instrument panel FORD MUSTANG 2003 Manual PDF

REMOVAL AND INSTALLATION
Instrument Panel —
Center Finish Panel
Removal and Installation
All vehicles 1. Disconnect the battery ground cable. For additional information, refer to Section 414 - 01 .
Vehicles with automatic transmission 2. Place the selector lever in the 1 position.
Vehicles with manual transmission
3. Remove the gearshift lever handle.
All vehicles
4. Remove the floor console finish panel. zDisconnect the electrical connector.
5. Remove the instrument panel center finish panel. zDisconnect the electrical connector.
6. To install, reverse the removal procedure.
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REMOVAL AND INSTALLATION
Floor Console
Removal and Installation
All vehicles
1. Disconnect the battery ground cable. For additional information, refer to Section 414 - 01 .
2. Apply the parking brake.
Vehicles with automatic transmission 3. Place the selector lever in the 1 position.
Vehicles with manual transmission 4. Remove the gearshift lever handle.
All vehicles 5. Remove the floor console finish panel. zDisconnect the electrical connector.
6. Open the floor console glove compartment door.
7. Remove the floor console screws.
8. Disconnect the floor console electrical connector.
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4. If the concern remains after the inspection, connect the scan tool to the data link connector
(DLC) located beneath the instrument panel and select the vehicle to be tested from the scan
tool menu. If the scan tool does not communicate with the vehicle:
zcheck that the program card is correctly installed.
z check the connections to the vehicle.
z check the ignition switch position.
5. If the scan tool still does not communicate with the vehicle, refer to the scan tool manual.
6. Carry out the DATA LINK DIAGNOSTIC TEST. If the scan tool responds with: zCKT914, CKT915 or CKT70 = ALL ECUS NO RESP/NOT EQUIP, refer to Section 418 -
00 .
z NO RESP/NOT EQUIP for GEM, go to Pinpoint Test A.
z SYSTEM PASSED, retrieve and record the continuous diagnostic trouble codes (DTCs),
erase the continuous DTCs, and carry out the self- test diagnostics for the GEM.
7. If the DTCs retrieved are related to the concern, go to the GEM Diagnostic Trouble Code (DTC) Index to continue diagnostics.
8. If no DTCs related to the concern are retrieved, proceed to Symptom Chart to continue diagnostics.
GEM Diagnostic Trouble Code (DTC) Index Mechanical Electrical
z
Binding latches z
CJB Fuses:
„39 (5A)
„ 19 (15A)
„ 25 (25A)
z BJB Fuse POWER WINDOWS (40A)
z Damaged wiring harness
z Loose or corroded connector(s)
z Circuitry open/shorted
z Damaged relays
z Remote transmitter
z Remote transmitter batteries DTC Description Source Action
B1217 Horn Relay Coil Circuit Failure GEM GO to
Pinpoint Test E .
B1218 Horn Relay Coil Circuit Short to
Vbatt GEM GO to
Pinpoint Test E .
B1312 Lamp Headlamp Input Circuit
Short to Battery GEM REFER to
Section 417 - 01 .
B1317 Battery Voltage High GEM REFER to
Section 414 - 00 .
B1318 Battery Voltage Low GEM REFER to
Section 414 - 00 .
B1322 Driver Door Ajar Circuit Short to
Ground GEM REFER to
Section 417 - 02 .
B1330 Passenger Door Ajar Circuit
Short to Ground GEM REFER to
Section 417 - 02 .
B1334 Decklid Ajar Rear Door Circuit GEM REFER to
Section 417 - 02 . Klj . 3 ba
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Washers
When the GEM detects the ignition switch circuits are in RUN or ACC states, and the GEM detects a
WASH request from the wiper delay/wash circuits, the GEM will activate the washer pump relay circuit
for as long as the request is present up to 10 seconds.
Activation of the washer pump when in INTERVAL or OFF is delayed until a wash request is active for
a minimum amount of time. In this scenario, the wash request must be present continuously for at least
210 ms. This allows a wash request that is present for less than 210 ms, to provide additional
functionality by initiating a single wipe, called "mist wipe". The mist wipe function is a single wipe at low
speed without activating the washer motor.
When in LOW or HIGH, any WASH request, regardless of the length of time it is present, will activate
the washer pump. When in INTERVAL or OFF mode, upon deactivation of the washer motor, this
feature shall provide two wipes at low speed before returning to the INTERVAL or OFF state as
defined by the inputs. These additional wipes are provided to clear residual washer fluid from the front
windshield.
Inspection and Verification
1. Verify the customer concern by operating the wiper/washer system.
2. Visually inspect for obvious signs of mechanical and electrical damage.
3. If the concern remains after the inspection, connect the diagnostic tool to the data link connector (DLC) located beneath the instrument panel and select the vehicle to be tested from the
diagnostic tool menu. If diagnostic tool does not communicate with the vehicle:
zCheck that the program card is correctly installed.
z Check the connections to the vehicle.
z Check the ignition switch position.
4. If diagnostic tool still does not communicate with the vehicle, refer to the diagnostic tool manual.
5. Carry out the DATA LINK DIAGNOSTIC TEST. If diagnostic tool responds with: zCKT914, CKT915 or CKT70 = ALL ECUS NO RESP/NOT EQUIP, refer to Section 418 -
00 .
z NO RESPONSE/NOT EQUIPPED for GEM, go to Pinpoint Test A.
z SYSTEM PASSED, retrieve and record the continuous diagnostic trouble codes (DTCs),
erase the continuous DTCs and carry out self- test diagnostics for the GEM.
Visual Inspection Chart Mechanical Electrical
z
Hoses to windshield washer pump
z Wiper linkage z
CJB Fuse 39 (5A)
z CJB Fuse 26 (30A)
z Wiring harness
z Loose or corroded connector(s)
z Relays
z Motors
z Multifunction switch
z GEM Klj . 2 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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current and historical DTCs through the DLC, using a scan tool. If the air bag indicator does not
function, and the system detects a fault condition, the RCM will signal the GEM to activate an audible
chime. The chime is a series of five sets of five tone bursts. If the chime is heard, the SRS and the air
bag indicator require repair.
LFCs are prioritized. If two or more faults occur at the same time, the fault having the highest priority
will be displayed. After that fault has been corrected, the next highest priority fault will be displayed.
The RCM includes a backup power supply. This feature provides sufficient backup power to deploy the
air bags in the event that the ignition circuit is damaged in a collision before the safing and air bag
sensors determine that deployment is required. The backup power supply will deplete its stored energy
approximately one minute after the battery ground cable is disconnected.
Electrical System
The electrical system that supports the air bag supplemental restraint system (SRS):
zis powered from the battery through the ignition circuit.
z provides the electrical path from the restraints control module (RCM) to the air bag modules.
z provides the electrical path from the RCM to the air bag indicator.
z provides the electrical path from the RCM to the data link connector (DLC).
z provides the electrical path from the RCM to the generic electronic module (GEM).
Sensor WARNING: The restraints control module (RCM) orientation is critical for proper system
operation. If a vehicle equipped with an air bag supplemental restraint system (SRS) has been
involved in a collision in which the center tunnel area has been damaged, inspect the mounting
and bracket for deformation. If damaged, the RCM must be replaced whether or not the air bags
have deployed. In addition, make sure the area of the RCM mounting is restored to its original
condition.
The SRS contains two sensors which are integral to the RCM. The RCM is mounted on the center
tunnel under the instrument panel. Klj . 3 ba
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Most air bag supplemental restraint system (SRS) diagnostic procedures will require the use of the
deactivation and reactivation procedures in this section.
The deactivation and reactivation require the installation and removal of restraint system diagnostic
tools. These procedures require removal of driver air bag module, and the disconnection of the
passenger air bag module. This reduces the risk of deployment of air bag modules and safety belt
pretensioners while diagnostics are being carried out.
Restraint system diagnostic tools are required to carry out diagnosis and testing of the supplemental
restraint system (SRS). It is not acceptable to short-circuit the air bag module connections with a
jumper wire. If a jumper wire is used to short- circuit the air bag module connections, a lamp fault code
(LFC) will be displayed.
WARNING: The restraint system diagnostic tool is for restraint system service only.
Remove from vehicle prior to road use. Failure to remove could result in injury and possible
violation of vehicle safety standards.
The reactivation procedure requires the removal of any restraint system diagnostic tools installed and
the reconnection of any air bag modules disconnected.
Deactivation Procedure
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.
1. WARNING: To avoid accidental deployment and possible personal injury, the
backup power supply must be depleted before repairing or replacing any front or side air
bag supplemental restraint system (SRS) components and before servicing, replacing,
adjusting or striking components near the front or side air bag sensors, such as doors,
instrument panel, console, door latches, strikers, seats and hood latches.
Please refer to the appropriate vehicle shop manual to determine location of the front air
bag sensors.
The side air bag sensors are located at or near the base of the B- pillar. Klj . 2 ba
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GENERAL PROCEDURES
Inspection and Repair After a Supplemental Restraint
System (SRS) Deployment
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 a 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.
1. When any deployable device (driver air bag, passenger air bag, seat side air bag, safety belt pretensioner, etc.) or combination of devices are deployed and/or the RCM has the DTC B1231
(Crash Data Memory Full) in memory, the repair of the vehicle's supplemental restraint system
(SRS) is to include the removal of all deployed devices and installation of new deployable
devices, the removal and installation of new impact sensors, and the removal and installation of
a new RCM.
2. When any damage to the impact sensor mounting points or mounting hardware has occurred, repair or install new mounting points and mounting hardware as needed.
3. When the driver air bag module has deployed a new clockspring must be installed.
4. Inspect the entire vehicle for damage, including the following components: zsteering column.
z instrument panel knee bolsters and mounting points.
z instrument panel braces and brackets.
z instrument panel and mounting points.
z seats and seat mounting points.
z safety belts, safety belt buckles, and safety belt retractors. For additional information,
refer to Section 501 - 20A .
z supplemental restraint system (SRS) wiring, wiring harnesses, and connectors.
5. After carrying out the review and inspection of the entire vehicle for damage, repair or install new components as needed.
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NOTE:
If a seat equipped with a seat mounted side air bag and/or a safety belt pretensioner (if
equipped) system is being serviced, the air bag system must be deactivated.
NOTE: Restraint system diagnostic tools MUST be installed under the seats in the seat side air bag (if
equipped) and safety belt pretensioner (if equipped) to floor connectors.
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.
1. WARNING: To avoid accidental deployment and possible personal injury, the
backup power supply must be depleted before repairing or replacing any front or side air
bag supplemental restraint system (SRS) components and before servicing, replacing,
adjusting or striking components near the front or side air bag sensors, such as doors,
instrument panel, console, door latches, strikers, seats and hood latches.
Please refer to the appropriate vehicle shop manual to determine location of the front air
bag sensors.
The side air bag sensors are located at or near the base of the B- pillar.
To deplete the backup power supply energy, disconnect the battery ground cable and
wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if
equipped).
Disconnect the battery ground cable and wait at least one minute. For additional information,
refer to Section 414 - 01 .
2. Remove the steering column opening lower finish panel. 1. Remove the screws.
2. Pull out to release the retaining clips and remove the steering column opening lower finish panel.
3. Remove the steering column opening lower reinforcement. 1. Remove the bolts.
2. Remove the steering column opening lower reinforcement. Klj . 2 ba
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GENERAL PROCEDURES
Weld Nut Repair
—"J" Nut, Restraints Control Module
(RCM)
WARNING: To avoid accidental deployment and possible personal injury, the backup
power supply must be depleted before repairing or replacing any front or side air bag
supplemental restraint system (SRS) components and before servicing, replacing, adjusting or
striking components near the front or side air bag sensors, such as doors, instrument panel,
console, door latches, strikers, seats and hood latches.
Please refer to the appropriate vehicle shop manual to determine location of the front air bag
sensors.
The side air bag sensors are located at or near the base of the B- pillar.
To deplete the backup power supply energy, disconnect the battery ground cable and wait at
least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped).
NOTE: There are two procedures to repair a vehicle having missing restraints control module attaching
weld nut(s). Read both procedures before proceeding with the repair.
NOTE: If two or more weld nuts are missing, do not install the "J" nuts as outlined in this procedure.
Weld nuts must be installed as outlined in Weld Nut Repair — Missing Weld Nut, Restraints Control
Module (RCM).
NOTE: The following procedure applies to vehicles that have a rectangular hole in the sheet metal that
is in close proximity to the missing weld nut.
1. Obtain a "J" nut (part number N623332- S301) or any of the following optional "J" nuts (part
numbers: N623342- S101, N800854-S100, N800925- S100).
2. Obtain a 6 mm (0.24 in) grounding screw (part number N806327- S190) or equivalent.
3. Install the "J" nut through the rectangular hole in the sheet metal.
4. NOTE: Be sure the threaded portion of the "J" nut is aligned with the clearance hole in the sheet
metal.
Install the crash sensor.
5. Tighten the attaching screws to specification. For additional information, refer to Torque Specifications in this section.
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