check engine FORD MUSTANG 2003 Manual PDF

6. Carry out an oil consumption test:
a. Drain the engine oil, remove the oil bypass filter (6714) and refill with one liter (quart) less than
the recommended amount.
b. Run the engine for three minutes (10 minutes if cold), and allow the oil to drain back for at least five minutes with the vehicle on a level surface.
c. Remove oil level dipstick and wipe clean. (Do not wipe with anything contaminated with silicone compounds.) Reinstall the oil level dipstick, being sure to seat it firmly in the oil level indicator
tube (6754). Remove the oil level dipstick and draw a mark on the back (unmarked) surface at
the indicated oil level. This level should be about the same as the MIN or ADD mark on the face
of the oil level dipstick.
d. Add one liter (quart) of oil. Restart the engine and allow to idle for at least two minutes. Shut off the engine and allow the oil to drain back for at least five minutes. Mark the oil level dipstick,
using the procedure above.
e. Record the vehicle mileage. f. Instruct the customer to drive the vehicle as usual and perform the following:
„Check the oil level regularly at intervals of 160 to 240 km (100- 150 miles).
„ Return to the service point when the oil level drops below the lower (MIN or ADD) mark
on the oil level dipstick.
„ Add only full liters (quarts) of the same oil in an emergency. Note the mileage at which
the oil is added.
g. Check the oil level under the same conditions and at the same location as in Steps 6c and 6d.
„Measure the distance from the oil level to the UPPER mark on the oil level dipstick and
record.
„ Measure the distance between the two scribe marks and record.
„ Divide the first measurement by the second.
„ Divide the distance driven during the oil test by the result. This quantity is the
approximate oil consumption rate in kilometers per liter or in miles per quart.
h. If the oil consumption rate is unacceptable, go to Step 7.
7. Check the positive crankcase ventilation (PCV) system. Make sure the system is not plugged.
8. Check for plugged oil drain- back holes in the cylinder heads and cylinder block.
9. If the condition still exists after performing the above steps, go to Step 10.
10. Perform a cylinder compression test or perform a cylinder leak detection test with Engine Cylinder Leak Detection/Air Pressurization Kit. This can help determine the source of oil
consumption such as valves, piston rings or other areas.
11. NOTE: After determining if new parts should be installed, make sure correct parts are used.
Check valve guides for excessive guide clearance. Install new all valve stem seals (6571) after
verifying valve guide clearance.
12. Worn or damaged internal engine components can cause excessive oil consumption. Small deposits of oil on the tips of spark plugs can be a clue to internal oil consumption. If internal oil
consumption still persists, proceed as follows:
a. Remove the engine from the vehicle and place it on an engine work stand. Remove the intake manifolds (9424), cylinder heads, oil pan (6675) and oil pump (6600).
b. Check piston ring clearance, ring gap and ring orientation. Repair as necessary.
c. Check for excessive bearing clearance. Repair as necessary.
13. Repeat the oil consumption test (Step 6) to confirm the oil consumption concern has been resolved. Klj . 10 ba
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Engines need oil to lubricate the following internal components:
zcylinder block cylinder walls
z pistons and piston, pin and rings (6102)
z intake and exhaust valve stems
z intake and exhaust valve guides
z all internal engine components
When the pistons move downward, a thin film of oil is left on the cylinder walls. As the vehicle is
operated, some oil is also drawn into the combustion chambers past the intake and exhaust valve
stem seals and burned.
The following is a partial list of conditions that can affect oil consumption rates:
zengine duty cycle
z operator driving habits
z ambient temperature
z quality and viscosity of the oil
Operation under varying conditions can frequently be misleading. A vehicle that has been run for
several thousand miles on short trips or in below- freezing ambient temperatures may have consumed
a "normal" amount of oil. However, when checking the engine oil level, it may measure up to the FULL
or MAX on the oil level dipstick due to dilution (condensation and fuel) in the engine crankcase. The
vehicle might then be driven at high speeds on the highway where the condensation and fuel boil off.
The next time the engine oil is checked, it may appear that a liter (quart) of oil was used in about 160
km (100 miles). This perceived 160 km (100 miles) per liter (quart) oil consumption rate causes
customer concern even though the actual overall oil consumption rate is about 2,400 km (1,500 miles)
per liter (quart).
Make sure the selected engine oil meets the current recommended API performance category with
SAE viscosity grade as shown in the vehicle Owner's Guide. It is also important that the engine oil is
changed at the intervals specified. Refer to the vehicle Owner's Guide.
Oil Pressure Test
1. Disconnect and remove the oil pressure sensor (9278) from the engine.
2. Connect the Oil Pressure Gauge to the oil pressure sender oil galley port.
3. Run the engine until normal operating temperature is reached.
4. Run the engine at the specified rpm and record the gauge reading.
5. The oil pressure should be within specifications; refer to the specification chart in the appropriate engine section.
6. If the pressure is not within specification, check the following possible sources: zinsufficient oil
z oil leakage
z worn or damaged oil pump
z oil pump screen cover and tube (6622)
z excessive main bearing clearance Klj . 13 ba
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z
excessive connecting rod bearing clearance
Valve Train Analysis— Engine Off—Valve Cover Removed
Check for damaged or severely worn parts and correct assembly. Make sure correct parts are used
with the static engine analysis as follows.
Valve Train Analysis— Engine Off, Rocker Arm
z Check for loose mounting bolts, studs and nuts.
z Check for plugged oil feed in the rocker arms (6564) or cylinder head.
Valve Train Analysis— Engine Off, Camshaft Roller Followers and Hydraulic Lash Adjusters,
Overhead Camshaft
zCheck for loose mounting bolts on camshaft carriers.
z Check for plugged oil feed in the camshaft roller followers, lash adjusters or cylinder heads.
Valve Train Analysis— Engine Off, Camshaft— Engines
z Check for broken or damaged parts.
Valve Train Analysis— Engine Off, Push Rods
z Check for bent push rods (6565) and restricted oil passage.
Valve Train Analysis— Valve Springs
z Check for broken or damaged parts.
Valve Train Analysis— Engine Off, Valve Spring Retainer and Valve Spring Retainer Keys
z Check for correct seating of the valve spring retainer key (6518) on the valve stem and in valve
spring retainer (6514).
z Check for correct seating on the valve stem.
Valve Train Analysis— Engine Off, Valves and Cylinder Head
z Check for plugged oil drain back holes.
z Check for worn or damaged valve tips.
z Check for missing or damaged guide- mounted valve stem seal.
z Check collapsed valve tappet gap.
z Check installed valve spring height.
z Check for missing or worn valve spring seats.
z Check for plugged oil metering orifice in cylinder head oil reservoir (if equipped).
Static checks (engine off) are to be made on the engine prior to the dynamic procedure. Klj . 14 ba
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Valve Train Analysis—
Engine Running
z Start the engine and, while idling, check for correct operation of all parts. Check the following:
Valve Train Analysis— Engine Running, Valves and Cylinder Head
z Check for plugged oil drain back holes.
z Check for missing or damaged valve stem seals or guide mounted valve stem seals.
z Check for a plugged oil metering orifice in the cylinder head oil reservoir (4.6L engine only).
If insufficient oiling is suspected, check oil passages for blockage, then accelerate the engine to 1,200
rpm with the transmission in NEUTRAL and the engine at normal operating temperature. Oil should
spurt from the rocker arm oil holes such that valve tips and camshaft roller followers are well oiled.
With the valve covers (6582) off, some oil splash may overshoot camshaft roller followers.
Valve Train Analysis— Engine Running, Camshaft Lobe Lift— OHC Engines
Check the lift of each camshaft lobe in consecutive order and make a note of the readings. 1. Remove the valve covers.
2. Remove the spark plugs.
3. Install the Dial Indicator Gauge with Holding Fixture so the rounded tip of indicator is on top of the camshaft lobe and on the same plane as the valve tappet.
4. Rotate the crankshaft using a breaker bar and socket attached to the crankshaft pulley retainer bolt. Rotate the crankshaft until the base circle of the camshaft lobe is reached.
5. Zero the dial indicator. Continue to rotate the crankshaft until the (1) high- lift point of the
camshaft lobe is in the fully- raised position (highest indicator reading).
6. To check the accuracy of the original indicator reading, continue to rotate crankshaft until the (2) base circle is reached. The indicator reading should be zero. If zero reading is not obtained,
repeat Steps 1 through 6.
7. NOTE: If the lift on any lobe is below specified service limits, install a new camshaft, and new
camshaft roller followers.
Remove the Dial Indicator Gauge with Holding Fixture.
8. Install the spark plugs. Klj . 15 ba
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9. Install the valve covers.
Valve Train Analysis— Engine Running, Camshaft Lobe Lift— Push Rod Engine
Check the lift of each lobe in consecutive order and make a note of the readings. 1. Remove the valve covers.
2. Remove the rocker arm seat bolts, rocker arm seat (6A528) and rocker arms.
Typical Engine With Push Rods
3. Make sure the valve tappet is seated against camshaft (6250). Install (1) Dial Indicator Gauge with Holding Fixture so the ball socket adapter of the indicator is on top of the valve tappet or (2)
Dial Indicator Gauge Adapter is on top of push rod and in same plane as valve tappet push rod
movement.
4. Remove the spark plugs.
5. Connect an auxiliary starter switch in the starting circuit. Crank the engine with ignition switch in OFF position. Bump crankshaft over until valve tappet is on base circle of camshaft lobe. At this
point, valve tappet will be in its lowest position. If checking during engine assembly, turn
crankshaft using a socket or ratchet.
6. Zero the dial indicator. Continue to rotate crankshaft slowly until valve tappet is in fully- raised
position (highest indicator reading).
7. NOTE: If lift on any lobe is below specified service limits, install a new camshaft, and new valve
tappets.
Remove the Dial Indicator with Holding Fixture, Dial Indicator Gauge Adapter, and auxiliary
starter switch.
8. Install rocker arm seats, rocker arms and rocker arm seat bolts.
9. Install valve covers.
10. Install spark plugs.
Valve Train Analysis— Engine Running, Valve Tappet
Valve tappet noise can be caused by any of the following:
zexcessive valve tappet gap (collapsed) Klj . 16 ba
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GENERAL PROCEDURES
Rocker Arms —
Inspection
CAUTION: Do not attempt to true surfaces by grinding. Check the rocker arm pad, side
rails and seat for excessive wear, cracks, nicks or burrs. Check the rocker arm seat bolt for
stripped or broken threads. Install new components as ncessary or possible damage may
occur.
1. Inspect the rocker arm push rod bore for nicks, scratches, scores or scuffs. Install new components as necessary. Refer to the appropriate section in Group 303 for the procedure.
2. Inspect the pad at the valve end of the rocker arm for indications of scuffing or abnormal wear. If the pad is grooved, install a new rocker arm. Refer to the appropriate section in Group 303 for
the procedure.
SECTION 303-
00: Engine System — General Information 2003 Mustang Workshop Manual Klj . 1 ba
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GENERAL PROCEDURES
Push Rods —
Inspection
1. CAUTION: Do not attempt to straighten push rods.
Check the ends of the push rods for nicks, grooves, roughness or excessive wear. Install new
push rods as necessary. Refer to the appropriate section in Group 303 for the procedure.
z The push rods can be checked for straightness while they are installed in the engine by
rotating them with the valve closed.
z They also can be checked using a Dial Indicator with Bracketry.
2. If the push rod is bent beyond specifications, install a new push rod. Refer to the appropriate section in Group 303 for the procedure.
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GENERAL PROCEDURES
Camshaft Journal —
Clearance, Push Rod Engines,
Micrometer Method
1. NOTE: The camshaft journals must meet specifications before checking camshaft journal
clearance.
Measure each camshaft bearing (6261) in two directions.
zSubtract the camshaft journal diameter from the camshaft bearing diameter.
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GENERAL PROCEDURES
Camshaft Journal —
Clearance, Plastigage Method
NOTE: The camshaft journals must meet specifications before checking camshaft journal clearance.
1. Remove the camshaft bearing cap and lay Plastigage across the surface. Refer to the appropriate section in Group 303 for the procedure.
2. NOTE: Do not turn the camshaft while carrying out this procedure.
Position the camshaft bearing cap and install the bolts. Refer to the appropriate section in
Group 303 for the procedure.
3. Use Plastigage to verify the camshaft journal clearance. zIf out of specification, install new components as necessary. Refer to the appropriate
section in Group 303 for the procedure.
SECTION 303-
00: Engine System — General Information 2003 Mustang Workshop Manual Special Tool(s)
Plastigage
303-
D031 (D81L-6002- B) or
equivalent Klj . 1 ba
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GENERAL PROCEDURES
Camshaft End Play —
OHC Engines
1. Remove the roller followers. Refer to the appropriate section in Group 303 for the procedure.
2. Use a Dial Indicator Gauge with Holding Fixture to measure camshaft end play.
3. Position the camshaft to the rear of the cylinder head.
4. Zero the indicator.
5. Move the camshaft to the front of the cylinder head. Note and record the camshaft end play. zIf camshaft end play exceeds specifications, install new camshaft and recheck end play.
Refer to the appropriate section in Group 303 for the procedure.
z If camshaft end play exceeds specification after camshaft installation, install a new
cylinder head. Refer to the appropriate section in Group 303 for the procedure.
SECTION 303-
00: Engine System — General Information 2003 Mustang Workshop Manual Special Tool(s)
Dial Indicator Gauge with
Holding Fixture
100-
002 (TOOL- 4201-C) or
equivalent Klj . 1 ba
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