clutch FORD MUSTANG 2003 Manual PDF

3.
NOTE: Running this test with the vehicle in gear or with the A/C compressor clutch engaged
(running) will cause incorrect diagnosis.
Place the transmission in PARK (P) or NEUTRAL (N).
4. Start the engine and allow the engine to idle throughout this test. Allow the engine to run for 2 minutes, then record the ECT (4.6L) or CHT (3.8L) voltage. Record the ECT (4.6L) or CHT
(3.8L) voltage every 60 seconds. When the ECT (4.6L) or CHT (3.8L) voltage trend changes
direction or only changes slightly (0.03 volts or less) from the previous reading, record this as
the thermostat opening voltage. Use the voltage and corresponding coolant temperature chart
listed below for 4.6L engines only.
5. If the thermostat opening voltage is greater than 0.75 volts and less than 82°C (180°F), install a new water thermostat.
6. If the thermostat opening voltage is less than 0.75 volts and greater than 82°C (180°F), the water thermostat is good and a new water thermostat should not be installed. GO to Symptom Chart for further instructions.
Thermostat — Mechanical Test
1. Remove the water thermostat.
2. Check the water thermostat for seating. Hold the water thermostat up to a lighted background. Leakage of light around the thermostat valve at room temperature indicates that a new water
thermostat should be installed. Some water thermostats have a small leakage notch at one
location on the perimeter of the thermostat valve, which is considered normal.
3. Immerse the water thermostat in a boiling coolant and water mixture.
4. See the General Specifications chart for water thermostat opening temperatures.
Radiator Leak Test, Removed From the Vehicle CAUTION: Never leak test an aluminum radiator 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.
NOTE: Always install plugs in the oil cooler fittings before leak- testing or cleaning any radiator.
NOTE: Clean the radiator before leak- testing to avoid contamination of tank. Coolant Temperature °C (°F) ECT (Volts)
22 (71) 3.00
43 (109) 2.01
71 (159) 1.01
82 (180) 0.75
91 (195) 0.059
97 (206) 0.050
105 (221) 0.040 Klj . 9 ba
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12 — Coolant reservoir bottle electrical connector
13 — Radio ignition interference capacitor electrical
connector
14 — Fuel injector electrical connectors
15 — Exhaust vacuum regulator (EVR) electrical
connector
16 — Differential pressure feedback EGR electrical
connector
17 — RH ignition coil electrical connectors
18 — Ignition coil electrical connectors
19 — Throttle position (TP) sensor electrical connector
20 — Idle air control (IAC) solenoid electrical connector
21 — Voltage regulator electrical connector
22 — Engine coolant temperature (ECT) electrical
connector
23 — Generator battery electrical connector
24 — Radio ignition interference capacitor electrical
connector
25 — Crankshaft position (CKP) sensor electrical
connector
26 — Air conditioning compressor clutch electrical
connector
27 — 16 pin electrical connector Klj . 3 ba
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9. Raise the vehicle. For additional information, refer to
Section 100 - 02 .
10. Disconnect the crankshaft position (CKP) sensor electrical connector.
11. Disconnect the A/C compressor clutch electrical connector.
12. Disconnect the RH heated oxygen sensor (HO2S) electrical connector.
13. Disconnect the LH heated oxygen sensor (HO2S) electrical connector. Klj . 3 ba
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15. Raise the vehicle.
16. Connect the LH (HO2S) electrical connector.
17. Connect the RH (HO2S) electrical connector.
18. Connect the A/C compressor clutch electrical connector.
19. Connect the CKP electrical connector. Klj . 11 ba
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DESCRIPTION AND OPERATION
Accessory Drive
Component Locations—
3.8L
Component Locations— 4.6L
SECTION 303-
05: Accessory Drive 2003 Mustang Workshop Manual Item Part Number Description
1 19D784 A/C clutch pulley
2 8620 Drive belt
3 8509 Coolant pump pulley
4 8678 Belt idler pulley
5 10344 Generator pulley
6 10344 Power steering pump pulley
7 63126 Crankshaft vibration damper
8 6B209 Drive belt tensioner
9 — Drive belt tensioner (part of 6B209)
Item Part Number Description
1 10344 Generator pulley
2 8620 Drive belt
3 8A528 Coolant pump pulley
4 3D673 Power steering pump pulley
5 6316 Crankshaft vibration damper
6 19D784 A/C clutch pulley Klj . 1 ba
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Item Part Number Description
1 8678 Belt idler pulley
2 8678 Belt idler pulley
3 8678 Belt idler pulley
4 3A733 Power steering pulley
5 10344 Coolant pump pulley
6 6C254 Crankshaft pulley
7 6B209 Belt tensioner
8 19D784 A/C clutch pulley
9 8620 Drive belt Klj . 2 ba
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Component Tests
Drive Belt Noise/Flutter
Drive belt chirp occurs due to pulley misalignment or excessive pulley runout. It can be the result of a
damaged pulley or an incorrectly aligned pulley.
To correct, determine the area where the noise comes from. Check each of the pulleys in that area
with a straightedge to the crankshaft pulley, looking for accessory pulleys out of position in the fore/aft
direction or at an angle to the straightedge.
Drive belt squeal is an intermittent noise that occurs when the drive belt slips on a pulley during certain
conditions, such as: engine start up, rapid engine acceleration, or A/C clutch engagement.
Drive belt squeal can occur:
zif any of the accessories are damaged, have a worn or damaged bearing, internal torsional
resistance above normal. All accessories should be rotatable by hand in the unloaded condition.
If not, inspect the accessory.
z if fluid gets on the drive belt. This includes power steering fluid, engine coolant, engine oil or air
conditioning system lubricant. If fluid does get on the drive belt during service, clean the drive
belt with soap and water and thoroughly rinse with clean water.
z NOTE: The drive belt tensioner arm should rotate freely without binding.
if the drive belt is too long. A drive belt that is too long will allow the drive belt tensioner arm to
go all the way to the arm travel stop under certain load conditions, which will release tension to
the drive belt. If the drive belt tensioner indicator is outside the installation wear range window,
install a new drive belt.
z if the drive belt tensioner is worn or damaged.
Belt Tension
NOTE: Drive belt tension is not adjustable.
The drive belt tensioner automatically adjusts drive belt tension. Symptom Chart Condition
Possible Sources Action
z Drive belt
noise, chirping,
flutter z
Defective/worn drive
belt.
z Misaligned pulley.
z Pulley runout.
z Damaged
accessories.
z Fluid contamination
of drive belt. z
GO to Component Tests, Drive
Belt, Noise/Flutter.
z Damaged or worn
drive belt tensioner. z
GO to Component Tests, Belt
Tensioner, Automatic.
z Premature
drive belt wear z
Defective drive belt.
z Misaligned pulley.
z Pulley runout.
z Damaged
accessories.
z Incorrectly installed
drive belt. z
GO to Component Tests, Drive
Belt Noise/Flutter and Drive
Belt Misalignment diagnosis. Klj . 2 ba
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DESCRIPTION AND OPERATION
Starting System
Starter Motor
The starter motor is a 12-
volt unit that has the starter solenoid mounted on the drive end housing and
functions as follows:
zThe current flows through the solenoid energizing coil until the solenoid plunger is at the end of
its travel.
z The plunger closes a set of contacts that bypass the energizing coil, letting the holding coil keep
the starter drive engaged and passing starting current to the starter motor.
z The motor is energized when the starter solenoid contacts are closed.
z The starter drive engages the flywheel ring gear and starts the engine.
z An overrunning clutch in the starter drive protects the starter motor from excessive speed when
the engine starts.
Starter Relay
The starter interrupt relay consists of:
zpull in coil and contacts
When the ignition switch is in the START position:
zthe pull- in coil is activated and pulls the contacts together.
z current passes through the starter relay from the engine compartment power distribution box to
the starter solenoid.
Clutch Pedal Position (CPP) Switch
The CPP switch for:
za manual transmission closes when the clutch pedal is depressed, completing the starting
circuit.
z an automatic transmission is a jumper inserted in place of the CPP switch to complete the
circuit.
Starter System — Operation
When the ignition switch is turned to the START position the starter relay switches power to the starter
solenoid causing the starter motor to engage as long as:
zthe clutch pedal is depressed (manual transmission only).
z the digital transmission range (TR) sensor is in PARK or NEUTRAL (automatic transmission
only).
SECTION 303-
06: Starting System 2003 Mustang Workshop Manual Klj . 1 ba
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Symptom Chart
Pinpoint Tests
PINPOINT TEST A: THE ENGINE DOES NOT CRANK AND THE
RELAY DOES CLICK
SYMPTOM CHART Condition
Possible Sources Action
z The engine does
not crank and the
relay does click z
Battery.
z Fuse.
z Starter
motor/solenoid.
z Ignition switch.
z Circuit. z
Go To Pinpoint Test A .
z The engine does
not crank and the
relay does not
click z
Fuse.
z Battery.
z Starter relay.
z Ignition switch.
z Digital transmission
range (TR) sensor.
z Starter solenoid.
z Clutch pedal
position (CPP)
switch.
z Circuit. z
Go To Pinpoint Test B .
z The engine
cranks slowly z
Battery.
z Starter
motor/solenoid.
z Circuit. z
Go To Pinpoint Test C .
z Unusual starter
noise z
Starter motor
mounting.
z Starter motor.
z Incorrect starter
drive engagement. z
Go To Pinpoint Test D .
z The starter spins
but the engine
does not crank z
Starter Motor zINSPECT the starter motor
mounting and engagement.
REPAIR as necessary.
z Damaged
flywheel/ring gear
teeth. z
INSPECT the flywheel/ring
gear for damaged, missing or
worn teeth. REPAIR as
necessary. Test Step Result / Action to Take
A1 CHECK THE VOLTAGE TO THE STARTER RELAY
z
Measure the voltage between the starter relay pin 30,
circuit 1050 (LG/VT) and ground. Yes
GO to
A2 .
No
REPAIR circuit 1050 (LG/VT) Klj . 2 ba
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12, circuit 33 (WH/PK) and the starter motor relay pin 86, circuit
33 (WH/PK).
z Is the resistance less than 5 ohms? B4 CHECK DIGITAL TRANSMISSION RANGE (TR) SENSOR
ADJUSTMENT z
Carry out the digital TR sensor adjustment. Refer to Section 307 - 01 .
z Is the digital TR sensor adjusted correctly? Yes
INSTALL a new digital
TR sensor. TEST the
system for normal
operation.
No
ADJUST the digital TR
as necessary. TEST the
system for normal
operation.
B5 CHECK CIRCUIT 32 (RD/LB) FOR VOLTAGE AT THE CLUTCH
SWITCH OR JUMPER z
Key in OFF position.
z Disconnect: Clutch Pedal Switch C255.
z Key in START position.
z Measure the voltage between the clutch pedal switch C255 pin
2, circuit 32 (RD/LB) and ground while holding the key in the
START position.
z Is the voltage greater than 10 volts? Yes
GO to
B6 .
No
GO to B7 .
B6 CHECK CIRCUIT 33 (WH/PK)/32 (RD/LB) FOR OPEN
z
Key in OFF position.
z Measure the resistance between the clutch pedal switch C255
pin 1, circuit 33 (WH/PK)/32 (RD/LB) and the starter motor relay
pin 86, circuit 33 (WH/PK)/32 (RD/LB).
z Is the resistance less than 5 ohms? Yes
INSTALL a new clutch
pedal switch. TEST the
system for normal
operation.
No
REPAIR circuit 33
(WH/PK)/32 (RD/LB).
TEST the system for
normal operation.
B7 CHECK FOR VOLTAGE AT FUSE 6
z
Key in OFF position.
z Disconnect: Fuse #6.
z Key in START position. Yes
REPAIR circuit 32
(RD/LB). TEST the Klj . 5 ba
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