engine FORD MUSTANG 2003 Workshop Manual

DIAGNOSIS AND TESTING
Engine Ignition
Refer to the Powertrain Control/Emissions Diagnosis (PC/ED) manual.
SECTION 303-
07C: Engine Ignition — 4.6L (4V) 2003 Mustang Workshop Manual Klj . 1 ba
12003 Mustang Workshop Manual
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REMOVAL AND INSTALLATION
Ignition Coil-
On-Plug
Removal and Installation 1. Disconnect the battery ground cable. For additional information, refer to Section 414 - 01 .
2. Remove the air cleaner outlet pipe. For additional information, refer to Section 303 - 12 .
3. Remove the RH ignition coil cover bolts and the cover.
4. Remove the ignition coils. 1. Disconnect the electrical connectors.
2. Remove the ignition coils.
SECTION 303-
07C: Engine Ignition — 4.6L (4V) 2003 Mustang Workshop Manual Material
Item Specification
Silicone Brake Caliper Grease
and Dielectric Compound
D7AZ-
19A331-A or equivalent ESE-
M1C171-
A Klj . 1 ba
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REMOVAL AND INSTALLATION
Spark Plugs
Removal and Installation
1. Remove the ignition coil- on-plug. For additional information, refer to Ignition Coil - On - Plug in this
section.
2. NOTE: Use compressed air to remove any foreign material from the spark plug well before
removing the spark plugs.
NOTE: If an original spark plug is used, make sure it is installed in the same cylinder from which
it was taken. New spark plugs can be used in any cylinder.
Remove the RH spark plugs.
3. Remove the LH spark plugs.
4. Inspect the spark plugs. Install new spark plugs as necessary. For additional information, refer to Section 303 - 00
5. Adjust the spark plug gap as necessary.
SECTION 303-
07C: Engine Ignition — 4.6L (4V) 2003 Mustang Workshop Manual Klj . 1 ba
22003 Mustang Workshop Manual
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SPECIFICATIONS
SECTION 303-
08: Engine Emission Control 2003 Mustang Workshop Manual Torque Specifications
Description Nm lb-
ft lb-
in EGR vacuum regulator solenoid nuts 7 — 62
Differential pressure feedback EGR 7 — 62
Differential pressure feedback EGR —
Bullitt 10 — 89
EGR valve bolts 10 — 89
EGR valve-to-
exhaust manifold tube fitting 35 26 —
EGR tube-
to-exhaust manifold fitting (except Bullitt) 40 30 —
EGR tube-
to-exhaust manifold fitting 35 26 —
Vacuum accessory bracket fasteners 10 — 89
Air intake scoop bolts 25 18 —
Air intake scoop bracket bolt 25 18 —
Air intake scoop bracket nuts 25 18 —
Air intake scoop bracket throttle body nut 9 — 80
Exhuast gas recirculation (EGR) vacuum regulator solenoid bolts 10 — 89 Klj . 1 ba
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DESCRIPTION AND OPERATION
Engine Emission Control
CAUTION: Do not remove any part of the engine emission control system. Operating the
engine without the engine emission control system will reduce fuel economy and engine
ventilation. This will weaken engine performance and shorten engine life.
The engine emission control consists of the:
zpositive crankcase ventilation (PCV) system.
z exhaust gas recirculation (EGR) system.
Typical Vehicle Emission Control Information (VECI) Decal
The Vehicle Emission Control Information (VECI) decal shows:
zthe components of the emission control system.
z the correct vacuum hose routing.
SECTION 303-
08: Engine Emission Control 2003 Mustang Workshop Manual Item Part Number Description
1 — Adjustment procedure notes
2 — Ignition timing specification
3 — Engine vacuum hose routing (typical)
4 — Spark plug gap specification
5 — Engine type Klj . 1 ba
32003 Mustang Workshop Manual
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DIAGNOSIS AND TESTING
Engine Emission Control
Refer to the Powertrain Control/Emissions Diagnosis (PC/ED) manual.
SECTION 303-
08: Engine Emission Control 2003 Mustang Workshop Manual Klj . 1 ba
12003 Mustang Workshop Manual
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REMOVAL AND INSTALLATION
Exhaust Gas Recirculation (EGR) Valve
Removal and Installation
NOTE:
The 4.6L, 2V is shown. The 3.8L is similar.
1. Disconnect the vacuum hose.
2. Disconnect the EGR tube from the EGR valve.
3. Remove the two bolts, the EGR valve and the gasket.
4. NOTE: Install a new gasket.
To install, reverse the removal procedure.
SECTION 303-
08: Engine Emission Control 2003 Mustang Workshop Manual Klj . 1 ba
22003 Mustang Workshop Manual
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REMOVAL AND INSTALLATION
Exhaust Gas Recirculation (EGR) Valve —
Cobra
Removal and Installation 1. Disconnect the accelerator cable and the speed control cable.
2. Remove the accelerator cable bracket bolts.
3. Release the clip and position the accelerator cable bracket and the cables aside.
4. Disconnect the electrical connectors from the fuel pulse damper, EGR vacuum regulator solenoid, supercharger bypass vacuum solenoid, and the differential pressure feedback EGR
system.
SECTION 303-
08: Engine Emission Control 2003 Mustang Workshop Manual Klj . 1 ba
42003 Mustang Workshop Manual
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REMOVAL AND INSTALLATION
Exhaust Gas Recirculation (EGR) Valve —
Mach I
Removal and Installation 1. Remove the air intake scoop. For additional information, refer to Section 303 - 12 .
2. Remove the exhaust gas recirculation (EGR) valve. 1. Disconnect the EGR tube upper fitting.
2. Disconnect the vacuum hose.
3. Remove the two bolts and remove the EGR valve and gasket.
3. CAUTION: Do not use metal scrapers, wire brushes, power abrasive disks or other
abrasive means to clean the sealing surfaces. These tools cause scratches and gouges,
which make leak paths. Use a plastic scraping tool to remove all traces of old sealant.
Clean and inspect the mating surfaces.
4. To install, reverse the removal procedure. zInstall a new gasket.
SECTION 303-
08: Engine Emission Control 2003 Mustang Workshop Manual Klj . 1 ba
22003 Mustang Workshop Manual
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REMOVAL AND INSTALLATION
Exhaust Manifold to Exhaust Gas Recirculation (EGR)
Valve Tube
Removal and Installation
NOTE:
3.8L shown, 4.6L (2V) similar.
1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Section 100 - 02 .
2. Disconnect the exhaust gas recirculation (EGR) valve tube from the exhaust manifold.
3. Remove the differential feedback exhaust gas recirculation (EGR) system vacuum hoses and the bracket bolts. Position the bracket assembly aside.
4. Disconnect the EGR tube from the EGR valve.
SECTION 303-
08: Engine Emission Control 2003 Mustang Workshop Manual Klj . 1 ba
22003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_4464/S3B~us~en~ ...