2003 FORD MUSTANG heating

z
Did any abnormal occurrence coincide with or proceed its appearance?
Use the information gained from the customer to accurately begin the diagnostic process.
Pre- Drive Check
It is important to do a pre- drive check before road testing the vehicle. A pre- drive check verifies that
the vehicle is relatively safe to drive and eliminates any obvious faults on the vehicle.
The pre- drive check consists of a brief visual inspection. During this brief inspection, take note of
anything that will compromise safety during the road test and make those repairs/adjustments before
taking the vehicle on the road.
Preparing for the Road Test
Observe the following when preparing for the road test:
zReview the information recorded on the NVH Diagnostic Guide. It is important to know the
specific concern the customer has with the vehicle.
z Do not be misled by the reported location of the noise/vibration. The cause can actually be
some distance away.
z Remember that the vibrating source component (originator) may only generate a small
vibration. This small vibration can in turn cause a larger vibration/noise to emanate from another
receiving component (reactor), due to contact with other components (transfer path).
z Conduct the road test on a quiet street where it is safe to duplicate the vibration/noise. The ideal
testing route is an open, low- traffic area where it is possible to operate the vehicle at the speed
in which the condition occurs.
z If possible, lower the radio antenna in order to minimize turbulence. Identify anything that could
potentially make noise or be a source of wind noise. Inspect the vehicle for add- on items that
create vibration/noise. Turn off the radio and the heating and cooling system blower.
z The engine speed is an important factor in arriving at a final conclusion. Therefore, connect an
accurate tachometer to the engine, even if the vehicle has a tachometer. Use a tachometer that
has clearly defined increments of less than 50 rpm. This ensures an exact engine speed
reading.
Verify the Customer Concern
Verify the customer concern by carrying out a road test, an engine run- up test, or both.
The decision to carry out a road test, an engine run- up test, or both depends on the type of NVH
concern. A road test may be necessary if the symptom relates to the suspension system or is sensitive
to torque. A drive engine run- up (DERU) or a neutral engine run- up (NERU) test identifies noises and
vibrations relating to engine and drivetrain rpm. Remember, a condition will not always be identifiable
by carrying out these tests, however, they will eliminate many possibilities if carried out correctly.
Road Test Klj . 5 ba
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port. DISCARD the leaking
parts, and INSTALL a new
component.
z Vehicles with a
plastic intake
manifold. z
Acceptable condition. Some
plastic manifolds exhibit this
noise, which is the effect of
the plastic manifold.
z Automatic
transmission buzz or
hiss z
Incorrect
driveline
angles. z
CHECK for correct driveline
angles. REPAIR as
necessary. REFER to
Section 205 - 00 .
z Worn or
damaged main
control
solenoids or
valves. z
Using a transmission tester,
activate the solenoids to
duplicate sound. INSTALL
new components as
necessary. REFER to
Section 307 - 01 .
z Manual Transmission
Clutch throw- out
bearing whine. A
change in noise pitch
or loudness while
depressing the clutch
pedal z
Worn throw- out
bearing. z
INSTALL a new throw- out
bearing. REFER to Section 308 - 01 .
z Heating, vacuum and
air conditioning
(HVAC) system chirp
— most audible inside
the vehicle. Listen for
a change in noise
pitch or loudness
while changing the
HVAC system blower
speed z
Damaged or
worn HVAC
blower bearing. z
INSTALL a new blower
motor. REFER to Section 412 - 02 .
z Air conditioning (A/C)
clutch ticking —
occurs when the
compressor clutch
engages z
Acceptable
noise.
z Incorrect air
gap. z
LISTEN to the clutch to
determine if the noise occurs
with clutch engagement. A
small amount of noise is
acceptable. If the noise is
excessive, CHECK the A/C
clutch air gap. INSPECT the
A/C clutch for wear or
damage. INSTALL a new
clutch as necessary. REFER
to Section 412 - 03 .
z Intermittent rattle, or
scraping/rubbing
noise z
Loose exhaust
heat shield(s). z
INSPECT the exhaust
system for loose parts using
a glove or clamps to verify
cause. REPAIR as
necessary. REFER to
Section 309 - 00 .
z Wiring, hose or
other part
interfering with
accessory drive
belt or pulley. z
INSPECT accessory drive
system closely verifying
there is adequate clearance
to all rotating components.
REPAIR as necessary.
z Engine ticking or
knocking noise —
occurs during idle or z
Piston noise or
valvetrain noise
(bled down z
Go To Pinpoint Test G . Klj . 30 ba
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Component Tests
Driveline Vibration
An analysis of driveline vibration can also be conducted using the Vibration Analyzer; follow the
manufacturer's directions.
Driveline vibration exhibits a higher frequency and lower amplitude than does high-
speed shake.
Driveline vibration is directly related to the speed of the vehicle and is usually noticed at various speed
ranges. Driveline vibration can be perceived as a tremor in the floorpan or is heard as a rumble, hum,
or boom. Driveline vibration can exist in all drive modes, but may exhibit different symptoms depending
upon whether the vehicle is accelerating, decelerating, floating, or coasting. Check the driveline angles
if the vibration is particularly noticeable during acceleration or deceleration, especially at lower speeds.
Driveline vibration can be duplicated by supporting the axle upon a hoist or upon jack stands, though
the brakes may need to be applied lightly in order to simulate road resistance.
1. Raise the vehicle promptly after road testing. Use a twin- post hoist or jack stands to prevent tire
flat- spotting. Engage the drivetrain and accelerate to the observed road test speed to verify the lubricant type.
205 - 02B . CLEAN and
REFILL the axle to
specification.
z Axle overheating zLubricant level too
low. z
CHECK the lubricant level.
FILL the axle to specification.
z Incorrect or
contaminated
lubricant type. z
INSPECT the axle for
damage. REPAIR as
necessary. CLEAN and
REFILL the axle to
specification.
z Bearing preload
adjusted too tight. z
CHECK the ring and pinion for
damage. INSPECT the ring
and pinion wear pattern.
ADJUST the preload as
necessary.
z Excessive gear
wear. z
INSPECT all the axle gears
for wear or damage. INSTALL
new components as
necessary.
z Incorrect ring gear
backlash. z
INSPECT the ring gear for
scoring. INSPECT the ring
and pinion wear pattern.
ADJUST the ring gear
backlash as necessary.
z Broken gear teeth
on the ring gear
or pinion z
Overloading the
vehicle. z
INSTALL a new ring and
pinion. REFER to Section 205 - 02A or
Section 205 - 02B .
z Axle shaft broken zOverloading the
vehicle. z
INSTALL a new axle shaft.
REFER to Section 205 - 02A or
Section 205 - 02B .
z Misaligned axle
shaft tube. z
INSPECT the axle for
damage. CHECK axle shaft
tube alignment. INSTALL a
new axle shaft. REFER to
Section 205 - 02A or
Section 205 - 02B . Klj . 11 ba
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4. Inspect for normal burning.
zCheck for light tan or gray deposits on the firing tip.
5. Inspect for pre- ignition, identified by melted electrodes and a possibly damaged insulator.
Metallic deposits on the insulator indicate engine damage. This may be caused by incorrect
ignition timing, wrong type of fuel or the unauthorized installation of a heli- coil insert in place of
the spark plug threads.
zInstall a new spark plug.
6. Inspect for overheating, identified by a white or light gray spots and with bluish- burnt
appearance of electrodes. This is caused by engine overheating, wrong type of fuel, loose spark
plugs, spark plugs with an incorrect heat range, low fuel pump pressure or incorrect ignition
timing.
zInstall a new spark plug. Klj . 2 ba
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meeting Ford specification WSS-
M97B44-D. Mixing coolants may degrade the coolant's
corrosion protection.
z Do not add alcohol, methanol, or brine, or any engine coolants mixed with alcohol or methanol
antifreeze. These can cause engine damage from overheating or freezing.
z Do not mix with recycled coolant unless it meets the requirements of Ford specification WSS-
M97B51- A1. Not all coolant recycling processes meet these Ford specifications. Use of such
coolants can harm the engine and cooling system components.
The coolant temperature sensor (4.6L) or cylinder head temperature sensor (3.8L) provides a signal to
the temperature gauge.
The optional block heater:
zelectrical heating element is installed in the core plug opening.
„uses a standard 110V electrical supply
z keeps the engine coolant warm during cold weather. Klj . 3 ba
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To maintain the integrity of the coolant and the cooling system:
zAdd Motorcraft Premium Gold Engine Coolant VC -7-A (in Oregon VC -7-B) or equivalent
meeting Ford specification WSS- M97B51-A1 (yellow color). Use the same coolant that
was drained from the cooling system. Do not mix coolant types.
z Do not add/mix orange- colored Motorcraft Speciality Orange Engine Coolant VC- 2 or
equivalent meeting Ford specification WSS- M97B44-D. Mixing coolants may degrade the
coolant's corrosion protection.
z Do not add alcohol, methanol, or brine, or any engine coolants mixed with alcohol or
methanol antifreeze. These can cause engine damage from overheating or freezing.
z Do not mix with recycled coolant unless it meets the requirements of Ford specification
WSS- M97B51- A1. Not all coolant recycling processes meet these Ford specifications.
Use of such coolants can harm the engine and cooling system components.
NOTE: The addition of Motorcraft Cooling System Stop Leak Pellets, VC- 6, darkens Motorcraft
Premium Gold Engine Coolant from yellow to golden tan.
1. Place the heater temperature selector in the maximum cool position.
2. CAUTION: On 3.8L engines, the vent plug must be removed before radiator fill or
the engine may not fill completely.
NOTE: It is important to maintain engine coolant concentrate between 40 percent or - 24°C (-11°
F) and 60 percent or - 52°C (-62°F).
Fill the engine cooling system with 50/50 mixture of water and engine coolant.
3. After filling the engine cooling system, add coolant to the vent until full. Install the vent plug.
4. Leave the pressure relief cap off and run the engine until it reaches normal operating temperature.
5. Stop the engine and add the correct engine coolant mixture to the degas bottle/coolant expansion tank until the coolant level is between the COOLANT FILL LEVEL marks.
6. Turn the engine off and allow the cooling system to cool. Check the level in the degas bottle/coolant expansion tank, and add a 50/50 mix as needed. Filling — 4.6L (2V) Klj . 2 ba
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CAUTION: Vehicle cooling systems are filled with Motorcraft Premium Gold Engine
Coolant VC -7-A (in Oregon VC -7-B) or equivalent meeting Ford specification WSS- M97B51-A1
(yellow color). Always fill the cooling system with the same coolant that is present in the
system. Do not mix coolant types.
CAUTION: Engine coolant provides freeze protection, boil protection, cooling efficiency,
and corrosion protection to the engine and cooling components. In order to obtain these
protections, the engine coolant must be maintained at the correct concentration and fluid level
in the degas bottle.
When adding engine coolant, use a 50/50 mixture of engine coolant and deionized water.
To maintain the integrity of the coolant and the cooling system:
zAdd Motorcraft Premium Gold Engine Coolant VC -7-A (in Oregon VC -7-B) or equivalent
meeting Ford specification WSS- M97B51-A1 (yellow color). Use the same coolant that
was drained from the cooling system. Do not mix coolant types.
z Do not add/mix orange- colored Motorcraft Speciality Orange Engine Coolant VC- 2 or
equivalent meeting Ford specification WSS- M97B44-D. Mixing coolants may degrade the
coolant's corrosion protection.
z Do not add alcohol, methanol, or brine, or any engine coolants mixed with alcohol or
methanol antifreeze. These can cause engine damage from overheating or freezing.
z Do not mix with recycled coolant unless it meets the requirements of Ford specification
WSS- M97B51- A1. Not all coolant recycling processes meet these Ford specifications.
Use of such coolants can harm the engine and cooling system components.
NOTE: The addition of Motorcraft Cooling System Stop Leak Pellets, VC- 6, darkens Motorcraft
Premium Gold Engine Coolant from yellow to golden tan.
1. Remove the thermostat. For additional information, refer to Thermostat — 4.6L(2V) in this
section.
2. Disconnect the heater core coolant supply hose from the fitting at the rear of the manifold.
3. Add the coolant/water mixture through the thermostat opening until coolant appears at the heater core coolant supply outlet fitting at the rear of the manifold.
4. Install the heater hose, using an appropriately sized worm style clamp in place of the constant tension clamp.
5. Reinstall the thermostat gasket (O- ring) and the thermostat. For additional information, refer to
Thermostat — 4.6L(2V) in this section.
6. Add the correct engine coolant mixture to the degas bottle until the coolant level is between the Klj . 3 ba
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"COOLANT FILL LEVEL" marks and replace the pressure cap.
7. Select the maximum cool temperature setting.
8. Run the engine until it reaches operating temperature.
9. CAUTION: If the engine coolant temperature gauge does not move, the engine
coolant level in the engine is low and must be filled. Stop the engine, allow it to cool and
fill the cooling system.
Add the correct engine coolant mixture to the degas bottle until the coolant level is between the
"COOLANT FILL LEVEL" marks.
10. Repeat the two previous steps until the engine coolant mixture is between the "COOLANT FILL LEVEL" marks on the degas bottle. Turn off the engine and allow it to cool.
11. Check the freeze protection of the engine coolant mixture with the Battery/Anti- freeze Tester
014- R1060 or equivalent. Adjust freezing point range if necessary.
Filling — Cobra
CAUTION: Vehicle cooling systems are filled with Motorcraft Premium Gold Engine
Coolant VC -7-A (in Oregon VC -7-B) or equivalent meeting Ford specification WSS- M97B51-A1
(yellow color). Always fill the cooling system with the same coolant that is present in the
system. Do not mix coolant types.
CAUTION: Engine coolant provides freeze protection, boil protection, cooling efficiency,
and corrosion protection to the engine and cooling components. In order to obtain these
protections, the engine coolant must be maintained at the correct concentration and fluid level
in the degas bottle.
When adding engine coolant, use a 50/50 mixture of engine coolant and deionized water.
To maintain the integrity of the coolant and the cooling system:
zAdd Motorcraft Premium Gold Engine Coolant VC -7-A (in Oregon VC -7-B) or equivalent
meeting Ford specification WSS- M97B51-A1 (yellow color). Use the same coolant that
was drained from the cooling system. Do not mix coolant types.
z Do not add/mix orange- colored Motorcraft Speciality Orange Engine Coolant VC- 2 or
equivalent meeting Ford specification WSS- M97B44-D. Mixing coolants may degrade the
coolant's corrosion protection.
z Do not add alcohol, methanol, or brine, or any engine coolants mixed with alcohol or
methanol antifreeze. These can cause engine damage from overheating or freezing.
z Do not mix with recycled coolant unless it meets the requirements of Ford specification
WSS- M97B51- A1. Not all coolant recycling processes meet these Ford specifications.
Use of such coolants can harm the engine and cooling system components.
NOTE: The addition of Motorcraft Cooling System Stop Leak Pellets, VC- 6, darkens Motorcraft
Premium Gold Engine Coolant from yellow to golden tan.
1. Check all hose clamps for correct tightness. Make sure the radiator draincock is closed.
2. Place the heater temperature selector in maximum cool position. Klj . 4 ba
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