2003 FORD MUSTANG light

REMOVAL AND INSTALLATION
Fuel Charging Wiring Harness
Removal and Installation
WARNING: Do not smoke or carry lighted tobacco or open flame of any type when
working on or near any fuel related components. Highly flammable mixtures are always present
and can ignite. Failure to follow these instructions can result in personal injury.
1. Disconnect the battery ground cable.
2. Remove the exhaust gas recirculation (EGR) valve and the exhaust manifold to EGR valve tube. For additional information, refer to Section 303 - 08 .
3. Remove the bolts and the LH ignition coil cover.
4. Disconnect the LH ignition coil electrical connectors. 5. Disconnect the barometric pressure (BARO) sensor electrical connector. SECTION 303-
04C: Fuel Charging and Controls — Cobra 4.6L (4V) 2003 Mustang Workshop Manual Klj . 1 ba
72003 Mustang Workshop Manual
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REMOVAL AND INSTALLATION
Fuel Injection Supply Manifold and Fuel Injector
Removal and Installation
WARNING: Do not smoke or carry lighted tobacco or open flame of any type when
working on or near any fuel related components. Highly flammable mixtures are always present
and can ignite. Failure to follow these instructions can result in personal injury.
WARNING: Fuel in the fuel system remains under high pressure even when the engine is
not running. Before working on or disconnecting any of the fuel lines or fuel system
components, the fuel system pressure must be relieved. Failure to follow these instructions
can result in personal injury.
1. Disconnect the battery ground cable.
2. Remove the air cleaner outlet tube. For additional information, refer to Section 303 - 12 .
3. Release the fuel pressure. For additional information, refer to Section 310 - 00 .
4. Disconnect the fuel supply hose spring lock coupling. For additional information, refer to Section 310 - 00 .
5. Remove the exhaust gas recirculation (EGR) valve and the exhaust manifold- to-EGR valve
tube. For additional information, refer to Section 303 - 08 .
6. Remove the throttle body and spacer assembly.
7. Disconnect the vacuum hose.
SECTION 303-
04C: Fuel Charging and Controls — Cobra 4.6L (4V) 2003 Mustang Workshop Manual Material
Item Specification
SAE 5W-
20 Premium Synthetic
Blend Motor Oil
XO- 5W20- QSP WSS-
M2C153-
H Klj . 1 ba
42003 Mustang Workshop Manual
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REMOVAL AND INSTALLATION
Throttle Body
Removal
WARNING: Do not smoke or carry lighted tobacco or open flame of any type when
working on or near any fuel related components. Highly flammable mixtures are always present
and can ignite. Failure to follow these instructions can result in personal injury.
CAUTION: The throttle body bore and plate area have a special coating and cannot be
cleaned.
1. Remove the air intake scoop bracket. For additional information, refer to Section 303 - 12 .
2. Remove the air cleaner outlet tube. For additional information, refer to Section 303 - 12 .
3. Disconnect the throttle position (TP) sensor electrical connector.
4. Disconnect the accelerator controls. zDisconnect the accelerator cable.
z Disconnect the speed control cable.
z Disconnect the return spring.
5. NOTE: Discard the throttle body gasket after removing the throttle body.
Remove the throttle body. zRemove the four bolts.
SECTION 303-
04D: Fuel Charging and Controls — Mach I 4.6L (4V) 2003 Mustang Workshop Manual Klj . 1 ba
22003 Mustang Workshop Manual
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REMOVAL AND INSTALLATION
Fuel Injectors
Removal
WARNING: Do not smoke or carry lighted tobacco or open flame of any type when
working on or near any fuel related components. Highly flammable mixtures are always present
and can ignite. Failure to follow these instructions can result in personal injury.
WARNING: Fuel in the fuel system remains under high pressure even when the engine is
not running. Before working on or disconnecting any of the fuel lines or fuel system
components, the fuel system pressure must be relieved. Failure to follow these instructions
can result in personal injury.
1. Remove the supply manifold. For additional information, refer to Supply Manifold in this section.
2. Remove the eight fuel injectors from the supply manifold.
Installation CAUTION: The retaining clip must be in the upper groove on the injector or the injector
can become loose.
1. NOTE: Inspect the two O- rings from each fuel injector. Install new O- rings as needed.
NOTE: Lubricate the new O- rings with clean engine oil.
To install, reverse the removal procedure.
SECTION 303-
04D: Fuel Charging and Controls — Mach I 4.6L (4V) 2003 Mustang Workshop Manual Klj . 1 ba
22003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_4464/S3B~us~en~ ...

REMOVAL AND INSTALLATION
Wiring Harness
Removal
WARNING: Do not smoke or carry lighted tobacco or open flame of any type when
working on or near any fuel related components. Highly flammable mixtures are always present
and can ignite. Failure to follow these instructions can result in personal injury.
1. With the vehicle in neutral, position it on a hoist. For additional information, refer to Section 100 -
02 .
2. Disconnect the battery ground cable. For additional information, refer to Section 414 - 01 .
3. Remove the upper intake manifold. For additional information, refer to Section 303 - 01D .
4. Disconnect the following connectors: zThe 42 pin engine bulkhead electrical connector.
z The 16 pin electrical connector.
5. Separate the wiring harness from the dash panel.
6. Remove the RH ignition coil cover. zRemove the bolts.
z Remove the coil cover.
SECTION 303-
04D: Fuel Charging and Controls — Mach I 4.6L (4V) 2003 Mustang Workshop Manual Klj . 1 ba
112003 Mustang Workshop Manual
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REMOVAL AND INSTALLATION
Supply Manifold
Removal
WARNING: Do not smoke or carry lighted tobacco or open flame of any type when
working on or near any fuel related components. Highly flammable mixtures are always present
and can ignite. Failure to follow these instructions can result in personal injury.
WARNING: Fuel in the fuel system remains under high pressure even when the engine is
not running. Before working on or disconnecting any of the fuel lines or fuel system
components, the fuel system pressure must be relieved. Failure to follow these instructions
can result in personal injury.
1. Disconnect the battery ground cable. For additional information, refer to Section 414 - 01 .
2. Remove the upper intake manifold. For additional information, refer to Section 303 - 01D .
3. Relieve the fuel pressure. For additional information, refer to Section 310 - 00 .
4. Disconnect the fuel line. For additional information, refer to Section 310 - 00 .
5. Position the wiring harness aside. zDisconnect the RH fuel injector electrical connectors.
z Separate the harness from the RH fuel supply manifold stud bolt.
6. Disconnect the fuel pressure sensor. zDisconnect the electrical connector.
z Disconnect the vacuum hose.
SECTION 303-
04D: Fuel Charging and Controls — Mach I 4.6L (4V) 2003 Mustang Workshop Manual Klj . 1 ba
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7. Inspect for normal burning.
zThis can be identified by light tan or gray deposits on the firing tip.
8. Inspect for pre- ignition.
z This can be identified by melted electrodes and possibly a blistered insulator. Metallic
deposits on the insulator indicate engine damage.
z Install a new spark plug.
9. Inspect for overheating. zThis can be identified by a white or light gray insulator with small black or gray brown
spots and a bluish- burnt appearance of the electrodes.
z This may be caused by engine overheating, the wrong type of fuel, loose spark plugs, too
hot a plug, low fuel pump pressure or incorrect ignition timing.
z Install a new spark plug. Klj . 3 ba
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z
Install a new spark plug.
5. Inspect for carbon fouling. zThis can be identified by black, dry fluffy carbon deposits on insulator tips, exposed shell
surfaces and electrodes.
z This may be caused by too cold a plug, dirty air cleaner, damaged fuel pump, too rich a
fuel mixture or excessive idling.
z Clean the spark plug.
6. Inspect for normal burning. zThis can be identified by light tan or gray deposits on the firing tip.
7. Inspect for pre- ignition.
z This can be identified by melted electrodes and possibly a blistered insulator. Metallic
deposits on insulator indicate engine damage.
z Install a new spark plug. Klj . 2 ba
42003 Mustang Workshop Manual
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