oil FORD MUSTANG 2003 Workshop Manual

COOL (blue) to WARM (red) causes a corresponding movement on the air temperature control
door and determines the temperature that the system will maintain.
z The A/C heater function selector switch combines a vacuum selector valve for direct control of
the vacuum control motors and electrical input to the instrument control module.
Control System Outputs
Blower Motor Switch Resistor
The heater blower motor switch resistor has the following features:
zThe assembly is located on the passenger side of the plenum assembly behind the glove
compartment (06010).
z Three resistance elements are mounted on the resistor board to provide four A/C blower motor
speeds.
z Depending on the heater blower motor switch position, series resistance is added or bypassed
in the A/C blower motor circuit to decrease or increase A/C blower motor speed.
z An overheating protective device (thermal limiter) will open the resistor coil circuit when the
temperature reaches 105°- 110°C (221°-230°F), interrupting the blower motor operation in all
speeds except HI.
z The thermal limiter cannot be reset and is not serviceable.
Control Actuators
Temperature Control Cable
The temperature control cable (19988) has the following features:
zThe cable assembly has a constant tension (pull- pull) dual cable design.
z The pull- pull design allows for constant smooth communication between the temperature control
knob and the air temperature blend door.
z The control cable can only be installed as an assembly.
Vacuum Control Motors
The vacuum control motors (18A318) control the position of the doors directing the air flow to the
different outlets. There are two types of vacuum control motors used in this system:
zSingle- diaphragm for air inlet and windshield defroster door operations.
z Double- diaphragm for air damper door operations.
Single- diaphragm motors have two positions:
z Shaft extended with no vacuum applied.
z Shaft retracted with vacuum applied.
Double- diaphragm motors have three positions:
z Shaft extended with no vacuum applied to either port.
z Shaft halfway retracted with vacuum applied to only one port. Klj . 3 ba
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DESCRIPTION AND OPERATION
Instrument Cluster
The instrument cluster (10849) consists of the following components:
Instrument Cluster—
Base 3.8L Engine
SECTION 413-
01: Instrument Cluster 2003 Mustang Workshop Manual 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
14 — Traction control indicator
15 — Overdrive off (O/D OFF) indicator (automatic Klj . 1 ba
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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
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Instrument Cluster—
Cobra 14 — Traction control indicator
15 — Overdrive off (O/D OFF) indicator (automatic
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 — Boost gauge
10 — Oil pressure gauge
11 — CHECK FUEL CAP indicator
12 — BRAKE warning indicator Klj . 3 ba
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The boost pressure gauge on the instrument cluster receives and measures the boost pressure
directly from the intake manifold. The boost pressure gauge will display between 0.0-
0.48 kpa (0.0-10
psi) boost pressure dependent upon accelerator position, engine load, and engine rpm.
LOW FUEL Level Indicator
The low fuel level indicator is hardwired from the fuel sender to the instrument cluster. The instrument
cluster will illuminate the low fuel indicator when the usable fuel quantity is less than 1/8 tank (15%) of
fuel tank capacity.
Oil Pressure Gauge
The oil pressure gauge is hardwired from the oil pressure switch to the instrument cluster. The oil
pressure gauge will indicate either normal or no oil pressure.
CHECK FUEL CAP
The CHECK FUEL CAP indicator is used to indicate significant leaks in the fuel tank evaporative
system due to a loose fuel cap. Fuel tank pressure is monitored by the PCM. If a leak is detected the
PCM signals a fault to the instrument cluster via the SCP network. Once the PCM has detected a
loose fuel cap and the CHECK FUEL CAP indicator is illuminated, the indicator will remain illuminated
until the fuel cap is secured and the vehicle has been running for several minutes. For additional
information, refer to the Powertrain Control/Emissions Diagnosis (PC/ED) manual.
BRAKE Warning Indicator
The BRAKE warning indicator activates when the generic electronic module (GEM) detects the ignition
switch circuits are in the RUN state, when the GEM detects low brake fluid level, or that the parking
brake is applied. The BRAKE warning indicator will prove out starting when the GEM detects that the
ignition circuits have made a transition to RUN or START from OFF, ACC, or keyout and ending when
either three seconds have elapsed or when the GEM detects the ignition circuits have made a
transition to OFF, ACC, or keyout.
Safety Belt Warning Indicator
The safety belt switch is hardwired to the GEM. The safety belt warning indicator will be illuminated
when the GEM sends a ground signal to the instrument cluster.
ABS Warning Indicator
The ABS warning indicator will be illuminated when the anti- lock brake control module sends a ground
signal to the instrument cluster. The prove- out of the ABS indicator is controlled by the anti- lock brake
control module.
SERVICE ENGINE SOON Indicator
The SERVICE ENGINE SOON indicator receives its signal from the PCM over the SCP network. If the
instrument cluster does not receive a message from the PCM within five seconds, the instrument
cluster will illuminate the SERVICE ENGINE SOON indicator and log a diagnostic trouble code (DTC).
High Beam Indicator
The high beam indicator will illuminate when the steering column multifunction switch is in the high
beam position by sending a battery signal to the instrument cluster. Right and Left Turn Indicator Klj . 3 ba
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3. If an obvious cause for an observed or reported concern is found, correct the cause (if possible)
before proceeding to the next step.
4. If the concern remains after the inspection, connect the diagnostic tool to the data link connector (DLC) located beneath the instrument panel and select the vehicle to be tested from the
diagnostic tool menu. If the diagnostic tool does not communicate with the vehicle:
zcheck that the program card is correctly installed.
z check the connections to the vehicle.
z check the ignition switch position.
5. If the diagnostic tool still does not power up, refer to the diagnostic tool operating manual.
6. Carry out the DATA LINK DIAGNOSTICS test. If the diagnostic tool responds with: zCKT914, CKT915 OR CKT70 = ALL ECUS NO RESP/NOT EQUIP, refer to Section 418 -
00 .
z NO RESP/NOT EQUIP for the instrument cluster, Go To Pinpoint Test A or for the
generic electronic module (GEM), Go To Pinpoint Test W .
z SYSTEM PASSED, retrieve and record the continuous diagnostic trouble codes (DTCs),
erase the continuous DTCs and carry out the self- test diagnostics for the instrument
cluster or the GEM.
7. If the DTCs retrieved are related to the concern, go to the Instrument Cluster Diagnostic Trouble Code (DTC) Index or the GEM Diagnostic Trouble Code Index to continue diagnostics.
8. If no DTCs related to the concern are retrieved, proceed to the Symptom Chart to continue diagnostics.
Instrument Cluster Self- Diagnostic Mode
To enter the instrument cluster self- diagnostic mode, press and hold the instrument cluster
SELECT/RESET button, turn the ignition switch to the RUN position, and then continue pressing the
SELECT/RESET button (five seconds) until tESt is displayed in the odometer. The SELECT/RESET
button must be released within three seconds of the odometer tESt display to begin the self- diagnostic
mode. Press the SELECT/RESET button to advance through the following steps until dtc is displayed.
Depressing the SELECT/RESET button will display any stored continuous DTCs before proceeding to
the next step. z
Engine coolant level
z Accessory drive belt
z Engine oil level
z Parking brake position switch
z Brake fluid level
z Boost gauge pressure line „
5 (15A)
„ 7 (15A)
„ 11 (15A)
„ 13 (15A)
„ 21 (5A)
„ 23 (15A)
„ 24 (30A)
„ 29 (15A)
„ 30 (15A)
„ 32 (15A)
„ 34 (20A)
„ 35 (15A)
„ 37 (5A)
„ 38 (20A)
„ 39 (5A)
z Circuitry Klj . 5 ba
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Odometer
Display Description
GAGE Activates gauge sweep of all gauges, then displays present gauge values. Also
carries out the checksum tests on ROM and EE. All segments
illuminated Illuminates all odometer segments.
bulb Illuminates all micro-controlled indicators and LEDs. Install a new indicator or LED as
necessary. r Returns to normal operation of all micro-
controlled indicators and LEDs and displays
hexadecimal value for ROM level (used when requesting assistance from the hotline). EE Displays hexadecimal value for EE level (used when requesting assistance from the
hotline). dt Displays hexadecimal coding of final manufacturing test date (used when requesting
assistance from the hotline). dtc Displays continuous DTCs in hexadecimal format. Pressing the SELECT/RESET
button will display any DTCs stored before proceeding to the next step. enG Displays the English speed in mph. Speedometer will indicate present speed within
tolerances. Display will show 0 if input is not received, if input received is invalid for one second or more, or if speed is 0. m Displays the metric speed data (km/h). Speedometer will indicate present speed
within tolerances. Display will show 0 if input is not received, if input received is invalid for one second or more, or if speed is 0. tAc Displays the tachometer data received from the PCM via the SCP network within
tolerances. Tachometer will indicate present rpm. Display will show 0 if input is not received, if input received is invalid for one second or more, or if engine rpm is 0. FUEL Displays the code (0-255) for the fuel sender input to the instrument cluster. The fuel
gauge will display a filtered fuel level value. This filter will keep the pointer from moving suddenly or erratically.
z255 = open send +/- 0
z 232 = full stop +/- 0
z 215 = full mark +/- 10
z 178 = 3/4 mark +/- 8
z 138 = 1/2 mark +/- 7
z 93 = 1/4 mark +/- 5
z 41 = E mark +/- 4
z 54=LOW FUEL (0- 59)
z 0-18=short (0- 20 max) OIL Displays the code (0-
250) for the oil pressure switch input to the instrument cluster.
Oil pressure gauge will indicate present oil pressure. Normal oil pressure (greater
than 6 psi) will display a value between 000 and 176. A low oil pressure or an
inoperative engine oil pressure switch (less than 6 psi) will display a value greater
than 176. dEGC Display of engine temperature in degrees C input from cylinder head temperature
sensor.
z 49 C = "C" mark
z 60 C = normal band start
z 120 C = normal band end
z -40 C = no SCP message for 5 seconds bAtt Displays the code (0-255) for the battery voltage input to the instrument cluster.
Battery voltage gauge will indicate present battery voltage. Klj . 6 ba
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To exit the instrument cluster self-
diagnostic mode, turn the ignition switch to the OFF position or press
and hold the SELECT/RESET button for three or more seconds and release. z
93- 102 = 6.9- 9.1 volts (low voltage)
z 115- 124 = 8.5- 10.7 volts (norm band start)
z 215- 225 = 15.8- 18 volts (norm band end)
z 230- 241 = 16.9- 19.1 volts (high voltage) rhEo Displays the present decimal rheostat dimming input, 0-
255 (used when requesting
assistance from the hotline). rhi
rhS rho Not used.
Cr Displays the present RUN/START sense input. Display will show -
h for high input with
the ignition switch in the START position and - L for low input with the ignition switch in
the RUN position. PA-
PE7 Not used.
GAGE Repeats test display cycle.
Instrument Cluster Diagnostic Trouble Code (DTC) Index Diagnostic
Tool
Displayed DTC Self-
Diagnostic
Mode Displayed DTC Description Source Action
B1202 9202 Fuel Sender
Open Circuit Instrument
Cluster Go To Pinpoint Test B .
B1204 9204 Fuel Sender
Short to Ground Instrument
Cluster Go To Pinpoint Test B .
B1317 9317 Battery Voltage
High Instrument
Cluster Section 414 - 00 .
B1318 9318 Battery Voltage
Low Instrument
Cluster Section 414 - 00 .
B1342 9342 ECU is Defective Instrument
Cluster INSTALL a new instrument
cluster; REFER to Instrument Cluster in this section. TEST the
system for normal operation. B1343 9343 Heated Backlight
Input Circuit Failure Instrument
Cluster Section 501 - 11 .
B1356 9356 Ignition Run
Circuit Open Instrument
Cluster Go To Pinpoint Test A .
B1364 9364 Ignition Start
Circuit Open Instrument
Cluster Go To Pinpoint Test A .
B2143 A143 Odometer NVM
Mmory Failure Instrument
Cluster Go To Pinpoint Test J .
C1284 5284 Oil Pressure
Switch Failure Instrument
Cluster Go To Pinpoint Test C .
P1197 1197 Mileage Switch
Circuit Failure Instrument
Cluster Go To Pinpoint Test J . Klj . 7 ba
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GEM Diagnostic Trouble Code (DTC) Index
DTC Description Source Action
B1218 Horn Relay Coil Circuit Short to
VBatt GEM REFER to
Section 501 - 14B .
B1312 Lamp Headlamp Input Circuit
Short to Battery GEM REFER to
Section 413 - 09 .
B1317 Battery Voltage High GEM REFER to
Section 414 - 00 .
B1318 Battery Voltage Low GEM REFER to
Section 414 - 00 .
B1322 Driver Door Ajar Circuit Short to
Ground GEM REFER to
Section 417 - 02 .
B1330 Passenger Door Ajar Circuit
Short to Ground GEM REFER to
Section 417 - 02 .
B1334 Decklid Ajar Rear Door Circuit
Short to Ground GEM REFER to
Section 417 - 02 .
B1339 Chime Input Request Circuit
Short to Battery GEM REFER to
Section 413 - 09 .
B1340 Chime Input Request Circuit
Short to Ground GEM REFER to
Section 413 - 09 .
B1342 ECU is Defective GEM Clear the DTCs. Retrieve the DTCs. If DTC B1342
is retrieved, INSTALL a new GEM. REFER to Section 419 - 10 .
B1353 Ignition Key-
In Circuit Open GEM REFER to
Section 413 - 09 .
B1359 Ignition Run/Acc Circuit Failure GEM REFER to
Section 211 - 05 .
B1396 Power Door Lock Circuit Short
to Battery GEM REFER to
Section 501 - 14B .
B1397 Power Door Unlock Circuit
Short to Battery GEM REFER to
Section 501 - 14B .
B1405 Driver Power Window Down
Circuit Short to Battery GEM REFER to
Section 501 - 11 .
B1408 Driver Power Window Up
Circuit Short to Battery GEM REFER to
Section 501 - 11 .
B1426 Lamp Safety Belt Circuit Short
to Battery GEM Go To Pinpoint Test K .
B1428 Lamp Safety Belt Circuit Failure GEM Go To Pinpoint Test K .
B1431 Wiper Brake/Run Relay Circuit
Failure GEM REFER to
Section 501 - 16 .
B1432 Wiper Brake/Run Relay Circuit
Short to Battery GEM REFER to
Section 501 - 16 .
B1434 Wiper Hi/Low Speed Relay Coil
Circuit Failure GEM REFER to
Section 501 - 16 .
B1436 Wiper Hi/Low Speed Relay Coil
Circuit Short to Battery GEM REFER to
Section 501 - 16 .
B1438 Wiper Mode Select Switch
Circuit Failure GEM REFER to
Section 501 - 16 .
B1441 Wiper Mode Select Switch
Circuit Short to Ground GEM REFER to
Section 501 - 16 . Klj . 8 ba
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Symptom Chart B1446 Wiper Park Sense Circuit
Failure GEM REFER to
Section 501 - 16 .
B1448 Wiper Park Sense Circuit Short
to Battery GEM REFER to
Section 501 - 16 .
B1450 Wiper Wash/Delay Switch
Circuit Failure GEM REFER to
Section 501 - 16 .
B1453 Wiper Wash/Delay Switch
Circuit Short to Ground GEM REFER to
Section 501 - 16 .
B1458 Wiper Washer Pump Motor
Relay Circuit Failure GEM REFER to
Section 501 - 16 .
B1460 Wiper Washer Pump Motor
Relay Coil Circuit Short to Battery GEM REFER to
Section 501 - 16 .
B1462 Safety Belt Switch Circuit
Failure GEM REFER to
Section 413 - 09 .
B1466 Wiper Hi/Low Speed Not
Switching GEM REFER to
Section 501 - 16 .
B1473 Wiper Low Speed Circuit Motor
Failure GEM REFER to
Section 501 - 16 .
B1476 Wiper High Speed Circuit Motor
Failure GEM REFER to
Section 501 - 16 .
B1551 Decklid Release Circuit Failure GEM REFER to
Section 501 - 14B .
B1553 Decklid Release Circuit Short to
Battery GEM REFER to
Section 501 - 14B .
B1555 Ignition Run/Start Circuit
Failure GEM REFER to
Section 211 - 05 .
B1687 Lamp Dome Input Circuit Short
to Battery GEM REFER to
Section 417 - 02 .
B2486 Parklamp Output Relay Driver
Circuit Failure GEM REFER to
Section 419 - 01 .
B2488 Parklamp Output Relay Driver
Short to Battery GEM REFER to
C1189 Brake Fluid Level Sensor Input
Short Circuit to Ground GEM Go To Pinpoint Test O .
C1223 Lamp Brake Warning Output
Circuit Failure GEM Go To Pinpoint Test O .
C1225 Lamp Brake Warning Output
Circuit Short to Battery GEM Go To Pinpoint Test O .
Symptom Chart Condition
Possible Sources Action
z No communication with
the generic electronic
module (GEM) z
Central junction
box (CJB) fuse
(s):
„7 (15A).
„ 39 (5A).
„ 43 z
Go To Pinpoint Test W Klj . 9 ba
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