clock FORD MUSTANG 2003 Manual PDF

REMOVAL AND INSTALLATION
Instrument Cluster Bulb
Removal and Installation
1. Remove the instrument cluster. For additional information, refer to Section 413 - 01 .
2. Remove the necessary instrument cluster bulbs by rotating the bulb one quarter turn counterclockwise and lifting straight out of the instrument cluster.
3. To install, reverse the removal procedure.
SECTION 413-
00: Instrument Cluster and Panel Illumination 2003 Mustang Workshop Manual Klj . 1 ba
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REMOVAL AND INSTALLATION
Warning Indicator Bulb
Removal and Installation
1. Remove the instrument cluster. Refer to Instrument Cluster in this section.
2. Remove the necessary instrument cluster bulbs by rotating one quarter turn counterclockwise.
3. To install, reverse the removal procedure.
SECTION 413-
01: Instrument Cluster 2003 Mustang Workshop Manual Klj . 1 ba
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REMOVAL AND INSTALLATION
Bulb —
Headlamp
Removal
WARNING: The halogen bulb contains gas under pressure. The bulb may shatter if the
glass envelope is scratched or if the bulb is dropped. Handle the bulb only by its base. Grasp
the bulb only by its base. Avoid touching the glass envelope.
NOTE: The headlamp bulb should not be removed from the headlamp until just before a replacement
bulb is installed. Removing the bulb for an extended period of time may effect headlamp bulb
performance. Contaminants may enter the headlamp where they can settle on the lens and reflector.
Never turn on the headlamps with the bulb removed.
1. Remove the headlamp assembly. For additional information, refer to Lamp Assembly —
Headlamp .
2. Rotate the headlamp bulb retainer counterclockwise.
3. Remove the headlamp bulb and retainer. zGrasp the headlamp bulb by its base and remove the bulb.
Installation 1. WARNING: The halogen bulb contains gas under pressure. The bulb may shatter if
the glass envelope is scratched or if the bulb is dropped. Handle the bulb only by its
base. Grasp the bulb only by its base. Avoid touching the glass envelope.
To install, reverse the removal procedure.
SECTION 417-
01: Exterior Lighting 2003 Mustang Workshop Manual Klj . 1 ba
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REMOVAL AND INSTALLATION
Lock Cylinder —
Luggage Compartment Lid
Removal 1. NOTE: Individual lock cylinders are repaired by discarding the inoperative cylinder and building
a new lock cylinder using the appropriate lock repair package. The lock repair package includes
a detailed instruction sheet to build the new lock cylinder to the current key code of the vehicle.
Disconnect the luggage compartment lid lock actuator (432A38) cable.
2. Remove the luggage compartment lid lock cylinder (43262). 1. Remove the rivet.
2. Rotate the lock cylinder counterclockwise to remove.
Installation 1. To install, reverse the removal procedure.
SECTION 501-
14A: Handles, Locks, Latches and Mechanisms 2003 Mustang Workshop Manual Klj . 1 ba
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DESCRIPTION AND OPERATION
Air Bag Supplemental Restraint System (SRS)
The air bag supplemental restraint system (SRS) is designed to provide increased collision protection
for front seat occupants in addition to that provided by the three-
point safety belt system. Safety belt
use is necessary to obtain the best occupant protection and to receive the full advantages of the SRS.
The air bag supplemental restraint system (SRS) components are shown in the following illustration.
Air Bag Supplemental Restraint System (SRS) Components SECTION 501-
20B: Supplemental Restraint System 2003 Mustang Workshop Manual Item Part Number Description
1 044A74 Passenger air bag module
2 14B321 Restraints control module (RCM)
3 043B13 Driver air bag module
4 14A664 Clockspring Klj . 1 ba
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Driver Air Bag Module
The driver air bag module:
zis installed as an assembly.
z is mounted in the center of the steering wheel.
Clockspring
The clockspring: zis mounted on the steering column, behind the steering wheel.
z provides a continuous electrical path from the restraints control module (RCM) to the driver air
bag.
Passenger Air Bag Module
The passenger air bag module: zis installed as an assembly.
z is mounted in the RH side of the instrument panel.
Restraints Control Module (RCM)
The restraints control module (RCM) performs the following functions: zsignals the inflators to deploy the air bags in the event of a deployable crash.
z monitors the air bag supplemental restraint system (SRS) for faults.
z illuminates the air bag indicator if a fault is detected.
z flashes the air bag indicator to indicate the lamp fault code (LFC) detected.
z communicates through the data link connector (DLC) the current or historical diagnostic trouble
codes (DTCs).
z signals the generic electronic module (GEM) to activate a chime if the air bag indicator is not
available and another SRS fault exists.
NOTE: The safing sensor is internal to the RCM and is not repaired separately.
The RCM monitors the SRS for possible faults. If a fault is detected while the ignition switch is in the
RUN position, the RCM will illuminate the air bag indicator located in the instrument cluster.
When the ignition is cycled (turned off and then on), the air bag indicator will begin its prove out
sequence. During prove out the air bag indicator will illuminate for six seconds, go off for two seconds
and then, if a system fault exists, flash the two- digit LFC. The air bag indicator will flash the LFC five
times, then it will remain illuminated for the rest of the key cycle. The RCM will also communicate the Klj . 2 ba
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Pinpoint Test D: LFC 15/DTC B 1887—
Driver Air Bag Circuit Shorted to Ground
Normal Operation
The restraints control module (RCM) checks for driver air bag circuit shorts to ground by monitoring the
voltage of circuits 614 (GY/OG) and 615 (GY/WH) at pins 3 and 4. If the RCM detects a short to
ground on either of these pins, it will store a diagnostic trouble code (DTC) B1887 in memory and flash
a lamp fault code (LFC) 15 (or higher priority code if one exists) on the air bag indicator.
Possible Causes
A driver air bag circuit short to ground can be caused by:
za short to ground on circuit 614 (GY/OG).
z a short to ground on circuit 615 (GY/WH).
z a short to ground on the clockspring (14A664).
z a short to ground on the driver air bag module.
z an RCM internal concern.
PINPOINT TEST D: LFC 15/DTC B1887 — DRIVER AIR BAG CIRCUIT
SHORTED TO GROUND system. PROVE
OUT the system.
REFER to
Air Bag Supplemental
Restraint System
(SRS) in this
section. CLEAR
all DTCs. Test Step Result / Action to
Take D1 CHECK FOR A HARD OR INTERMITTENT DTC
z
Key in OFF position.
z Connect the diagnostic tool. Scan Tool
z Key in ON position.
z Enter the following diagnostic mode on the diagnostic tool:
Retrieve/Clear Continuous DTCs.
z Retrieve and record any continuous DTCs for use later in this
pinpoint test.
z Enter the following diagnostic mode on the diagnostic tool: On-
Demand Self Test.
z Was DTC B1887 retrieved during the on- demand self test? Yes
This is a hard fault.
The fault condition
is still present. This
fault cannot be
cleared until it is
corrected and the
DTC is no longer
retrieved during the
on-
demand self
test. GO to D2 .
No
This is an
intermittent fault.
The fault condition
is not present at
this time. GO to
D5 . Klj . 10 ba
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D2 CHECK THE DRIVER AIR BAG MODULE
WARNING: If the supplemental restraint system (SRS) is
being serviced, the system must be deactivated and restraint
system diagnostic tools must be installed. Refer to Air Bag Supplemental Restraint System (SRS) in this section.
The air bag restraint system diagnostic tools must be removed
and the air bag modules reconnected when the system is
reactivated to avoid non- deployment in a collision, resulting in
possible personal injury. NOTE: Diagnostics or repairs are not to
be performed on a seat equipped with a seat side air bag with the
seat in the vehicle. Prior to attempting to diagnose or repair a seat
concern when equipped with a seat side air bag, the seat must be
removed from the vehicle and the restraint system diagnostic tools
must be installed in the seat side air bag electrical connectors. The
restraint system diagnostic tools must be removed prior to
operating the vehicle over the road. NOTE: After diagnosing or
repairing an SRS, the restraint system diagnostic tools must be
removed before operating the vehicle over the road. NOTE:
After diagnosing or repairing a seat system, the restraint system
diagnostic tools must be removed before operating the vehicle
over the road. NOTE: The SRS must be fully operational and free
of faults before releasing the vehicle to the customer.
z Key in OFF position.
z Deactivate the system. Refer to Air Bag Supplemental Restraint System (SRS) in the Diagnosis and Testing portion of this section.
z Key in OFF position.
z Key in ON position.
z Enter the following diagnostic mode on the diagnostic tool: On-
Demand Self Test.
z Was DTC B1887 retrieved? Yes
GO to
D3 .
No
INSTALL a new
driver air bag
module. GO to D6 .
D3 CHECK THE DRIVER AIR BAG MODULE CIRCUIT
z
Key in OFF position.
z Disconnect: RCM C2041.
z NOTE: Do not separate or remove shorting bars from RCM C2041.
z Measure the resistance between RCM C2041 pin 3, circuit 614
(GY/OG), harness side and RCM C2041 pin 21, circuit 397
(BK/WH), harness side.
z Is the resistance less than 10,000 ohms? Yes
GO to
D4 .
No
INSTALL a new
RCM. GO to D6 .
D4 CHECK THE DRIVER AIR BAG MODULE WIRING AND THE
CLOCKSPRING z
Disconnect: Driver Air Bag Module C216.
z Disconnect: Clockspring C218b.
z Inspect all crimps, terminals, wires and connectors in circuit 614
(GY/OG) feeding the RCM pin 3, circuit 615 (GY/WH) feeding pin 4,
the clockspring C218b. Check for pinched wires and damaged
connector pin terminals.
z Was any damage found? Yes
REPAIR as
necessary. GO to
D6
.
No
GO to D6 . Klj . 11 ba
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Pinpoint Test E: LFC 15/DTC B1916 —
Driver Air Bag Circuit Shorted to Battery or Ignition
Normal Operation
The restraints control module (RCM) checks for driver air bag circuit shorts to battery or ignition by
monitoring the voltage of circuit 614 (GY/OG) and 615 (GY/WH) at pins 3 and 4. If the RCM detects a
short to battery or ignition on either of these pins, it will store a diagnostic trouble code (DTC) B1916 in
memory and flash a lamp fault code (LFC) 15 (or higher priority code if one exists) on the air bag
indicator.
Possible Causes D5 CHECK FOR AN INTERMITTENT FAULT
z
Refer to the continuous DTCs recorded during Step D1.
z Was the continuous DTC retrieved during Step D1 an
intermittent fault? Yes
CHECK for causes
of intermittent short
to ground on circuit
614 (GY/OG),
circuit 615
(GY/WH), and the
clockspring
assembly. Attempt
to recreate the hard
fault by flexing the
wire harness and
cycling the ignition
key frequently.
REPAIR any
intermittent
concerns found.
GO to
D6 .
No
GO to D6 .
D6 CHECK FOR ADDITIONAL DTCs
z
Refer to continuous DTCs recorded during Step D1.
z Were any continuous DTCs retrieved during Step D1? Yes
Do not clear any
DTCs until all DTCs
have been
resolved. GO to the
Restraints Control
Module (RCM)
Diagnostic Trouble
Code (DTC) Priority
Table in this section
for pinpoint test
direction.
No
RECONNECT the
system.
REACTIVATE the
system. PROVE
OUT the system.
REFER to
Air Bag Supplemental
Restraint System
(SRS) in this
section. CLEAR all
DTCs. Klj . 12 ba
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A driver air bag circuit short to battery or ignition can be caused by:
za short to battery or ignition on circuit 614 (GY/OG).
z a short to battery or ignition on circuit 615 (GY/WH).
z a short to battery or ignition on the clockspring.
z a short to battery or ignition on the driver air bag module.
z an RCM internal concern.
PINPOINT TEST E: LFC 15/DTC B1916 — DRIVER AIR BAG CIRCUIT
SHORTED TO BATTERY OR IGNITION Test Step Result / Action to
Take E1 CHECK FOR A HARD OR INTERMITTENT DTC
z
Key in OFF position.
z Connect the diagnostic tool. Scan Tool
z Key in ON position.
z Enter the following diagnostic mode on the diagnostic tool:
Retrieve/Clear Continuous DTCs.
z Retrieve and record any continuous DTCs for use later in this
pinpoint test.
z Enter the following diagnostic mode on the diagnostic tool: On-
Demand Self Test.
z Was DTC B1916 retrieved during the on- demand self test? Yes
This is a hard fault.
The fault condition
is still present. This
fault cannot be
cleared until it is
corrected and the
DTC is no longer
retrieved during the
on-
demand self
test. GO to E2 .
No
This in an
intermittent fault.
The fault condition
is not present at this
time. GO to E5 .
E2 CHECK THE DRIVER AIR BAG MODULE
WARNING: If the supplemental restraint system (SRS) is
being serviced, the system must be deactivated and restraint
system diagnostic tools must be installed. Refer to Air Bag Supplemental Restraint System (SRS) in this section.
The air bag restraint system diagnostic tools must be removed
and the air bag modules reconnected when the system is
reactivated to avoid non- deployment in a collision, resulting in
possible personal injury. NOTE: Diagnostics or repairs are not to
be performed on a seat equipped with a seat side air bag with the
seat in the vehicle. Prior to attempting to diagnose or repair a seat
concern when equipped with a seat side air bag, the seat must be
removed from the vehicle and the restraint system diagnostic tools
must be installed in the seat side air bag electrical connectors. The
restraint system diagnostic tools must be removed prior to
operating the vehicle over the road. NOTE: After diagnosing or
repairing an SRS, the restraint system diagnostic tools must be
removed before operating the vehicle over the road. NOTE:
After diagnosing or repairing a seat system, the restraint system
diagnostic tools must be removed before operating the vehicle Yes
GO to
E3 .
No
INSTALL a new
driver air bag
module. GO to E6 . Klj . 13 ba
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