2003 FORD MUSTANG key

21. Position the oil pump and tighten the bolts in the sequence shown.
22.
NOTE: Install a new O- ring if necessary.
Install the oil pump screen cover and tube.
23. Install the cylinder head gaskets.
24. CAUTION: The camshafts must be positioned so the camshaft keyway is 90 degrees
from the valve cover gasket surface to avoid damage to valves and pistons during timing Klj . 9 ba
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53. Apply silicone gasket and sealant to the woodruff key on the crankshaft pulley.
54. Using the special tool, install the crankshaft pulley.
55. Install the crankshaft pulley and tighten the bolt in four stages.
zStage 1: tighten to 90 Nm (66 lb- ft).
z Stage 2: loosen the bolt one full turn.
z Stage 3: tighten to 50 Nm (37 lb- ft).
z Stage 4: tighten an additional 90 degrees. Klj . 19 ba
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while the pressure is released from the cooling system.
When you are sure all the pressure has been released, turn
and remove the pressure relief cap (still with a cloth).
NOTE:
Allow the engine to cool before checking the engine
coolant level.
z Key in OFF position.
z Visually check the engine coolant level at the degas bottle or
coolant expansion tank.
z Is the engine coolant level within specification? A2 CHECK THE PRESSURE RELIEF CAP
z
Carry out the Cap— 3.8L or Cap—4.6L test. Go to Component
Tests in this section.
z Is pressure relief cap/radiator cap OK? Yes
GO to
A3 .
No
INSTALL a new
pressure relief
cap/radiator cap. TEST
the system for normal
operation. A3 CHECK THE ENGINE COOLANT FOR INTERNAL LEAK
z
Key in OFF position.
z Inspect the engine coolant in degas bottle/coolant expansion
tank for signs of transmission fluid or engine oil.
z Is oil or transmission fluid evident in the coolant? Yes
If engine oil is evident,
REFER to
Section 303 -
00 . If transmission fluid
is evident, REPAIR or
INSTALL a new radiator
as necessary.
No
GO to A4 .
A4 CHECK THE ENGINE AND THE TRANSMISSION FOR
COOLANT z
Remove the oil level dipstick from the engine and the
transmission.
z Is coolant evident in the oil or transmission fluid? Yes
If coolant is in engine,
REFER to
Section 303 -
00 . If coolant is in
transmission, REPAIR
or INSTALL a new
radiator as necessary.
To repair the automatic
transmission, REFER to
Section 307 - 01 .
No
GO to A5 .
A5 PRESSURE TEST THE ENGINE COOLING SYSTEM
z
Pressure test the engine cooling system. Go to Component
Tests in this section.
z Does the engine cooling system leak? Yes
REPAIR or install new
components. TEST the
system for normal
operation.
No
The cooling system is
operational. GO to
Symptom Chart
. Klj . 4 ba
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PINPOINT TEST B: THE ENGINE OVERHEATS
Test Step Result / Action to
Take B1 CHECK THE ENGINE COOLANT LEVEL
WARNING: Never remove the pressure relief cap while
the engine is operating or when the cooling system is hot.
Failure to follow these instructions can result in damage to
the cooling system or engine or personal injury. To avoid
having scalding hot coolant or steam blow out of the degas
bottle when removing the pressure relief cap, wait until the
engine is cooled, then wrap a thick cloth around the
pressure relief cap and turn it slowly. Step back while the
pressure is released from the cooling system. When you are
sure all the pressure has been released, turn and remove
the pressure relief cap (still with a cloth). NOTE: If the engine
is hot, allow the engine to cool before proceeding.
z Key in OFF position.
z Check the engine coolant level at the degas bottle/coolant
expansion tank.
z Is the engine coolant OK? Yes
GO to
B2 .
No
REFILL the engine
coolant at the degas
bottle/coolant
expansion tank. Go To Pinpoint Test A .
B2 CHECK THE COOLANT CONDITION
z
Check the coolant for dirt, rust or contamination.
z Is the coolant condition OK? Yes
GO to
B3 .
No
FLUSH the engine
cooling system.
REFER to Engine and Radiator Flushing in
this section. TEST the
system for normal
operation. B3 CHECK FOR AN AIRFLOW OBSTRUCTION
z
Inspect the A/C condenser core and radiator for obstructions
such as leaves or dirt.
z Is there an obstruction? Yes
REMOVE the
obstruction. CLEAN the
A/C condenser core
and radiator. TEST the
system for normal
operation.
No
GO to
B4 .
B4 CHECK THE WATER THERMOSTAT OPERATION
z
Start the engine and allow the engine to run for ten minutes.
z Feel the inlet and outlet heater water hoses and the underside of
the upper radiator hose.
z Are the upper radiator hose and the heater water hoses
cold? Yes
INSTALL a new water
thermostat. REFER to
Thermostat
— 3.8L ,
Thermostat — 4.6L(2V)
or
Thermostat — 4.6L
(4V) in this section.
TEST the system for
normal operation.
No
GO to B5 . Klj . 5 ba
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Component Tests Test Step Result / Action to
Take A1 CHECK THE INTERCOOLER COOLANT LEVEL
WARNING: Never remove the pressure relief cap under
any conditions while the engine is operating. Failure to follow
these instructions could result in damage to the cooling system
or engine and/or personal injury. To avoid having scalding hot
coolant or steam blow out of the cooling system, use extreme
care when removing the pressure relief cap from a hot degas
bottle. Wait until the engine has cooled, then wrap a thick cloth
around the pressure relief cap and turn it slowly one turn
(counterclockwise). Step back while the pressure is released
from the cooling system. When certain all the pressure has
been released, remove the pressure relief cap (still with a
cloth). NOTE: Allow the engine to cool before checking the engine
coolant level. The engine must be off to check the coolant.
z Key in OFF position.
z Visually check the intercooler coolant level at the degas bottle.
z Is the coolant level within specification? Yes
GO to
A2 .
No
REFILL the coolant
as necessary. GO
to A2 .
A2 CHECK THE DEGAS BOTTLE PRESSURE RELIEF CAP
z
WARNING: Never remove the pressure relief cap under
any conditions while the engine is operating. Failure to follow
these instructions could result in damage to the cooling system
or engine and/or personal injury. To avoid having scalding hot
coolant or steam blow out of the cooling system, use extreme
care when removing the pressure relief cap from a hot degas
bottle. Wait until the engine has cooled, then wrap a thick cloth
around the pressure relief cap and turn it slowly one turn
(counterclockwise). Step back while the pressure is released
from the cooling system. When certain all the pressure has
been released, remove the pressure relief cap (still with a
cloth).
z Remove the pressure relief cap.
z Inspect the pressure relief cap for foreign material between the
sealing gasket and the diaphragm.
z Is the pressure relief cap OK? Yes
GO to
A3 .
No
CLEAN or INSTALL
a new pressure
relief cap. TEST the
system for normal
operation. A3 CHECK THE DEGAS BOTTLE
z
WARNING: Never remove the pressure relief cap under
any conditions while the engine is operating. Failure to follow
these instructions could result in damage to the cooling system
or engine and/or personal injury. To avoid having scalding hot
coolant or steam blow out of the cooling system, use extreme
care when removing the pressure relief cap from a hot degas
bottle. Wait until the engine has cooled, then wrap a thick cloth
around the pressure relief cap and turn it slowly one turn
(counterclockwise). Step back while the pressure is released
from the cooling system. When certain all the pressure has
been released, remove the pressure relief cap (still with a
cloth).
z NOTE: The engine must be cool when coolant is added to the degas
bottle.
z Add coolant to the degas bottle until fluid is between the coolant fill
level marks.
z Does the degas bottle leak? Yes
INSTALL a new
degas bottle. TEST
the system for
normal operation.
No
CARRY OUT the
cooling system
pressure test.
REFER to the
Component Tests
in this section.
REPAIR as
necessary. TEST
the system for
normal operation. Klj . 4 ba
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PINPOINT TEST B: THE ENGINE DOES NOT CRANK AND THE
RELAY DOES NOT CLICK
Test Step Result / Action to Take
B1 CHECK CIRCUIT 33 (WH/PK) FOR VOLTAGE
z
Disconnect: Starter Motor Relay.
z Key in START position.
z Measure the voltage between the starter motor relay pin 85,
circuit 33 (WH/PK) and ground while holding the key in the
START position.
z Is the voltage greater than 10 volts? Yes
GO to
B10 .
No
For automatic
transmissions, GO to
B2 . For manual
transmissions, GO to
B5 .
B2 CHECK CIRCUIT 32 (RD/LB) FOR VOLTAGE AT THE DIGITAL
TR SENSOR z
Key in OFF position.
z Disconnect: Digital TR Sensor C110.
z Key in START position.
z Measure the voltage between the digital TR sensor C110 pin
10, circuit 32 (RD/LB) and ground while holding the key in the
START position.
z Is the voltage greater than 10 volts? Yes
GO to
B3 .
No
GO to B7 .
B3 CHECK CIRCUIT 33 (WH/PK) FOR OPEN
z
Key in OFF position.
z Measure the resistance between the digital TR sensor C110 pin Yes
GO to
B4 .
No
REPAIR circuit 33
(WH/PK). TEST the
system for normal
operation. Klj . 4 ba
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12, circuit 33 (WH/PK) and the starter motor relay pin 86, circuit
33 (WH/PK).
z Is the resistance less than 5 ohms? B4 CHECK DIGITAL TRANSMISSION RANGE (TR) SENSOR
ADJUSTMENT z
Carry out the digital TR sensor adjustment. Refer to Section 307 - 01 .
z Is the digital TR sensor adjusted correctly? Yes
INSTALL a new digital
TR sensor. TEST the
system for normal
operation.
No
ADJUST the digital TR
as necessary. TEST the
system for normal
operation.
B5 CHECK CIRCUIT 32 (RD/LB) FOR VOLTAGE AT THE CLUTCH
SWITCH OR JUMPER z
Key in OFF position.
z Disconnect: Clutch Pedal Switch C255.
z Key in START position.
z Measure the voltage between the clutch pedal switch C255 pin
2, circuit 32 (RD/LB) and ground while holding the key in the
START position.
z Is the voltage greater than 10 volts? Yes
GO to
B6 .
No
GO to B7 .
B6 CHECK CIRCUIT 33 (WH/PK)/32 (RD/LB) FOR OPEN
z
Key in OFF position.
z Measure the resistance between the clutch pedal switch C255
pin 1, circuit 33 (WH/PK)/32 (RD/LB) and the starter motor relay
pin 86, circuit 33 (WH/PK)/32 (RD/LB).
z Is the resistance less than 5 ohms? Yes
INSTALL a new clutch
pedal switch. TEST the
system for normal
operation.
No
REPAIR circuit 33
(WH/PK)/32 (RD/LB).
TEST the system for
normal operation.
B7 CHECK FOR VOLTAGE AT FUSE 6
z
Key in OFF position.
z Disconnect: Fuse #6.
z Key in START position. Yes
REPAIR circuit 32
(RD/LB). TEST the Klj . 5 ba
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z
Measure the voltage between the central junction box fuse 6,
circuit 33 (WH/PK) and ground while holding the key in the
START position.
z Is the voltage greater than 10 volts? system for normal
operation.
No
GO to
B8 .
B8 CHECK CIRCUIT 1050 (LG/VT) FOR VOLTAGE
z
Key in OFF position.
z Disconnect: Ignition Switch C209.
z Key in ON position.
z Measure the voltage between the ignition switch connector
C209 pin B4, circuit 1050 (LG/VT) and ground.
z Is the voltage greater than 10 volts? Yes
GO to
B9 .
No
REPAIR circuit 1050
(LG/VT). TEST the
system for normal
operation. B9 CHECK THE IGNITION SWITCH
z
Carry out the ignition switch component test. Refer to
Refer to Wiring Diagrams Cell 149 for schematic and connector
information.
.
z Does the ignition switch test good? Yes
REPAIR circuit 33
(WH/PK). TEST the
system for normal
operation.
No
INSTALL a new ignition
switch. TEST the
system for normal
operation.
B10 CHECK CIRCUIT 1205 (BK) FOR OPEN
z
Key in OFF position. Yes
INSTALL a new starter
motor relay. TEST the
system for normal
operation.
No
REPAIR circuit 1205
(BK). TEST the system
for normal operation. Klj . 6 ba
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