2003 FORD MUSTANG engine

GENERAL PROCEDURES
Fittings
—R-Clip
Disconnect 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 may be ignited, resulting in possible personal injury.
WARNING: Fuel in the fuel system remains under high pressure even when the engine is
not running. Before servicing or disconnecting any of the fuel lines or fuel system components,
the fuel system pressure must be relieved to prevent accidental spraying of fuel, causing
possible personal injury or a fire hazard.
CAUTION: Do not use any tools. The use of tools may cause a deformity in the clip
components which may cause fuel leaks.
1. Relieve the fuel system pressure. For additional information, refer to Pressure Relief in this
section.
2. Remove the shipping tab by bending.
3. Spread the R- clip legs and push the clip into the fitting.
SECTION 310-
00: Fuel System — General Information 2003 Mustang Workshop Manual Material
Item Specification
SAE 5W-
20 Super Premium
Synthetic Blend Motor Oil
XO- 5W20- QSP or equivalent WSS-
M2C153-
H Klj . 1 ba
32003 Mustang Workshop Manual
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4. Separate the fitting from the tube.
Connect 1. NOTE: Apply a light coat of clean engine oil.
Clean and inspect the fitting and the tube for damage.
2. Insert the R- clip into the fitting.
3. Insert the tube in the fitting and push together until a click is heard. Klj . 2 ba
32003 Mustang Workshop Manual
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DESCRIPTION AND OPERATION
Fuel Tank And Lines
WARNING: Do not smoke, carry lighted tobacco or an open flame of any type when
working on or near any fuel- related component. Highly flammable mixtures are always present
and may be ignited, possibly resulting in personal injury.
The vehicle utilizes a returnless fuel system consisting of:
zthe fuel tank.
z a fuel tank filler pipe which contains a restrictor plate to permit only unleaded fuel to be pumped
into the fuel tank.
z a 1/8 turn fuel tank filler cap.
z a fuel filter providing filtration to protect the fuel injectors.
z a single fuel line accommodating the returnless fuel system.
z a fuel injection supply manifold which contains a differential pressure sensor and a fuel
temperature sensor.
z a fuel pump and sender assembly which provides pressurized fuel to the engine and contains:
„an inlet filter.
„ a check valve which maintains system pressure after the pump is shut off.
„ a pressure relief valve for overpressure protection in the event of restricted flow.
The fuel pump is controlled by an electronic fuel pump driver module which is enabled by the
powertrain control module (PCM). Electrical power to the fuel pump is provided through the inertia fuel
shutoff (IFS) switch, which is located in the luggage compartment. SECTION 310-
01: Fuel Tank and Lines 2003 Mustang Workshop Manual Klj . 1 ba
12003 Mustang Workshop Manual
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REMOVAL AND INSTALLATION
Fuel Tank
Removal
WARNING: Do not smoke, carry lighted tobacco or an open flame of any type when
working on or near any fuel- related components. Highly flammable mixtures are always present
and may be ignited, possibly resulting in personal injury.
WARNING: Fuel supply lines on all vehicles equipped with fuel injected engines will
remain pressurized for long periods of time after engine shutdown. Fuel system pressure must
be relieved prior to fuel system service to prevent possible personal injury or a fire hazard.
1. Disconnect the battery. For additional information, refer to Section 414 - 01 .
2. Relieve the fuel system pressure. For additional information, refer to Section 310 - 00 .
3. Drain the fuel tank. For additional information, refer to Section 310 - 00 .
4. Raise the vehicle. For additional information, refer to Section 100 - 02 .
5. Remove the filler pipe bolt and disconnect the filler pipe hose connections to the fuel tank.
6. Disconnect the fuel tank electrical connector.
SECTION 310-
01: Fuel Tank and Lines 2003 Mustang Workshop Manual Material
Item Specification
Serfactant
(Merpol)
ESE-
M99B144- B Klj . 1 ba
52003 Mustang Workshop Manual
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REMOVAL AND INSTALLATION
Support Straps
Removal
WARNING: Do not smoke, carry lighted tobacco or an open flame of any type when
working on or near any fuel- related components. Highly flammable mixtures are always present
and may be ignited, possibly resulting in personal injury.
WARNING: Fuel supply lines on all vehicles equipped with fuel injected engines will
remain pressurized for long periods of time after engine shutdown. Fuel system pressure must
be relieved prior to fuel system service to prevent possible personal injury or a fire hazard.
1. Remove the fuel tank. For additional information, refer to Fuel Tank in this section.
2. Slide the strap and the retaining pin into the recess and remove the strap retaining pin.
3. Remove the strap.
Installation 1. To install, reverse the removal procedure.
SECTION 310-
01: Fuel Tank and Lines 2003 Mustang Workshop Manual Klj . 1 ba
22003 Mustang Workshop Manual
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REMOVAL AND INSTALLATION
Fuel Filter
Removal
WARNING: Fuel supply lines on all vehicles equipped with fuel injected engines will
remain pressurized for long periods of time after engine shutdown. Fuel system pressure must
be relieved prior to fuel system service to prevent possible personal injury or a fire hazard.
1. Disconnect the battery. For additional information, refer to Section 414 - 01 .
2. Relieve the fuel system pressure. For additional information, refer to Section 310 - 00 .
3. Raise the vehicle. For additional information, refer to Section 100 - 02 .
4. Disconnect the filter push connect fittings. For additional information, refer to Section 310 - 00 .
5. Unsnap the filter from the bracket and remove.
Installation 1. To install, reverse the removal procedure.
SECTION 310-
01: Fuel Tank and Lines 2003 Mustang Workshop Manual Klj . 1 ba
22003 Mustang Workshop Manual
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DESCRIPTION AND OPERATION
Acceleration Control
Component Locations
The throttle is controlled by the accelerator cable which is connected to the accelerator pedal and
shaft.
zThe accelerator pedal and shaft should travel smoothly from the idle to the wide- open throttle
(WOT) positions. Hesitation on return or prevention of return to the idle position must not occur.
z Surrounding components such as wiring, hoses, sound insulator and floor covering must not
contact the sliding inner member of the accelerator cable or the accelerator pedal and shaft.
z The sliding inner member of the accelerator cable should not be lubricated and is not
serviceable.
SECTION 310-
02: Acceleration Control 2003 Mustang Workshop Manual Item Part Number Description
1 9725 Accelerator pedal and shaft
2 9A758 Accelerator cable
3 9728 Accelerator cable bracket, 3.8L
4 9728 Accelerator cable bracket, 4.6L (2V)
5 — Accelerator cable bracket, Supercharged engine Klj . 1 ba
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DIAGNOSIS AND TESTING
Acceleration Control
Inspection and Verification
1. Verify the customer's concern by operating the acceleration control system to duplicate the condition.
2. Inspect to determine if any of the following mechanical concerns apply:
3. If the inspection reveals an obvious concern that can be readily identified, repair as required.
4. If the concern remains after the inspection, determine the symptom(s) and GO to Symptom Chart .
Symptom Chart SECTION 310-
02: Acceleration Control 2003 Mustang Workshop Manual Visual Inspection Chart
Mechanical
z
damaged accelerator pedal and shaft
z damaged linkage
z damaged accelerator cable
z high engine idle speed
z damaged throttle body
Symptom Chart Condition
Possible Sources Action
z Excessive effort
needed to
depress
accelerator pedal
and shaft z
Worn
accelerator lever
pivot bushing. z
INSTALL a new accelerator
pedal and shaft.
z Accelerator
cable binding. z
INSTALL a new accelerator
cable.
z Worn or
damaged
throttle body. z
INSTALL a new throttle body.
REFER to Section 303 - 04A or
Section 303 - 04B .
z Accelerator pedal
and shaft feels
rough or raspy z
Frayed or
binding
accelerator
cable. z
INSTALL a new accelerator
cable.
z Worn or
damaged
throttle body. z
INSTALL a new throttle body.
REFER to Section 303 - 04A or
Section 303 - 04B .
z Accelerator pedal
and shaft binds or
sticks z
Kinked
accelerator
cable. z
INSTALL a new accelerator
cable. Klj . 1 ba
22003 Mustang Workshop Manual
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