charging FORD MUSTANG 2003 Service Manual

GENERAL PROCEDURES
Idle Speed Adjustment
Powertrain Control/Emissions Diagnosis (PC/ED) manual
SECTION 303-
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REMOVAL AND INSTALLATION
Throttle Body
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.
CAUTION: The throttle body bore and plate area have a special coating and cannot be
cleaned.
1. Remove the air intake scoop bracket. For additional information, refer to Section 303 - 12 .
2. Remove the air cleaner outlet tube. For additional information, refer to Section 303 - 12 .
3. Disconnect the throttle position (TP) sensor electrical connector.
4. Disconnect the accelerator controls. zDisconnect the accelerator cable.
z Disconnect the speed control cable.
z Disconnect the return spring.
5. NOTE: Discard the throttle body gasket after removing the throttle body.
Remove the throttle body. zRemove the four bolts.
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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-
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REMOVAL AND INSTALLATION
Wiring Harness
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.
1. With the vehicle in neutral, position it on a hoist. For additional information, refer to Section 100 -
02 .
2. Disconnect the battery ground cable. For additional information, refer to Section 414 - 01 .
3. Remove the upper intake manifold. For additional information, refer to Section 303 - 01D .
4. Disconnect the following connectors: zThe 42 pin engine bulkhead electrical connector.
z The 16 pin electrical connector.
5. Separate the wiring harness from the dash panel.
6. Remove the RH ignition coil cover. zRemove the bolts.
z Remove the coil cover.
SECTION 303-
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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-
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24. Disconnect the positive crankcase ventilation (PCV) hose.
25. Separate the fuel charging wiring harness from the fuel injection supply manifold in four places
and position the harness aside.
26. Remove the ten bolts, the intake manifold, supercharger and fuel supply manifold as an assembly.
27. Disconnect and remove the PCV hoses. Klj . 6 ba
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DESCRIPTION AND OPERATION
Climate Control System
WARNING: To avoid accidental deployment and possible injury, the air bag system
backup power supply must be depleted before repairing any climate control components. To
deplete the backup power supply, disconnect the battery ground cable and wait one minute.
Failure to follow these instructions may result in personal injury.
WARNING: Carbon monoxide 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.
WARNING: R- 134a is classified as a safe refrigerant, but misuse can make it dangerous.
The following precautions must be observed:
zAlways wear safety goggles when repairing an air conditioning system.
z Avoid contact with liquid refrigerant R- 134a. R-134a vaporizes at approximately - 25°C (-
13°F) under atmospheric pressure and it will freeze skin tissue.
z Never allow refrigerant R- 134a gas to escape in quantity in an occupied space. R- 134a is
non- toxic, but it will displace the oxygen needed to support life.
z Never use a torch in an atmosphere containing R- 134a gas. R-134a is non-toxic at all
normal conditions, but when it is exposed to high temperatures, such as a torch flame, it
decomposes. During decomposition it releases irritation and toxic gases (as described in
the MSDS sheet from the manufacturer). Decomposition products are hydrofluoric acid,
carbon dioxide and water.
z Do not allow any portion of the charged air conditioning system to become too hot. The
pressure in an air conditioning system rises as the temperature rises and temperatures
of approximately 85°C (185°F) can be dangerous.
z Allow the engine to cool sufficiently prior to carrying out maintenance or serious burns
and injury can occur.
CAUTION: To avoid damaging the vehicle or A/C components, the following precautions
must be observed:
zThe A/C refrigerant of all vehicles must be identified and analyzed prior to refrigerant
charging. Failure to due so can contaminate the shop bulk refrigerant and other vehicles.
z Do not add R- 12 refrigerant to an A/C system that requires the use of R- 134a refrigerant.
These two types of refrigerant must never be mixed. Doing so can damage the A/C
system.
z Charge the A/C system with the engine running only at the low- pressure side to prevent
refrigerant slugging from damaging the A/C compressor.
z Use only R- 134a refrigerant. Due to environmental concerns, when the air conditioning
system is drained, the refrigerant must be collected using refrigerant recovery/recycling
equipment. Federal law REQUIRES that R- 134a be recovered into appropriate recovery
equipment and the process be conducted by qualified technicians who have been
certified by an approved organization, such as MACS, ASI etc. Use of a recovery machine
dedicated to R- 134a is necessary to reduce the possibility of oil and refrigerant
incompatibility concerns. Refer to the instructions provided by the equipment manufacturer when removing refrigerant from or charging the air conditioning system. SECTION 412-
00: Climate Control System - General Information 2003 Mustang Workshop Manual Klj . 1 ba
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z
Refrigerant R- 134a must not be mixed with air for leak testing or used with air for any
other purpose above atmospheric pressure. R- 134a is combustible when mixed with high
concentrations of air and higher pressures.
z A number of manufacturers are producing alternative refrigerant products that are
designed to be used instead of R- 134a refrigerant. The use of any unauthorized
substitute refrigerant can severely damage the A/C components. If repair is required, use
only new or recycled refrigerant R- 134a.
CAUTION: To avoid contamination of the A/C system, always observe the following:
z Keep service tools and the work area clean.
z Never open or loosen a connection before discharging the system.
z When loosening a connection, if any residual pressure is evident, allow it to leak out
before opening the fitting.
z Evacuate a system that has been opened to install a new component or one that has
been discharged through leakage before charging.
z Seal an open fitting with a cap or plug immediately after disconnecting a component
from the system.
z Clean the outside of the fittings thoroughly before disconnecting a component from the
system.
z Do not remove the sealing caps from a new component until ready to install.
z Refrigerant oil will absorb moisture from the atmosphere if left uncapped. Do not open
an oil container until ready to use, and install the cap immediately after using. Store the
oil in a clean, moisture- free container.
z Install a new O- ring seal before connecting an open fitting. Coat the fitting and the O- ring
seal with refrigerant oil before connecting.
z When installing a refrigerant line, avoid sharp bends. Position the line away from the
exhaust or any sharp edges that can chafe the line.
z Do not open a refrigerant system or uncap a new component unless it is as close as
possible to room temperature. This will prevent condensation from forming inside a
component that is cooler than the surrounding air.
The manual climate control system heats or cools the vehicle depending on the function selector
switch position and the temperature selected.
zThe function selector switch position determines heating or cooling and air distribution.
z The temperature control setting determines the air temperature.
z The heater blower motor switch (18578) varies the blower motor speed.
Principles of Operation
There are four main principles involved with the basic theory of operation:
zheat transfer
z latent heat of vaporization
z relative humidity
z effects of pressure Heat Transfer Klj . 2 ba
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to plot a vertical line for ambient temperature and a
horizontal line for A/C clutch OFF time in seconds.
z Is the intersection of the two lines above the upper
limit? DISCHARGE and RECOVER
the system to remove
excessive moisture or
refrigerant oil. REFER to
Air Conditioning (A/C) System
Recovery, Evacuation and
Charging . TEST the system
for normal operation.
No
GO to E7 .
E6 CHECK FOR A HIGH SUCTION PRESSURE
z
Refer to the data plot used to evaluate the system low
pressure performance in Step E3.
z Is the intersection of the two lines above the upper
limit? Yes
REMOVE the A/C evaporator
core orifice to repair missing or
damaged (leaking) O-
ring
seals. REFER to Section 412 -
03 . TEST the system for
normal operation.
No
INSTALL a new A/C cycling
switch when the intersection of
the two lines is below the
lower limit. REFER to Section 412 - 03 . TEST the system for
normal operation. E7 CHECK THE AMBIENT TEMPERATURE
z
Refer to the data plot used to evaluate the system A/C
clutch OFF time in Step E5.
z Is the ambient temperature above 26°C (80°F)? Yes
This is normal operation for
the refrigerant system in high
humidity conditions.
No
DISCHARGE and RECOVER
the system to correct an
overcharge condition. REFER
to
Air Conditioning (A/C) System Recovery, Evacuation
and Charging . TEST the
system for normal operation. E8 CHECK FOR A HIGH DISCHARGE PRESSURE
z
Refer to the data plot used to evaluate the system high
pressure performance in Step E2.
z Is the intersection of the two lines above the upper
limit? Yes
GO to
E9 .
No
GO to E11 .
E9 CHECK FOR A NORMAL LOW PRESSURE
z
Use the recorded data from the refrigerant system tests
to plot a vertical line for ambient temperature and a
horizontal line for compressor suction (low) pressure. Yes
REFER to
Section 303 - 03A or
Section 303 - 03B . to diagnose
the engine cooling system.
TEST the system for normal
operation. Klj . 27 ba
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z
Is the intersection of the two lines above the upper
limit? E13 CHECK FOR A NORMAL A/C CLUTCH OFF TIME
z
Use the recorded data from the refrigerant system tests
to plot a vertical line for ambient temperature and a
horizontal line for A/C clutch OFF time in seconds.
z Is the intersection of the two lines within the upper
and lower limits? Yes
INSPECT the A/C evaporator
core due to a low or restricted
airflow. TEST the system for
normal operation.
No
GO to
E14 .
E14 CHECK FOR A LONG A/C CLUTCH OFF TIME
z
Refer to the data plot used to evaluate the system A/C
clutch OFF time performance in Step E13.
z Is the intersection of the two lines above the upper
limit? Yes
INSTALL a new A/C
condenser core due to a
partially restricted or plugged
condition. REFER to
Section 412 - 03 . TEST the system for
normal operation.
No
EVACUATE and RECHARGE
the system when the
intersection of the two lines is
below the lower limit. REFER
to Air Conditioning (A/C) System Recovery, Evacuation
and Charging . TEST the
system for normal operation. E15 CHECK FOR A MISSING A/C EVAPORATOR CORE
ORIFICE z
Remove the A/C evaporator core orifice tube. Refer to
Section 412 - 03 .
z Is the A/C evaporator core orifice missing? Yes
INSTALL a new A/C
evaporator core orifice.
REFER to
Section 412 - 03 .
TEST the system for normal
operation.
No Klj . 29 ba
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