engine FORD MUSTANG 2003 Workshop Manual

REMOVAL AND INSTALLATION
Cooling Fan Motor and Shroud
Removal and Installation
1. Disconnect the battery ground cable.
2. Remove the degas bottle or coolant expansion tank. For additional information, refer to Degas Bottle — 4.6L(2V) and 4.6L(4V) in this section.
3. Disconnect the cooling fan electrical connector.
4. Separate the fan harness from the shroud.
5. Remove the LH bolt. 6. Remove the RH bolt. SECTION 303-
03A: Engine Cooling 2003 Mustang Workshop Manual Klj . 1 ba
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REMOVAL AND INSTALLATION
Water Bypass Hose —
3.8L
Removal and Installation 1. Drain the engine coolant. For additional information, refer to Cooling System Draining, Filling and Bleeding in this section.
2. Remove the bypass hose.
3. To install, reverse the removal procedure.
4. Fill and bleed the cooling system. For additional information, refer to Cooling System Draining, Filling and Bleeding in this section.
SECTION 303-
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REMOVAL AND INSTALLATION
Degas Bottle —
4.6L(2V) and 4.6L(4V)
Removal and Installation 1. Drain the engine coolant from the degas bottle only. For additional information, refer to Cooling System Draining, Filling and Bleeding in this section.
2. Disconnect the radiator vent hose.
3. Remove the degas bottle return hose.
4. Remove the nuts and the degas bottle.
5. To install, reverse the removal procedure.
6. Fill and bleed the cooling system. For additional information, refer to Cooling System Draining, Filling and Bleeding in this section.
SECTION 303-
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SPECIFICATIONS
a
Use the same type coolant that was drained from the cooling system. Do not mix coolant types.
b The addition of Motorcraft Cooling System Stop Leak Pellets, VC- 6, darkens Motorcraft Premium
Gold Engine Coolant from yellow to golden tan. SECTION 303-
03B: Supercharger Cooling 2003 Mustang Workshop Manual General Specifications
Item Specification
Cooling System Capacity
System capacity L (qts) 3.75 (4.0)
Coolant Type
Motorcraft Premium Engine Coolant VC-4-
A (CXC-10 in
Canada, VC- 5 in Oregon) a ESE-
M97B44- A Motorcraft Premium Gold Engine Coolant VC-7-
A (in
Oregon VC-7- B)
a b WSS-
M97B51- A1 Other Chemicals
Premium Cooling System Flush VC-
1 ESR-
M14P7-A Premium Long Life Grease XG-1-
C ESA-
M1C75- B Cooling System Stop Leak Pellets
VC-
6 ESE-
M99B37- 5 except as noted in ES-
F65E-19A511- AA Cooling System Pressure Test Specifications
System (radiator) kPa (psi) 138 (20)
System (intercooler) kPa (psi) 138 (20)
Cap (relief opening pressure)
kPa (psi) 69 (10)
Torque Specifications Description Nm lb-
ft lb-
in Water pump bolts 20 — 15
Dropping resistor screw 6 53 —
Degas bottle bolt 10 89 —
Intercooler radiator support bracket-
to-bumper bolts 12 — 9
Intercooler radiator support bracket bolts 10 89 — Klj . 1 ba
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DESCRIPTION AND OPERATION
Supercharger Cooling
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: The air that is produced from the supercharger is cooled by the intercooler.
Walter C. Avrea, the owner of patents 3,601,181 and RE 27,965, has granted Ford Motor Company
rights with respect to cooling systems covered by these patents.
The cooling system components include the:
zintercooler
z intercooler radiator (8K226)
z pressure relief cap
z degas bottle
z electric water pump (8501)
The degas bottle:
zprovides a location for system fill.
z contains coolant expansion and system pressurization.
z provides air separation during operation.
z replenishes the intercooler coolant to the system.
The intercooler coolant flows:
zfrom the intercooler to the degas bottle.
z from the degas bottle to the water pump.
z from the water pump to the intercooler radiator.
z from the intercooler radiator to the intercooler.
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.
When adding engine coolant, use a 50/50 mixture of engine coolant and clean, drinkable water.
To maintain the integrity of the coolant and the cooling system: SECTION 303-
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NOTE:
The addition of Motorcraft Cooling System Stop Leak Pellets, VC- 6, darkens Motorcraft
Premium Gold Engine Coolant from yellow to golden tan.
zAdd 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), or Motorcraft Premium
Gold Engine Coolant VC-7- A or equivalent meeting Ford specification WSS-M97B51- A1 (yellow
color). Use the same coolant that was drained from the cooling system. Do not mix coolant
types.
z Do not add/mix orange-colored Motorcraft Speciality Orange Engine Coolant VC- 2 or equivalent
meeting Ford specification WSS- M97B44-D. Mixing coolants may degrade the coolant's
corrosion protection.
z Do not add alcohol, methanol, brine, or any engine coolants mixed with alcohol or methanol
antifreeze. These can cause engine damage from overheating or freezing.
z Do not mix with recycled coolant unless it meets the requirements of Ford specification ESE-
M97B44- A or WSS-M97B51- A1. Not all coolant recycling processes meet these Ford
specifications. Use of such coolants can harm the engine and cooling system components. Klj . 2 ba
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DIAGNOSIS AND TESTING
Supercharger 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 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 you are sure all the pressure has been
released, (still with a cloth) turn and remove the pressure relief cap.
CAUTION: Check the coolant and engine oil levels. Top off the coolant level if needed. If
there is engine coolant in the engine oil, the cause must be corrected and the oil changed or major component damage can occur. SECTION 303-
03B: Supercharger Cooling 2003 Mustang Workshop Manual Special Tool(s)
Pressure Test Kit
014-
R1072 or equivalent Battery/Antifreeze Tester
014-
R1060 or equivalent
Material Item Specification
Motorcraft Premium
Engine Coolant
VC
-4-A (in Oregon
VC- 5, in Canada
CXC- 10) ESE-
M97B44- A Motorcraft Premium
Gold Engine Coolant
VC
-7-A WSS-
M97B51- A1 Motorcraft Cooling
System Stop Leak
Pellets
VC-
6 or equivalent ESE-
M99B37- 5 except as
noted in ES-F65E-19A511- AA Klj . 1 ba
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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.
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.
3. If the inspection reveals an obvious concern that can be readily identified, repair it as necessary.
4. Inspect the coolant condition. 1. 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 you are sure all the pressure has been
released, (still with a cloth) turn and remove the pressure relief cap.
Allow the engine to cool. Once pressure is released, remove the pressure relief cap.
2. CAUTION: Check the coolant and engine oil level and top off the coolant if
needed. If there is engine coolant in the engine oil the cause must be corrected
and oil/fluid changed or major component damage can occur.
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.
Inspect the coolant color:
„If Motorcraft Premium Engine Coolant (green color) VC-4- A or equivalent meeting
Ford specification ESE-M97B44- A has a clear, light green or blue color, this Visual Inspection Chart
Mechanical Electrical
z
Radiator brackets
z Leaks
z Damaged hoses
z Hose clamps
z Water pump
z Radiator
z Degas bottle
z Water pump bracket z
Damaged water pump wiring Klj . 2 ba
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indicates higher water content than required.
„ NOTE: The addition of Motorcraft Cooling System Stop Leak Pellets, VC- 6,
darkens Motorcraft Premium Gold Engine Coolant from yellow to golden tan.
If Motorcraft Premium Gold Engine Coolant (yellow color) VC-7- A 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-F65E-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 or a milky brown color can indicate a
trace of oil is entering the system. For additional information on engine diagnosis,
refer to Section 303 - 00 .
3. If the engine coolant appearance is acceptable, test the engine coolant freezing point
range with the special tool. The freezing point should be in the range - 50°F to -10°F. If
the vehicle is driven in cold climates less than - 34°F, it may be necessary to increase the
coolant concentration to get adequate freeze protection.
„Maximum coolant concentration is 60/40.
„ Minimum coolant concentration is 40/60.
4. Check the coolant system conditions:
„If the intercooler fluid is low, add the specified coolant mixture only.
„ If the intercooler coolant fluid tests weak, add straight engine coolant until the
readings are within acceptable levels.
„ If the engine coolant tests strong, remove some of the engine coolant and add
water until readings are within acceptable levels.
5. If the concern remains after the inspection, determine the symptom(s). GO to Symptom Chart .
6. Verify the cooling system is correctly filled and bled. Refer to Supercharger Cooling System Draining, Filling and Bleeding in this section.
Symptom Chart
Pinpoint Tests PINPOINT TEST A: LOSS OF COOLANT SYMPTOM CHART
Condition
Possible Sources Action
z Loss of intercooler
coolant z
Intercooler.
z Intercooler
radiator.
z Water pump.
z Coolant hoses.
z Degas bottle. z
Go To Pinpoint Test A . Klj . 3 ba
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Component Tests Test Step Result / Action to
Take A1 CHECK THE INTERCOOLER COOLANT LEVEL
WARNING: Never remove the pressure relief cap under
any conditions while the engine is operating. Failure to follow
these instructions could result in damage to the cooling system
or engine and/or personal injury. To avoid having scalding hot
coolant or steam blow out of the cooling system, use extreme
care when removing the pressure relief cap from a hot degas
bottle. Wait until the engine has cooled, then wrap a thick cloth
around the pressure relief cap and turn it slowly one turn
(counterclockwise). Step back while the pressure is released
from the cooling system. When certain all the pressure has
been released, remove the pressure relief cap (still with a
cloth). NOTE: Allow the engine to cool before checking the engine
coolant level. The engine must be off to check the coolant.
z Key in OFF position.
z Visually check the intercooler coolant level at the degas bottle.
z Is the coolant level within specification? Yes
GO to
A2 .
No
REFILL the coolant
as necessary. GO
to A2 .
A2 CHECK THE DEGAS BOTTLE PRESSURE RELIEF CAP
z
WARNING: Never remove the pressure relief cap under
any conditions while the engine is operating. Failure to follow
these instructions could result in damage to the cooling system
or engine and/or personal injury. To avoid having scalding hot
coolant or steam blow out of the cooling system, use extreme
care when removing the pressure relief cap from a hot degas
bottle. Wait until the engine has cooled, then wrap a thick cloth
around the pressure relief cap and turn it slowly one turn
(counterclockwise). Step back while the pressure is released
from the cooling system. When certain all the pressure has
been released, remove the pressure relief cap (still with a
cloth).
z Remove the pressure relief cap.
z Inspect the pressure relief cap for foreign material between the
sealing gasket and the diaphragm.
z Is the pressure relief cap OK? Yes
GO to
A3 .
No
CLEAN or INSTALL
a new pressure
relief cap. TEST the
system for normal
operation. A3 CHECK THE DEGAS BOTTLE
z
WARNING: Never remove the pressure relief cap under
any conditions while the engine is operating. Failure to follow
these instructions could result in damage to the cooling system
or engine and/or personal injury. To avoid having scalding hot
coolant or steam blow out of the cooling system, use extreme
care when removing the pressure relief cap from a hot degas
bottle. Wait until the engine has cooled, then wrap a thick cloth
around the pressure relief cap and turn it slowly one turn
(counterclockwise). Step back while the pressure is released
from the cooling system. When certain all the pressure has
been released, remove the pressure relief cap (still with a
cloth).
z NOTE: The engine must be cool when coolant is added to the degas
bottle.
z Add coolant to the degas bottle until fluid is between the coolant fill
level marks.
z Does the degas bottle leak? Yes
INSTALL a new
degas bottle. TEST
the system for
normal operation.
No
CARRY OUT the
cooling system
pressure test.
REFER to the
Component Tests
in this section.
REPAIR as
necessary. TEST
the system for
normal operation. Klj . 4 ba
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