oil pressure FORD MUSTANG 2003 Repair Manual

46. Remove the nut and the wiring harness bracket.
47. Remove the nuts and position the wiring harness aside.
48. Disconnect the oil pressure sensor.
49. Remove the nut and the engine ground cable.
50. Disconnect the hose from the oil filter adapter. Klj . 12 ba
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Disassembly
Manual transmission vehicles
1. Remove the clutch and pressure plate. For additional information, refer to Section 308 - 02 .
2. Remove the flywheel.
Automatic transmission vehicles 3. Remove the flexplate. For additional information, refer to Flexplate in this section.
All vehicles 4. Using the special tool, remove the rear oil slinger. 303-
567 (T97P-6565- AH) Remover, Crankshaft Front Oil
Seal
303-
107 (T74P-6700- A) Klj . 2 ba
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13. Disconnect the fuel pressure damper electrical connector.
14. Disconnect the EGR vacuum regulator electrical connector.
15. Disconnect the four LH fuel injector electrical connectors.
16. Remove the LH coil cover. Klj . 5 ba
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72. Install the LH coil cover.
73. Connect the EGR vacuum regulator (EVR) electrical connector.
74. Connect the fuel pressure sensor electrical connector.
75. Connect the EGR tube to the exhaust manifold. Klj . 25 ba
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25. Install the ground cable.
26. Connect the oil pressure sender.
27. Position the wiring harness and install the two nuts.
28. Position the wiring harness bracket and install the nut. Klj . 8 ba
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DESCRIPTION AND OPERATION
Engine Cooling
CAUTION: Vehicle cooling systems are filled with Motorcraft Premium Gold Engine
Coolant VC -7-A (in Oregon VC -7-B) 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.
The 4.6L cooling system components include the:
zblock heater
z engine coolant temperature (ECT) sensor
z fan blade, fan motor and fan shroud assembly
z radiator
z pressure relief cap
z radiator draincock
z coolant pump
z coolant thermostat
z oil filter adapter
z radiator overflow hose
z upper radiator hose
z lower radiator hose
The radiator overflow hose circulates the coolant.
The coolant thermostat:
zcontrols the engine coolant temperature.
z allows for quicker engine warm- up.
The degas bottle/coolant expansion tank:
zprovides a location for service fill.
z contains coolant expansion and system pressurization.
z provides air separation during operation.
z replenishes the engine coolant to the system.
The engine coolant flows:
zfrom the lower radiator hose to the coolant pump.
z from the coolant pump to the engine block and the cylinder heads.
SECTION 303-
03A: Engine Cooling 2003 Mustang Workshop Manual Klj . 1 ba
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DIAGNOSIS AND TESTING
Engine Cooling
Inspection and Verification
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 is 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 you are sure all the pressure has been
released, turn and remove the pressure relief cap (still with a cloth).
CAUTION: Check the coolant level, engine oil and transmission fluid, top off the coolant if
needed. If there is engine coolant in the engine oil or transmission fluid, the cause must be
corrected and oil/fluid changed or major component damage may occur.
1. Verify the customer's concern by operating the engine to duplicate the condition.
2. Inspect to determine if any of the following mechanical or electrical concerns apply.
SECTION 303-
03A: Engine Cooling 2003 Mustang Workshop Manual Special Tool(s)
Pressure Tester
014-
R1072 or equivalent 73III Automotive Meter
105-
R0057 or equivalent Worldwide Diagnostic System
(WDS)
418-
F224,
New Generation STAR (NGS)
Tester
418- F052, or equivalent scan
tool Battery/Anti-Freeze Tester
014- R1060 or equivalent Klj . 1 ba
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3. If the inspection reveals an obvious concern that can be readily identified, repair as necessary.
4.
CAUTION: Some vehicle cooling systems are filled with Motorcraft Premium Gold
Engine Coolant VC -7-A (in Oregon VC -7-B) 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.
Inspect the coolant condition. 1. Inspect the coolant color.
„If Motorcraft Premium Gold Engine Coolant (yellow color) VC-7- A (in Oregon VC-
7- B) or equivalent meeting Ford specification WSS-M97B51- A1 has a clear or
pale yellow color, this indicates higher water content than required.
„ Dark brown can indicate unauthorized stop leak may have been used. Use
Motorcraft Cooling System Stop Leak Pellets VC- 6 or equivalent meeting Ford
specification ESE-M99B37- 5 except as noted in ES-F6SE-19A511- AA only.
„ A light or reddish brown color indicates that rust may be present in the cooling
system. Flush the system and refill with the correct mixture of water and engine
coolant.
„ An iridescent sheen on top of the coolant can indicate a trace of oil is entering the
system. For additional information on engine diagnosis, refer to Section 303 - 00 .
„ A milky brown color may indicate that either engine oil or transmission fluid is
entering the cooling system. If transmission fluid is suspected, the cause may be a
leaky radiator. Pressure test the cooling system. For additional information, refer
to component tests in this section. If engine oil is suspected the cause of the leak
may be internal to the engine. For additional information, refer to Section 303 - 00 .
2. If the engine coolant appearance is acceptable, test the engine coolant freezing point
range with the battery and anti- freeze tester. The freezing point should be in the range -
40°C to - 20°C (-50°F to - 10°F). If the vehicle is driven in cold climates less than - 32°C (-
34°F), it may be necessary to increase the coolant concentration to get adequate freeze
protection.
„Maximum coolant concentration is 60% coolant/40% water.
„ Minimum coolant concentration is 40% coolant/60% water. 3. Adjust coolant range and level, if necessary: Visual Inspection Chart
Mechanical
z
Leaks
z Hoses
z Hose clamps
z Water gasket
z Head gaskets
z Intake manifold gasket
z Coolant pump
z Radiator
z Degas bottle/coolant expansion tank
z Heater core
z Fan/fan clutch
z Engine coolant temperature sensor (4.6L)
z Cylinder head temperature sensor (3.8L)
z Circuitry Klj . 2 ba
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while the pressure is released from the cooling system.
When you are sure all the pressure has been released, turn
and remove the pressure relief cap (still with a cloth).
NOTE:
Allow the engine to cool before checking the engine
coolant level.
z Key in OFF position.
z Visually check the engine coolant level at the degas bottle or
coolant expansion tank.
z Is the engine coolant level within specification? A2 CHECK THE PRESSURE RELIEF CAP
z
Carry out the Cap— 3.8L or Cap—4.6L test. Go to Component
Tests in this section.
z Is pressure relief cap/radiator cap OK? Yes
GO to
A3 .
No
INSTALL a new
pressure relief
cap/radiator cap. TEST
the system for normal
operation. A3 CHECK THE ENGINE COOLANT FOR INTERNAL LEAK
z
Key in OFF position.
z Inspect the engine coolant in degas bottle/coolant expansion
tank for signs of transmission fluid or engine oil.
z Is oil or transmission fluid evident in the coolant? Yes
If engine oil is evident,
REFER to
Section 303 -
00 . If transmission fluid
is evident, REPAIR or
INSTALL a new radiator
as necessary.
No
GO to A4 .
A4 CHECK THE ENGINE AND THE TRANSMISSION FOR
COOLANT z
Remove the oil level dipstick from the engine and the
transmission.
z Is coolant evident in the oil or transmission fluid? Yes
If coolant is in engine,
REFER to
Section 303 -
00 . If coolant is in
transmission, REPAIR
or INSTALL a new
radiator as necessary.
To repair the automatic
transmission, REFER to
Section 307 - 01 .
No
GO to A5 .
A5 PRESSURE TEST THE ENGINE COOLING SYSTEM
z
Pressure test the engine cooling system. Go to Component
Tests in this section.
z Does the engine cooling system leak? Yes
REPAIR or install new
components. TEST the
system for normal
operation.
No
The cooling system is
operational. GO to
Symptom Chart
. Klj . 4 ba
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1. Turn the engine OFF.
2.
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 is 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 you are
sure all the pressure has been released, turn and remove the pressure relief cap (still
with a cloth).
Check the engine coolant level; refer to Cooling System Draining, Filling and Bleeding in this
section.
3. Connect Radiator Heater Core Pressure Tester to the degas bottle nipple and vent hose. Install a pressure test pump to the quick- connect fitting of the test adapter.
4. CAUTION: Do not pressurize the cooling system beyond 152 kPa (22 psi).
NOTE: If the plunger of the pump is depressed too quickly, an erroneous pressure reading will
result.
Slowly depress the plunger of the pressure test pump until the pressure gauge reading stops
increasing and note the highest pressure reading obtained.
5. If the pressure relief cap does not hold pressure, remove and wash the pressure relief cap in clean water to dislodge all foreign particles from the gaskets. Check the sealing surface in the
filler neck.
6. If 110 kPa (16 psi) cannot be reached, install a new pressure relief cap. If more than 124 kPa (18 psi) shows on gauge, install a new pressure relief cap.
7. CAUTION: If the pressure drops, check for leaks at the engine- to-heater core hoses,
engine- to-radiator hoses, water valve hose (if applicable), oil cooler return tube gasket
(6N789), radiator and heater core or other system components and connections. Any
leaks which are found must be corrected and the system rechecked.
Pressurize the engine cooling system as described in Step 4 (using a pressure relief cap that
operates within the specified upper and lower pressure limits). Observe the gauge reading for
approximately two minutes; refer to General Specifications. Pressure should not drop during this
time.
8. Release the system pressure by loosening the pressure relief cap. Check the engine coolant level and replenish, if necessary, with the correct engine coolant mixture; refer to Cooling System Draining, Filling and Bleeding in this section.
Cap — 3.8L
1. Inspect the radiator cap and seals for damage or deterioration. Install a new radiator cap if necessary.
2. Fit the radiator cap to Radiator/Heater Core Pressure Tester Kit, using the aftermarket adapter.
3. NOTE: If the plunger of the pressure tester is depressed too fast, an incorrect pressure reading
will result. Slowly pump the pressure tester until the pressure gauge stops increasing and note the highest Klj . 7 ba
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