engine FORD MUSTANG 2003 Workshop Manual

DESCRIPTION AND OPERATION
Identification Codes
Vehicle Identification Number (VIN) Locator
The vehicle identification number (VIN) is a seventeen-
digit alphanumeric code. The VIN is stamped
on a metal tab riveted to the instrument panel, top upper left of the dash. The VIN number is also found
on the vehicle certification (VC) label. SECTION 100-
01: Identification Codes 2003 Mustang Workshop Manual Item Description
1 World manufacturer identifier (WMI)
2 Restraint type code
3 Line, series, body type (passenger car)
4 Engine code Klj . 1 ba
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Positions 5 through 7 indicate vehicle line, series and body type.
zP40 — Two-door coupe
z P42 — Two-door coupe, GT (Mach One available in GT Coupe only)
z P44 — Two-door convertible
z P45 — Two-door convertible, GT
z P48 — Two-door coupe, Cobra
z P49 — Two-door convertible, Cobra
Engine Code
The eighth VIN position is the engine displacement and number of cylinders code.
z4 — 3.8L, OHV, EFI, six cylinder
z R — 4.6L, DOHC, EFI, eight cylinder (Mach One)
z X — 4.6L, SOHC, EFI, eight cylinder
z Y— 4.6L, DOHC, S/C, EFI, eight cylinder (Cobra) Computer Generated Check Digit Klj . 3 ba
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NOTE:
Powertrain calibration information is limited to a maximum of five characters per line on the
Vehicle Certification Label. Because of this, calibration identification consisting of more than five
characters will wrap to the second line on the VC label.
Powertrain calibration information is printed in the lower right corner of the Vehicle Certification Label.
Only the base calibration information is printed. Revision levels will not appear, however, this
information can be found in the On Line Automotive Service Information System (OASIS). For the
current model year, Ford Motor Company is using three different protocols which describe powertrain
base calibration. These protocols are designed to provide worldwide standardization for vehicle
calibration. If the electronic calibration strategy has been used since 1998 and carried into the current
model year, protocol 1 will be used. Refer to Protocol 1 below. If the electronic calibration strategy has
been used since 1999 and is carried into the current model year, protocol 2 will be used. Refer to
Protocol 2 below. For new electronic calibration strategies introduced since the 2000 model year, use
protocol 3. Refer to Protocol 3 below.
Protocol 1
Protocol 2 Item Description
1 Model year (model year in which calibration strategy was first introduced)
2 Engine code
3 Engine revision level
Item Description
1 Model year (model year in which calibration strategy was first introduced)
2 Engine code
3 Transmission code
4 Emission standard (designates the specific country emission standard) Klj . 13 ba
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Protocol 3
Protocol 3
The following offers a more detailed explanation of the coding strategy used for protocol 3.
Model Year
z Y — 2000
z 1 — 2001
z 2 — 2002
z 3 — 2003
Vehicle Line
z ZE — Mustang
Transmission
z 1 — Automatic transmission
z 2 — Manual transmission
Unique Calibration
The Emissions/CAFE/CO2 Compliance Department is responsible for assigning these calibration
numbers. Unique calibration identifications are assigned to cover similar vehicles to differentiate tires,
drive configurations, final drive ratios and other calibration- significant factors. 5 Design level (design level assigned to the engine)
Item Description
1 Model year (model year in which calibration strategy was first introduced)
2 Vehicle code
3 Transmission code
4 Unique calibration (designates different hardware to similar vehicles). Example: tires, drive
ratios, etc.
5 Fleet code (describes fleet to which the vehicle belongs). Example: 6 -
evaporative emissions 6 Certification region (lead region where multiple regions are included in one calibration).
Example: A - U.S. federal
7 Revision level (will advance as revisions occur). Not printed on label Klj . 14 ba
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These two characters are chosen by the analyst to provide easily identifiable information unique to
each calibration. For example, using the number 2 to denote a two-
valve engine versus using the
number 4 to denote a four- valve engine.
Fleet Code
z 1 — HDGE/Dyno
z 2 — Fast AMA, U.S.
z 3 — ADP, U.S.
z 4 — Not assigned
z 5 — Not assigned
z 6 — Evaporative emissions
z 7 — MACAA
z 8 — On-board diagnostics (OBD)
z 9 — Not assigned
Certification Region
z 5 — U.S. fifty states
z A — U.S. federal, including altitude, may include Canada and/or Mexico
z B — U.S. California standard, includes U.S. green states
z C — Canada
z D — China
z E — European Community (Austria, Belgium, Denmark, Finland, France, Germany, Greece,
Ireland, Italy, Luxembourg, Netherlands, Portugal, Spain, Sweden and United Kingdom)
z F — Extended European Community (E plus Croatia, Czech Republic, Estonia, Hungary,
Norway, Poland, Romania, Russian Federation, Slovakia, Slovenia, Switzerland and
Yugoslavia)
z G — Gulf Cooperative Council (Bahrain, Kuwait, Oman, Qatar, Saudi Arabia and UAE)
z H — Hong Kong
z J — Japan
z K — Korea
z L — Malaysia
z M — Mexico
z N — New Zealand
z P — Australia
z Q — South America (Brazil)
z S — Singapore
z T — Taiwan
z U — South America (unleaded fuel regions)
z V — Vietnam
z X — Rest of world (ROW)
z Y — Military
z Z — Israel Revision Level (not printed on label) Klj . 15 ba
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DESCRIPTION AND OPERATION
Jacking
WARNING: Never run the engine with one wheel off the ground, such as when changing a
tire. The wheel still on the ground could cause the vehicle to move.
CAUTION: The jack (17080) provided with the vehicle is intended to be used in an
emergency for changing a deflated tire. To avoid damage to the vehicle, never use the jack to
lift the vehicle for any other purpose. Refer to the Owner Guide when using the jack supplied
with the vehicle.
CAUTION: Under no circumstances should the vehicle ever be lifted by the suspension
arm brackets, rear stabilizer or differential housing or convertible cross brace. Severe damage
to the vehicle could result.
CAUTION: Do not attempt to use jack pressure on either the front bumper (17757) or the
rear bumper (17906) of any vehicle. Damage to the bumper covers will occur.
Lift the vehicle using the Jacking Points procedure in this section.
Jacking Points
To lift the front or either side of the front end, position the floor jack under the front frame lift points. SECTION 100-
02: Jacking and Lifting 2003 Mustang Workshop Manual Klj . 1 ba
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DESCRIPTION AND OPERATION
Maintenance Schedule —
Vehicles with Gasoline Engines
The maintenance schedule is designed to protect against major repairs resulting from neglect or
inadequate maintenance and to prolong the life of the vehicle.
General Maintenance Information
NOTE: This is a generic maintenance schedule for all Ford, Lincoln and Mercury vehicles. There may
be items listed that do not apply to all vehicles.
The Normal Schedule applies to operation of the vehicle under typical, everyday driving conditions.
The maintenance frequency in this schedule typifies what the vast majority of vehicles will require. The
listed services should be carried out at specified mileage intervals. There are, however, additional
services required that only the noted vehicles require.
If the vehicle is operated in one or more of the following special operating conditions, those additional
services will be required. The special operating conditions are:
ztowing or carrying heavy loads.
z extensive idling and/or driving at low speeds for long distances.
z driving in dusty conditions.
z off- road operation.
There are also exceptions to the Normal Operating Schedule which will require more frequent
maintenance for some components. Those exceptions are:
znatural gas and propane vehicles — fuel tank intervals.
z normal vehicle axle — maintenance and lubrication.
z police and taxi vehicles — maintenance and lubrication.
z engine oil and yellow coolant — time and mileage-based interval.
Special Operating Condition Requirements
When towing a trailer or using a camper or car- top carrier:
z Change engine oil and install a new oil filter every 4,800 km (3,000 miles) or 3 months.
z Change transfer case fluid every 96,000 km (60,000 miles).
z Change manual transmission fluid as required.
z Inspect and lubricate U- joints as required.
During extensive idling and/or low speed driving for long distances, as in heavy commercial use such
as delivery, taxi, patrol car or livery: SECTION 100-
03: Maintenance Schedule 2003 Mustang Workshop Manual Klj . 1 ba
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z
Change engine oil and install a new oil filter, lube front lower control arm and steering linkage
ball joints with zerk fittings (if equipped) every 4,800 km (3,000 miles) or 3 months.
z Inspect brake system and check battery electrolyte level (Patrol cars) every 8,000 km (5,000
miles).
z Install a new fuel filter every 24,000 km (15,000 miles).
z Change automatic transmission fluid, lubricate 4x2 wheel bearings, install new grease seals and
adjust bearings every 48,000 km (30,000 miles).
z Install new spark plugs and change transfer case fluid every 96,000 km (60,000 miles).
z Install a new cabin air filter as required.
When operating in dusty conditions such as unpaved or dusty roads:
zChange engine oil and install a new oil filter every 4,800 km (3,000 miles) or 3 months.
z Install a new fuel filter every 24,000 km (15,000 miles).
z Change automatic transmission fluid every 48,000 km (30,000 miles).
z Change transfer case fluid every 96,000 km (60,000 miles).
z Install a new engine air filter as required.
z Install a new cabin air filter as required.
When operating in off- road conditions:
z Change automatic transmission fluid every 48,000 km (30,000 miles).
z Change transfer case fluid every 96,000 km (60,000 miles).
z Install a new cabin air filter as required.
z Inspect and lubricate U- joints.
z Inspect and lubricate steering linkage ball joints with zerk fittings.
Checks and Services
Certain basic maintenance checks and inspections should be carried out at specified intervals. Any
recognized adverse condition should be corrected as soon as possible.
Maximum Oil Change Interval (Normal Schedule) z8,000 km (5,000 miles) or 6 months, whichever occurs first.
Maximum Oil Change Interval (Special Operating Conditions)
z4,800 km (3,000 miles) or 3 months.
Monthly Checks
Check each of the following items every month:
zAll interior and exterior lights.
z Tires for wear and correct air pressure. Klj . 2 ba
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z
Engine oil fluid level.
z Windshield washer solvent fluid level.
z Check and drain fuel/water separator.
Six Month Checks
Check each of the following items at least every six months:
zLap/shoulder belts and seat latches for wear and function.
z Spare tire air pressure.
z Power steering fluid level.
z Parking brake for correct operation.
z Safety warning lamps (brake, ABS, air bag, safety belt) for correct operation.
z Coolant system fluid level and correct strength.
z Battery connections. Clean if necessary.
z Clutch fluid level, if equipped.
z Windshield washer spray, wiper operation, clean all wiper blades.
z Lubricate all hinges, latches and outside locks. Inspect for correct operation.
z Lubricate door rubber weatherstrips. Inspect for excessive wear.
z Clean body and door drain holes. Inspect for clogs and obstructions.
Special Checks (Mustang Only)
Carry out the following check every 8,000 km (5,000 miles):
zAdjust clutch by lifting pedal (manual transmission Mustang only, as described in owner guide).
Normal Schedule
The following checks or procedures should be carried out for all cars, minivans, light trucks, sport
utilities, vans, 4x4s, natural gas and propane vehicles.
8,000 Km (5,000 Miles) zChange engine oil and install a new oil filter.
z Rotate tires and inspect for wear.
16,000 Km (10,000 Miles)
zChange engine oil and install a new oil filter.
z Inspect tires for wear. Rotation recommended for optimal tire life.
24,000 Km (15,000 Miles)
zChange engine oil and install a new oil filter. Klj . 3 ba
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z
If equipped, inspect automatic transmission fluid level with dipstick.
z Inspect brake pads, shoes, rotors, drums, brake lines, hoses and parking brake system.
z Inspect wheel ends for end play and noise.
z Inspect engine cooling system and hoses.
z Inspect steering linkage, suspension and (if equipped) driveshaft and ball joints.
z Rotate tires and inspect for wear.
z If equipped, install a new cabin air filter.
32,000 Km (20,000 Miles)
zChange engine oil and install a new oil filter.
z Inspect tires for wear. Rotation recommended for optimal tire life.
40,000 Km (25,000 Miles)
zChange engine oil and install a new oil filter.
z Inspect tires for wear. Rotation recommended for optimal tire life.
z Drain coalescent fuel filter and replace filter (NGV).
48,000 Km (30,000 Miles)
zChange engine oil and install a new oil filter.
z Inspect brake pads, shoes, rotors, drums, brake lines, hoses and parking brake system.
z Inspect wheel ends for end play and noise.
z Inspect engine cooling system and hoses.
z Inspect exhaust system and heat shields.
z Inspect steering linkage, suspension and (if equipped) driveshaft and ball joints.
z Rotate tires and inspect for wear.
z Install a new engine air filter.
z Install a new fuel filter. (See ADDITIONAL INFORMATION below.)
z If equipped, install a new cabin air filter.
z Change automatic transmission/transaxle fluid on all vehicles equipped with AX4S, 4F50N,
4R100, 4F27E. Inspect automatic transmission fluid level using dipstick on all other vehicles, if
equipped.
z If equipped, install new climate controlled seat filters (Navigator, Lincoln LS and Aviator).
ADDITIONAL INFORMATION: If vehicle is registered in California, the California Air Resources Board
(CARB) has determined that failure to install a new fuel filter at this interval will not nullify the emission
warranty or limit recall liability prior to completion of the vehicle's useful life. It is, however,
recommended that maintenance checks be carried out and recorded at the indicated intervals.
Natural gas and propane vehicles also require checking the fuel tanks and installing a new filter
(propane vehicles). 56,000 Km (35,000 Miles) Klj . 4 ba
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