engine FORD MUSTANG 2003 Workshop Manual

Pressure Test
1. Turn the engine OFF.
2. 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, never remove 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).
Check the intercooler coolant level. For additional information, refer to Supercharger Cooling System Draining, Filling and Bleeding in this section.
3. Connect the Radiator/Heater Core Pressure Tester to the degas bottle nipple. Install a pressure test pump to the quick- connect fitting of the test adapter.
4. NOTE: If the plunger of the pump is depressed too fast, 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 69 kPa (10 psi) cannot be reached, install a new pressure relief cap. If more than 12 kPa (18 psi) shows on the gauge, install a new pressure relief cap.
7. CAUTION: If the pressure drops, check for leaks at the intercooler hoses or other
system components and connections. Any leaks which are found must be corrected and
the system rechecked.
NOTE: Intercooler system is not connected to the main engine cooling system.
Pressurize the intercooler 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. zIf the pressure drops and no external leak is found, the intercooler may be the cause.
Remove and inspect the intercooler. Install a new intercooler if necessary.
8. Release the system pressure by loosening the pressure relief cap. Check the coolant level and replenish, if necessary, with the correct coolant mixture. For additional information, refer to
Supercharger Cooling System Draining, Filling and Bleeding in this section.
Cap WARNING: Never remove the pressure relief cap under any conditions while the engine is Klj . 5 ba
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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 pressure relief
cap (still with a cloth).
1. Immerse the pressure relief cap in water and install it on the shallow filler neck of Radiator/Heater Core Pressure Tester and Radiator Cap Adapter, part of Radiator/Heater Core
Pressure Tester.
2. Immerse the filler neck seal in water and install it in the filler neck adapter.
3. Install the filler neck adapter with the filler neck seal to the Radiator Cap Adapter.
4. Connect the female quick- connect fitting of the pressure test pump to the male quick- connect
fitting of the filler neck adapter.
5. NOTE: If the plunger of the pump is depressed too fast, 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.
6. Release the pressure by turning the relief screw counterclockwise. Then tighten the pressure relief screw and repeat Step 6 (at least twice) to make sure the reading is repeatable within the
specifications of the pressure relief cap.
7. If the pressure test gauge readings are not within specifications, install a new pressure relief cap. If the pressure test gauge readings are within specifications, carry out the cooling system
pressure test.
Radiator Leak Test, Removed From the Vehicle CAUTION: Never leak test an aluminum radiator or intercooler in the same water that
copper/brass radiators are tested in. Flux and caustic cleaners may be present in the cleaning
tank and they will damage aluminum radiators and intercoolers.
NOTE: Clean the radiator or intercooler before leak testing to avoid contamination of tank.
1. Leak test the radiator or intercooler in clean water with 138 kPa (20 psi) air pressure. Klj . 6 ba
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GENERAL PROCEDURES
Supercharger Cooling System Draining, Filling and
Bleeding
Draining
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 certain all the pressure has been released,
(still with a cloth) turn and remove the pressure relief cap.
CAUTION: The coolant must be recovered in a suitable, clean container for reuse. If the
coolant is contaminated, it must be recycled or disposed of correctly and replaced.
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: Less than 80% of coolant capacity can be recovered with the engine in the vehicle. Dirty, rusty
or contaminated coolant requires replacement.
1. Raise and support the vehicle. For additional information, refer to Section 100 - 02 .
2. Remove the lower hose from the intercooler radiator and allow the coolant to drain.
Filling and Bleeding
CAUTION: 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.
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: When adding engine coolant, use a 50/50 mixture of engine coolant and clean, drinkable
water. SECTION 303-
03B: Supercharger Cooling 2003 Mustang Workshop Manual Klj . 1 ba
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1. To maintain the integrity of the coolant and the cooling system:
1. Add 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.
2. 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.
3. 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.
4. 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.
2. Fill the degas bottle. Use 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.
3. Start the engine and allow to run until coolant circulation is observed in the intercooler degas bottle. Absence of circulation indicates air is trapped in the system.
zTurn the engine off.
4. Add coolant as needed. Use 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.
5. Repeat the above procedure to make sure all entrapped air is released. Klj . 2 ba
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GENERAL PROCEDURES
Supercharger Cooling System Flushing
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.
Once pressure is released, remove the pressure relief cap.
2. Drain the cooling system. For additional information, refer to Supercharger Cooling System Draining, Filling and Bleeding in this section.
3. NOTE: Refer to the cooling system flusher manufacturer's operating instructions for specific
vehicle hook- up.
Using an appropriate cooling system flusher, flush the intercooler cooling system.
Use Premium Cooling System Flush VC- 1 meeting Ford specification ESR-M14P7-A.
4. Fill the cooling system. For additional information, refer to Supercharger Cooling System Draining, Filling and Bleeding in this section.
SECTION 303-
03B: Supercharger Cooling 2003 Mustang Workshop Manual Klj . 1 ba
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SPECIFICATIONS
SECTION 303-
04A: Fuel Charging and Controls — 3.8L 2003 Mustang Workshop Manual General Specifications
Item Specification
Lubricants and Chemicals
SAE 5W-
20 Premium Synthetic Blend Motor Oil XO-5W20- QSP WSS-
M2C153- H
Torque Specifications Description Nm lb-
in Throttle body nuts and bolts 9 80
Fuel injection supply manifold bolts 10 89
42-
pin engine bulkhead electrical connector bolt 6 53 Klj . 1 ba
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REMOVAL AND INSTALLATION
Fuel Injectors
Removal and Installation
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 may ignite. Failure to follow these instructions may 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 pressure must be relieved. Failure to follow these instructions may result
in personal injury
1. Remove the supply manifold. For additional information, refer to Supply Manifold in this section.
2. Remove the six fuel injectors from the supply manifold.
3. CAUTION: The retaining clip must be in the upper groove on the injector or the
injector may become loose.
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 aid installation.
To install, reverse the removal procedure.
SECTION 303-
04A: Fuel Charging and Controls — 3.8L 2003 Mustang Workshop Manual Material
Item Specification
SAE 5W-
20 Premium Synthetic
Blend Motor Oil
XO- 5W20-QSP or equivalent WSS-
M2C153-
H Klj . 1 ba
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REMOVAL AND INSTALLATION
Fuel Charging Wiring Harness
Removal and Installation
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 may ignite. Failure to follow these instructions may 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 - 01A .
3. Disconnect the following electrical connectors. z42- pin engine bulkhead connector
z 16- pin connector
z 8-pin connector
z A/C pressure switch
4. Separate the wiring harness from the dash panel.
5. Disconnect the intake manifold runner control (IMRC) actuator electrical connector.
SECTION 303-
04A: Fuel Charging and Controls — 3.8L 2003 Mustang Workshop Manual Klj . 1 ba
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10. Disconnect the cylinder head temperature (CHT) sensor electrical connector on the back of the
left cylinder head.
11. Disconnect the engine oil pressure sender electrical connector.
12. Disconnect the fuel pressure sensor electrical connector. 13. Disconnect the LH heated oxygen sensor (HO2S) electrical connector. Klj . 3 ba
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REMOVAL AND INSTALLATION
Supply Manifold
Removal and Installation
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 may ignite. Failure to follow these instructions may 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
may result in personal injury.
1. Disconnect the battery ground cable.
2. Remove the upper intake manifold. For additional information, refer to Section 303 - 01A .
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. Separate the wiring harness from the supply manifold.
6. NOTE: Right side shown, left side similar.
Disconnect the six fuel injector electrical connectors. 7. Disconnect the fuel pressure sensor. SECTION 303-
04A: Fuel Charging and Controls — 3.8L 2003 Mustang Workshop Manual Klj . 1 ba
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