for 45 minutes, close the gauge set valves and stop the vacuum pump. Observe the low pressure gauge; it should remain at the 101 kPa (30 in- Hg) mark.
z If the low pressure gauge reading rises 34 or more kPa (10 or more in- Hg) of vacuum
from the 101 kPa (30 in- Hg) position in 10 minutes, a leak is indicated.
z If a very small leak is suspected, wait 30 minutes and observe the vacuum gauge.
z If a small amount of vacuum is lost, operate the vacuum pump with gauge valves open
for an additional 30 minutes to remove any remaining refrigerant from the oil in the A/C Klj . 39 ba
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evaporator core or A/C condenser core. Then recheck for loss of vacuum.
z If a very small leak is suspected, allow the system to sit overnight with vacuum applied
and check for vacuum loss.
9. If the A/C evaporator core or A/C condenser core does leak, as verified by the above procedure, install a new A/C evaporator core or A/C condenser core. For additional information, refer to
Section 412 - 03 .
A/C Compressor— External Leak Test
1. Install the A/C pressure test adapter on the rear head of the A/C compressor using the existing manifold retaining bolt.
2. Connect the high and low pressure lines of a manifold gauge set or a refrigerant recovery/recycling station such as the R- 134a A/C Service Center to the corresponding fittings
on the A/C pressure test adapter.
3. Attach the center hose of the manifold gauge set to a refrigerant container standing in an upright position.
4. Hand- rotate the compressor shaft 10 complete revolutions to distribute the oil inside the A/C
compressor.
5. Open the low pressure gauge valve, the high pressure gauge valve and the valve on the refrigerant container to allow the refrigerant vapor to flow into the A/C compressor.
6. Using the Refrigerant Leak Detector, check for leaks at the compressor shaft seal and the compressor center seal.
7. If a shaft seal leak is found, install a new shaft seal. For additional information, refer to Section 412 - 03 . If an external leak is found at the center joint of the A/C compressor, install a new A/C
compressor.
8. When the leak test is complete, recover the refrigerant. For additional information, refer to Air Conditioning (A/C) System Recovery, Evacuation and Charging in this section. Klj . 40 ba
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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
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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
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GENERAL PROCEDURES
Refrigerant System Tests
1. Connect the R- 134a Manifold Gauge Set. For additional information, refer to Manifold Gauge Set Connection in this section.
2. Adjust the climate controls for maximum cooling. zStart the engine.
z Select MAX A/C operation.
z Set the blower motor speed to maximum.
3. Stabilize the in- vehicle temperature at 21- 27°C (70-80°F).
4. NOTE: When the ambient temperatures exceed 38°C (100°F), do not run the engine above
normal idle speed.
Maintain the engine speed at 1,500 rpm.
5. Determine the compressor discharge (high) pressure. 1. Record the ambient temperature.
2. Record the discharge (high) pressure.
3.NOTE: In ambient temperatures between 38- 43°C (100-110°F), the system performance
pressures will be the same as those for ambient temperatures shown on the chart in the
32- 38°C (90- 100°F) range.
The system performance is acceptable when the pressure reading falls between the
upper and lower limits shown.
SECTION 412-
00: Climate Control System - General Information 2003 Mustang Workshop Manual Special Tool(s)
R-
134a Manifold Gauge Set
176- R032A or equivalent Klj . 1 ba
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GENERAL PROCEDURES
Electronic Leak Detection
CAUTION: Good ventilation is necessary in the area where electronic A/C leak testing is to
be carried out. If the surrounding air is contaminated with refrigerant gas, the leak detector will
indicate this gas all the time. Odors from other chemicals such as anti- freeze, diesel fuel, disc
brake cleaner, or other cleaning solvents can cause the same problem. A fan, even in a well-
ventilated area, is very helpful in removing small traces of contamination from the air that
might affect the leak detector.
1. NOTE: The system pressure should be between 413- 551 kPa (60-80 psi) at 24°C (75°F) with
the engine off.
Leak test the refrigerant system using the Refrigerant Leak Detector. Follow the instructions
included with the leak detector for handling and operation techniques.
2. If a leak is found, discharge and recover the refrigerant. For additional information, refer to Air Conditioning (A/C) System Recovery, Evacuation and Charging in this section.
z Repair the system.
z Test the system for normal operation.
SECTION 412-
00: Climate Control System - General Information 2003 Mustang Workshop Manual Special Tool(s)
H10PM Refrigerant Leak
Detector With Battery
216-
00001 or equivalent Klj . 1 ba
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Ford Motor Company has approved a procedure to provide technicians with a non-
CFC method
of flushing contaminated A/C system heat exchangers, A/C evaporator core, and A/C
condenser core. The procedure allows the specific components to be cleaned and flushed while
installed in their normal in- vehicle location. The types of contamination flushed include particle
matter that results from A/C compressor or desiccant failure within the suction accumulator/drier
and gummy residue that can form when refrigerant oil is overheated during A/C compressor
seizure. The flushing process is a two- step procedure that involves the use of an A/C Flush and
Purge Machine 219- 00022 to:
z Circulate the flushing solvent through the heat exchanger in the reverse direction of
normal refrigerant flow (back- flushing). Particulate matter picked up during flushing is
filtered from the returning solvent before the solvent is returned to the reservoir for
continued circulation.
z Remove the flushing solvent from the heat exchanger. In this step of the procedure,
pressurized air 621- 862 kPa (90-125 psi) is used to push and evaporate any remaining
flush solvent from the heat exchanger.
2. Discharge the A/C system. Observe all safety precautions. For additional information, refer to the procedure in this section.
3. Disconnect the refrigerant lines from the heat exchanger(s) to be flushed.
4. Connect the A/C Flush and Purge Machine 219- 00022 and A/C Flush and Purge Fitting Kit 219-
00024 to the heat exchanger to be flushed. Do not flush through the A/C evaporator core orifice,
mufflers or hoses. Internal plumbing and material make- up of these components make it
impossible to correctly remove foreign material or residual flushing solvent.
5. Use 3.785 liters (one gallon) of A/C Systems Flushing Solvent part number F4AZ-19579- A to
flush the heat exchanger for a minimum of 15 minutes. The flush solvent may be used for one
or both heat exchangers in the A/C system. However, the flush solvent is intended for one
vehicle only. The filter used on the flushing unit is also intended for use on one vehicle only.
6. Flush the component for a minimum of 15 minutes.
7. Apply 621- 862 kPa (90-125 psi) pressurized air to the component for a minimum of 30 minutes.
The 30- minute purge time is required to force and evaporate all residual solvent from the A/C
system component. Failure to successfully remove all residual solvent within the component
can result in system damage when reconnected and operated. Dispose of the used flush
solvent and filter in accordance with local, state and federal emissions.
8. NOTE: A/C system filtering as described in this section is optional if system flushing is carried
out. However, the filter kit use is recommended after flushing if the A/C system contamination is
extensive.
Install a new A/C evaporator core orifice in any vehicle being serviced for A/C compressor or
desiccant failure.
9. Install new refrigerant hoses if clogged with foreign material.
10. Reconnect the heat exchanger being serviced.
11. Add additional refrigerant oil as required. For additional information, refer to the procedure in this section.
12. Evacuate, leak test and charge the A/C system. For additional information, refer to the procedure in this section.
13. Check the system for normal operation. Klj . 2 ba
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