AC system FORD MUSTANG 2003 Workshop Manual

DIAGNOSIS AND TESTING
Glass, Frames and Mechanisms
Refer to Wiring Diagrams Cell
100 , Power Windows for schematic and connector information.
Refer to Wiring Diagrams Cell 56 , Rear Window Defrost for schematic and connector information.
Principles of Operation
Power Window Control
NOTE: Battery power and ground must be removed before disconnecting the GEM connectors to
avoid setting false DTCs.
The driver power window one- touch down operation is controlled by the generic electronic module
(GEM). This feature functions only when the ignition switch is in the RUN or ACCY positions. The GEM
determines ignition switch position by monitoring the key- in ignition, RUN/ACCY and RUN/START
circuits. The one-touch down operation is requested of the GEM by momentarily pressing the driver
window regulator control switch DOWN for 62 ms to 320 ms. The GEM uses the initial voltage input
from the down switch to begin the one- touch down operation. If the voltage input was less than 320
ms, the GEM will maintain the voltage supply to the motor down circuit. The GEM will maintain the
operation until:
zseven seconds expires.
z motor stall is detected by monitoring the current draw.
z a voltage input is received by the GEM on either the up or down switch circuits.
The ground for one- touch down operation does not pass through the GEM. The ground is supplied
through the driver window regulator control switch as with normal operation. If the GEM continues to
see voltage on the down circuit for more than 320 ms after initial activation the GEM will not effect
operation. The down circuit through the GEM is a direct connection to the motor in its normal state.
This allows the driver window regulator control switch to control the motor for normal operation.
The passenger window motors are hardwired directly to the window regulator control switches. SECTION 501-
11: Glass, Frames and Mechanisms 2003 Mustang Workshop Manual Special Tool(s)
Worldwide Diagnostic System
(WDS)
418-
F224,
New Generation STAR (NGS)
Tester
418- F052, or equivalent
diagnostic tool 73III Automotive Meter
105-
R0057 or equivalent Klj . 1 ba
322003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_5108/S3B~us~en~ ...

Inspection and Verification
1. Verify the customer concern by operating the system.
2. Visually inspect for obvious signs of mechanical or electrical damage.
3. If an obvious cause for an observed or reported concern is found, correct the cause (if possible) before proceeding to the next step.
4. If the diagnostic tool does not communicate with the vehicle, refer to the diagnostic tool manual.
5. Carry out the DATA LINK DIAGNOSTIC TEST. If the diagnostic tool responds with: zCKT 914, CKT 915 or CKT70 - ALL ECUS NO RESP/NOT EQUIP, refer to Section 418 -
00 .
z NO RESP/NOT EQUIP for the generic electronic module (GEM), go to Pinpoint Test A.
z NO RESP/NOT EQUIP for the instrument cluster module (ICM), refer to Section 413 - 01 .
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 or ICM.
6. If the GEM or ICM DTCs retrieved are related to the concern, go to the GEM or ICM Diagnostic Trouble Code (DTC) Index.
7. If no DTCs related to the concern are retrieved, proceed to the Symptom Chart to continue diagnostics.
GEM DIAGNOSTIC TROUBLE CODE (DTC) INDEX Visual Inspection Chart Mechanical Electrical
z
Power window
regulator
z Window run
weatherstrip
z Door window glass z
Central junction box (CJB) circuit breaker 43 (20A), fuse 39
(5A) or 23 (15A)
z Battery junction box (BJB) fuse HTD BL (40A)
z Generic electronic module (GEM)
z Window regulator control switch
z Window regulator motor
z Instrument cluster module (ICM)
z Heated rear window relay
z Rear window defrost switch
z Heated rear window grid
z Circuitry DTC Description Source Action
B1217 Horn Relay Output Driver
Circuit Failure GEM GO to
Section 501 - 14B .
B1218 Horn Relay Output Driver
Short to Battery GEM GO to
Section 501 - 14B .
B1312 Lamp Headlamp Input Circuit GEM GO to
Section 413 - 09 . Klj . 2 ba
322003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_5108/S3B~us~en~ ...

Pinpoint Tests
PINPOINT TEST A: NO COMMUNICATION WITH THE GENERIC
ELECTRONIC MODULE (GEM) inoperative —
rear,
convertible only z
Window regulator
motor.
z Driver window
regulator control
switch. Test G .
z The defrost system is
inoperative z
BJB fuse HTD BL
(30A).
z CJB fuse 23 (15A).
z Circuitry.
z Instrument cluster
module (ICM).
z Rear window
defrost switch.
z Heated rear
window grid. z
GO to Pinpoint Test H .
z The defrost system will not
shut off automatically z
Circuit.
z ICM.
z Rear window
defrost switch. z
GO to Pinpoint Test I .
Test Step Result / Action to Take
CAUTION: Use the correct probe adapter(s) when making measurements. Failure to
use the correct probe adapter(s) may damage the connector. A1 CHECK THE GENERIC ELECTRONIC MODULE (GEM)
POWER SUPPLY z
Key in OFF position.
z Disconnect: Generic Electronic Module (GEM) C201a.
z Disconnect: GEM C201b.
z Key in ON position.
z Using the following table, measure the voltage between the
GEM, harness side and ground.
z Are the voltages greater than 10 volts? Connector Pin Circuit
C201a 4 400 (LB/BK)
C201a 1 1006 (DG/WH)
C201b 2 1001 (WH/YE)
C201b 3 193 (YE/LG) Yes
GO to
A2 .
No
REPAIR the circuit(s) in
question. TEST the system
for normal operation. A2 CHECK THE GEM GROUND CIRCUIT 397 (BK/WH) FOR
OPEN z
Key in OFF position.
z Measure the resistance between the GEM C201b pin 4,
circuit 397 (BK/WH), harness side and ground. Yes
GO to
A3 .
No Klj . 6 ba
322003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_5108/S3B~us~en~ ...

PINPOINT TEST B: ALL POWER WINDOWS ARE INOPERATIVE —
CONVERTIBLE z
Is the resistance less than 5 ohms? REPAIR the circuit(s) in
question. TEST the system
for normal operation.
A3 CHECK CIRCUIT 397 (BK/WH) FOR SHORT TO POWER
z
Measure the voltage between the GEM C201b pin 4, circuit
397 (BK/WH), harness side and ground.
z Is any voltage present? Yes
REPAIR the circuit. TEST
the system for normal
operation.
No
REFER to
Section 418 - 00 .
Test Step Result / Action to Take
B1 CHECK THE POWER SUPPLY TO THE WINDOW
REGULATOR CONTROL SWITCH z
Key in OFF position.
z Disconnect: Driver Window Regulator Control Switch
C537.
z Key in ON position.
z Measure the voltage between driver window regulator
control switch C537 pin 15, circuit 400 (LB/BK), harness
side and ground.
z Is the voltage greater than 10 volts? Yes
GO to
B2 .
No
REPAIR the circuit. TEST the
system for normal operation. B2 CHECK CIRCUIT 1205 (BK) FOR AN OPEN
z
Measure the resistance between driver window regulator Yes Klj . 7 ba
322003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_5108/S3B~us~en~ ...

PINPOINT TEST C: ALL POWER WINDOWS ARE INOPERATIVE —
COUPE control switch C537 pin 14, circuit 1205 (BK), harness
side and ground.
z Is the resistance less than 5 ohms? INSTALL a new driver window
regulator control switch.
REFER to
Switch — Window
Regulator Control in this
section. TEST the system for
normal operation.
No
REPAIR the circuit. TEST the
system for normal operation. Test Step Result / Action to Take
C1 CHECK THE POWER SUPPLY TO THE WINDOW
REGULATOR CONTROL SWITCH z
Key in OFF position.
z Disconnect: Driver Window Regulator Control Switch
C508.
z Key in ON position.
z Measure the voltage between driver window regulator
control switch C508 pin 10, circuit 400 (LB/BK), harness
side and ground.
z Is the voltage greater than 10 volts? Yes
GO to
C2 .
No
REPAIR the circuit. TEST the
system for normal operation. C2 CHECK CIRCUIT 1205 (BK) FOR AN OPEN
z
Measure the resistance between driver window regulator
control switch C508 pin 14, circuit 1205 (BK), harness
side and ground. Yes
INSTALL a new driver window
regulator control switch.
REFER to
Switch — Window
Regulator Control in this
section. TEST the system for
normal operation.
No
REPAIR the circuit. TEST the
system for normal operation. Klj . 8 ba
322003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_5108/S3B~us~en~ ...

PINPOINT TEST D: A SINGLE POWER WINDOW IS INOPERATIVE —
DRIVER, CONVERTIBLE z
Is the resistance less than 5 ohms? Test Step Result / Action to Take
D1 CHECK THE IGNITION SWITCH INPUT TO THE GEM
z
Select GEM PID IGN_A, IGN_R, IGN_S and IGN_KEY.
z Insert the ignition key in the ignition switch and turn to each
position while monitoring PIDs.
z Did the PID values agree with the ignition switch
positions? Yes
GO to
D2 .
No
REFER to Section 211 - 05
for ignition switch
diagnosis.
D2 CHECK THE DRIVER WINDOW REGULATOR CONTROL
SWITCH INPUT TO THE GEM z
Key in ON position.
z Enter the following diagnostic mode on the diagnostic tool:
GEM PID D_UP_SW and D_DN_SW.
z Actuate the driver window regulator control switch to the UP
and DOWN position.
z Did the PID values agree with the driver window regulator
control switch positions? Yes
GO to
D9 .
No
GO to D3 .
D3 CHECK THE POWER SUPPLY TO THE WINDOW
REGULATOR CONTROL SWITCH z
Disconnect: Driver Window Regulator Control Switch C537.
z Key in ON position.
z Measure the voltage between driver window regulator control
switch C537 pin 15, circuit 400 (LB/BK), harness side and
ground.
z Is the voltage greater than 10 volts? Yes
GO to
D4 .
No
GO to D8 .
D4 CHECK CIRCUIT 1205 (BK) FOR AN OPEN
z
Measure the resistance between driver window regulator
control switch C537 pin 14, circuit 1205 (BK), harness side
and ground. Yes
GO to
D5 .
No
REPAIR the circuit. TEST
the system for normal
operation. Klj . 9 ba
322003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_5108/S3B~us~en~ ...

z
Is the resistance less than 5 ohms? D5 CHECK THE DRIVER WINDOW REGULATOR CONTROL
SWITCH z
Carry out the driver window regulator control switch
component test. Refer to the Wiring Diagrams Cell 149,
Component Testing.
z Did the driver window regulator control switch pass? Yes
GO to
D6 .
No
INSTALL a new driver
window regulator control
switch. REFER to
Switch — Window
Regulator Control in this
section. TEST the system
for normal operation. D6 CHECK CIRCUIT 226 (WH/BK) FOR A SHORT TO BATTERY
z
Key in OFF position.
z Disconnect: GEM C201a.
z Measure the voltage between GEM C201a pin 2, circuit 226
(WH/BK), harness side and ground.
z Key in ON position.
z Measure the voltage between GEM C201a pin 2, circuit 226
(WH/BK), harness side and ground.
z Is either voltage greater than 10 volts? Yes
REPAIR the circuit. TEST
the system for normal
operation.
No
GO to
D7 .
D7 CHECK CIRCUIT 991 (TN/LB) AND 992 (WH/BK) FOR AN
OPEN Klj . 10 ba
322003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_5108/S3B~us~en~ ...

z
Key in OFF position.
z Disconnect: GEM C201c.
z Measure the resistance between driver window regulator
control switch C537 pin 8, circuit 991 (TN/LB), harness side
and GEM C201a pin 3, circuit 991 (TN/LB), harness side.
z Measure the resistance between driver window regulator
control switch C537 pin 6, circuit 992 (WH/BK), harness side
and GEM C201c pin 14, circuit 992 (WH/BK), harness side.
z Are the resistances less than 5 ohms? Yes
INSTALL a new GEM.
REFER to
Section 419 -
10 . TEST the system for
normal operation.
No
REPAIR the circuit. TEST
the system for normal
operation. D8 CHECK CIRCUIT 400 (LB/BK) FOR AN OPEN
z
Key in OFF position.
z Disconnect: CJB Circuit Breaker 43 (20A).
z Measure the resistance between driver window regulator
control switch C537 pin 15, circuit 400 (LB/BK), harness side
and CJB circuit breaker 43 (20A) output pin, circuit 400
(LB/BK). Yes
REPAIR the power supply
to CJB circuit breaker 43
(20A). TEST the system
for normal operation.
No
REPAIR the circuit. TEST
the system for normal
operation. Klj . 11 ba
322003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_5108/S3B~us~en~ ...

z
Is the resistance less than 5 ohms? D9 CHECK THE GEM CONTROL OF THE DRIVER POWER
WINDOW z
Key in ON position.
z Enter the following diagnostic mode on the diagnostic tool:
GEM Active Command FRONT WINDOW CONTROL.
z Trigger DR DOWN ON.
z Did the driver window move down? Yes
INSTALL a new GEM.
REFER to
Section 419 -
10 . TEST the system for
normal operation.
No
GO to D10 .
D10 CHECK THE WINDOW REGULATOR MOTOR OPERATION
z
Disconnect: Driver Window Regulator Motor C518.
z Connect a 20 amp fused jumper wire between battery positive
and one pin of the window regulator motor (component side).
z Momentarily connect a jumper wire between second pin of the
window regulator motor and ground.
z Reverse the jumper wires on the window regulator motor.
z Did the window regulator motor operate in both
directions? Yes
GO to
D11 .
No
INSTALL a new window
regulator motor. REFER
to Motor — Window
Regulator in this section.
TEST the system for
normal operation. D11 CHECK CIRCUIT 992 (WH/BK) FOR AN OPEN BETWEEN
THE DRIVER WINDOW MOTOR AND THE WINDOW
REGULATOR CONTROL SWITCH z
Disconnect: Driver Window Regulator Control Switch C537.
z Measure the resistance between driver window regulator
control switch C537 pin 6, circuit 992 (WH/BK), harness side
and driver window regulator motor C518, circuit 992 (WH/BK),
harness side. Yes
GO to
D12 .
No
REPAIR the circuit. TEST
the system for normal
operation. Klj . 12 ba
322003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_5108/S3B~us~en~ ...

PINPOINT TEST E: A SINGLE POWER WINDOW IS INOPERATIVE —
DRIVER, COUPE z
Is the resistance less than 5 ohms? D12 CHECK CIRCUIT 226 (WH/BK) FOR AN OPEN
z
Disconnect: GEM C201a.
z Measure the resistance between GEM C201a pin 2, circuit
226 (WH/BK), harness side and driver window regulator motor
C518, circuit 226 (WH/BK), harness side.
z Is the resistance less than 5 ohms? Yes
GO to
D13 .
No
REPAIR the circuit. TEST
the system for normal
operation. D13 CHECK CIRCUIT 400 (LB/BK) FOR AN OPEN TO THE GEM
z
Key in OFF position.
z Disconnect: CJB Circuit Breaker 43 (20A).
z Measure the resistance between GEM C021a pin 4, circuit
400 (LB/BK), harness side and CJB circuit breaker 43 (20A)
output pin, circuit 400 (LB/BK).
z Is the resistance less than 5 ohms? Yes
INSTALL a new GEM.
REFER to
Section 419 -
10 . TEST the system for
normal operation.
No
REPAIR the circuit. TEST
the system for normal
operation. Test Step Result / Action to Take
E1 CHECK THE IGNITION SWITCH INPUT TO THE GEM
z
Select GEM PID IGN_A, IGN_R, IGN_S and IGN_KEY.
z Insert the ignition key in the ignition switch and turn to each Yes
GO to
E2 . Klj . 13 ba
322003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_5108/S3B~us~en~ ...