2003 FORD MUSTANG Workshop Manual

fuel cap torque wiper size transmission radio open hood

Page 97 of 4378

FORD MUSTANG 2003 Workshop Manual �z
Is the ticking noise gone? CHECK for TSB for applicable vehicle.
REPAIR as necessary. TEST the system
for normal operation.
No
GO to
B2 .
B2 CHECK FOR TICKING NOISE AT THE FUEL
INJECTOR �

z
Is the ticking noise gone? CHECK for TSB for applicable vehicle.
REPAIR as necessary. TEST the system
for normal operation.
No
GO to
B2 .
B2 CHECK FOR TICKING NOISE AT THE FUEL
INJECTOR z
Using an EngineEAR, listen at the fuel
injectors by placing a probe on each injector.
To isolate the faulty injector, disconnect the
injector electrical connector and listen for the
noise.
z Is the fuel injector the source of the ticking
noise? Yes
INSTALL a new fuel injector. REFER to
Section 303
- 04A for 3.8L engines or
Section 303 - 04B for 4.6L (2V) engines.
TEST the system for normal operation.
No
GO to B3 .
B3 CHECK THE BELT TENSIONER FOR TICKING
NOISE z
Inspect the accessory drive. Check for the belt
tensioner bottoming at end of travel or not at
end of stroke.
z Using an EngineEAR, listen at the belt
tensioner.
z Is the belt tensioner the source of the
noise? Yes
INSTALL a new belt tensioner. TEST the
system for normal operation.
No
GO to
B4 .
B4 CHECK THE WATER PUMP FOR TICKING
NOISE z
Using an EngineEAR, listen at the water pump
for ticking noise.
z Is the water pump the source of the noise? Yes
INSTALL a new water pump. REFER to
Section 303
- 03A . TEST the system for
normal operation.
No
GO to B5 .
B5 CHECK FOR AN OBSTRUCTION OF THE
COOLING FAN z
Inspect the cooling fan for obstructions.
z Check the cooling fan and shroud for wear or
damage.
z Was there an obstruction or does the
cooling fan show signs of damage? Yes
REPAIR or INSTALL a new cooling fan.
REFER to
Section 303 - 03A . TEST the
system for normal operation.
No
GO to B6 .
B6 CHECK THE OIL PUMP FOR TICKING NOISE
z
Check the oil pump using EngineEARs and
probe at the oil filter adapter to verify the oil
pump as a source.
z Is the oil pump the source of the noise? Yes
INSTALL a new oil pump. REFER to
Section 303
- 01A for 3.8L engines or
Section 303 - 01B for 4.6L (2V) engines.
TEST the system for normal operation.
No
GO to B7 .
B7 CHECK VALVE LIFTERS OR LASH
ADJUSTERS FOR CORRECT OPERATION z
Check valve lifter/lash adjuster for correct
operation, using EngineEARs.
z Are the valve lifters/lash adjusters Yes
VERIFY customer concern. CONDUCT a
diagnosis of other suspect components. Klj . 50 ba
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FORD MUSTANG 2003 Workshop Manual PINPOINT TEST C: ACCESSORY DRIVE BEARING HOOT
PINPOINT TEST D: POWER STEERING MOAN
PINPOINT TEST E: ENGINE DRIVEN COOLING FAN MOAN operating correctly?
No
INSTALL a new valve lifter/lash adjuster

PINPOINT TEST C: ACCESSORY DRIVE BEARING HOOT
PINPOINT TEST D: POWER STEERING MOAN
PINPOINT TEST E: ENGINE DRIVEN COOLING FAN MOAN operating correctly?
No
INSTALL a new valve lifter/lash adjuster
(s). TEST the system for normal
operation.
Test Step Result / Action to Take
C1 CHECK THE IDLER AND TENSIONER
PULLEY BEARINGS z
Carry out the Vehicle Cold Soak
Procedure in this section.
z Key in START position.
z Place an EngineEAR probe directly on the
pulley center post or bolt to verify which
bearing is making the noise.
z Key in OFF position.
z Is either bearing making the noise? Yes
INSTALL a new pulley/idler. CARRY OUT the
Vehicle Cold Soak Procedure and TEST the
system for normal operation.
No
CONDUCT a diagnosis on other suspect
accessory drive components.
Test Step Result / Action to Take
D1 CHECK THE POWER STEERING
SYSTEM z
Carry out the Vehicle Cold Soak
Procedure in this section.
z Key in START position.
z Turn the steering wheel while the noise
is occurring and listen for changes in
sound pitch or loudness.
z Key in OFF position.
z Does the sound pitch or loudness
change while turning the steering
wheel? Yes
GO to
D2 .
No
CONDUCT a diagnosis on other suspect
accessory drive components. D2 VERIFY THE SOURCE
z
Key in START position.
z Place an EngineEAR probe near the
power steering pump/reservoir while the
noise is occurring. While an assistant
turns the steering wheel, listen for
changes in sound pitch or loudness.
z Key in OFF position.
z Does the sound pitch or loudness
change while turning the steering
wheel? Yes
VERIFY that the supply tube to the pump is
unobstructed. CHECK the fluid condition and
level. DRAIN the fluid and REFILL. CARRY
OUT the Vehicle Cold Soak Procedure and
TEST the system for normal operation. REFER
to Section 211
- 02 .
No
Normal system operation. Test Step Result / Action to Take
E1 CHECK THE ENGINE DRIVEN COOLING
FAN AFTER A COLD SOAK Klj . 51 ba
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Page 99 of 4378

FORD MUSTANG 2003 Workshop Manual PINPOINT TEST F: DRUMMING NOISE �z
Carry out the Vehicle Cold Soak Procedure
in this section.
�z Key in START position.
�z Assess the airflow.
�z Raise the engine speed to 1500 rpm while
listeni

PINPOINT TEST F: DRUMMING NOISE z
Carry out the Vehicle Cold Soak Procedure
in this section.
z Key in START position.
z Assess the airflow.
z Raise the engine speed to 1500 rpm while
listening for the moan to increase in
proportion to the airflow.
z Key in OFF position.
z Does the moan increase in proportion to
the airflow? Yes
TEST the fan for normal operation. If the
fan tests normal, GO to
E2 . Otherwise,
REPAIR as necessary.
No
Normal system operation. E2 CHECK THE ENGINE DRIVEN COOLING
FAN AT NORMAL OPERATING TEMPERATURE z
Key in START position.
z Run the engine to normal operating
temperature while listening for the moan to
stop.
z Key in OFF position.
z Does the moan stop? Yes
Normal clutch operation.
No
INSTALL a new fan clutch. TEST the
system for normal operation.
Test Step Result / Action to Take
F1 CHECK THE EXHAUST SYSTEM
z
Key in START position.
z Increase the engine rpm until the noise is the loudest. Note
the engine rpm.
z Key in OFF position.
z Add approximately 9 kg (20 lb) of weight to the exhaust
system. First place the weight at the tail pipe and test, then
at the front pipe.
z Key in START position.
z Increase the engine rpm and listen for the drumming noise.
Note the engine rpm if the noise occurs.
z Key in OFF position.
z Using a vibration analyzer (VA), determine the amount of
vibration that occurs with the drumming noise.
z Is the noise/vibration reduced or eliminated, or does the
noise/vibration occur at a different rpm? Yes
CARRY OUT
Exhaust System Neutralizing in this
section. TEST the system
for normal operation.
No
GO to F2 .
F2 POWERTRAIN/DRIVETRAIN MOUNT NEUTRALIZING
z
Carry out Powertrain/Drivetrain Mount Neutralizing in this
section. Test the system for normal operation.
z Is the noise reduced or eliminated? Yes
Vehicle OK. TEST the
system for normal
operation.
No Klj . 52 ba
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FORD MUSTANG 2003 Workshop Manual PINPOINT TEST G: ENGINE TICKING, KNOCKING OR CONTINUOUS
RATTLE
PINPOINT TEST H: FRONT SUSPENSION NOISE CONDUCT diagnosis of
other suspect components.
Test Step Result / Action to Take
G1 CHECK

PINPOINT TEST G: ENGINE TICKING, KNOCKING OR CONTINUOUS
RATTLE
PINPOINT TEST H: FRONT SUSPENSION NOISE CONDUCT diagnosis of
other suspect components.
Test Step Result / Action to Take
G1 CHECK FOR NOISE AT THE VALVE COVERS
AND THE FRONT COVERS (OHC ENGINES) z
Carry out the Vehicle Cold Soak Procedure in
this section.
z Key in START position.
z NOTE: For a short- duration ticking noise,
multiple engine starts may be necessary.
z Using an EngineEAR, listen closely at the valve
covers and the front covers (OHC engines) by
placing the probe near the surface of the valve
cover and then on the surface front cover.
z Key in OFF position.
z Is the noise source apparent? Yes
REMOVE the appropriate cover and
INSPECT for loose, worn/broken
components. REPAIR as necessary.
TEST the system for normal operation.
No
GO to
G2 .
G2 CHECK FOR NOISE AT THE CYLINDER
BLOCK z
Key in START position.
z Using an EngineEAR, listen closely at the
cylinder block by placing a probe on or near
each freeze plug.
z Key in OFF position.
z Is the noise source apparent? Yes
REPAIR or INSTALL new components
as necessary.
No
GO to
G3 .
G3 CHECK FOR NOISE WHILE DISCONNECTING
EACH FUEL INJECTOR ELECTRICAL
CONNECTOR, ONE AT A TIME z
Key in START position.
z Disconnect each fuel injector electrical
connector, one at a time, to decrease piston
force and listen for the noise.
z Key in OFF position.
z Is the noise reduced or eliminated? Yes
INSTALL a new fuel injector. TEST the
system for normal operation.
No
INSPECT accessory drive system or the
transmission as a possible source.
Test Step Result / Action to Take
H1 ROAD TEST THE VEHICLE
z
Test drive the vehicle.
z NOTE: An assistant will be needed for this road test.
z During the road test, drive the vehicle over a rough road.
Using ChassisEARs, determine from which
area/component the noise is originating.
z Is there a squeak, creak or rattle noise? Yes
GO to
H2 .
No
The suspension system is
OK. CONDUCT a diagnosis
on other suspect systems. H2 INSPECT THE STEERING SYSTEM
Yes Klj . 53 ba
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Page 101 of 4378

FORD MUSTANG 2003 Workshop Manual PINPOINT TEST I: REAR SUSPENSION NOISE �z
WARNING: The electrical power to the air
suspension system must be shut off prior to hoisting,
jacking or towing an air suspension vehicle. This can
be a

PINPOINT TEST I: REAR SUSPENSION NOISE z
WARNING: The electrical power to the air
suspension system must be shut off prior to hoisting,
jacking or towing an air suspension vehicle. This can
be accomplished by turning off the air suspension
switch. Failure to do so can result in unexpected
inflation or deflation of the air springs, which can result
in shifting of the vehicle during these operations.
z Raise and support the vehicle.
z Check the steering system for wear or damage. Carry out a
steering linkage test. Refer Section 211 - 00 .
z Inspect the tire wear pattern. Refer to Tire Wear Patterns
chart in this section.
z Are the steering components worn or damaged? REPAIR the steering
system. INSTALL new
components as necessary.
TEST the system for normal
operation.
No
GO to
H3 .
H3 FRONT SHOCK ABSORBER/STRUT CHECK
z
Check the front shock absorbers/strut mounts for loose
bolts or nuts.
z Check the front shock absorbers/struts for wear or damage.
Carry out a "bounce test".
z Are the front shock absorbers/struts loose or
damaged? Yes
TIGHTEN to specifications if
loose. INSTALL new front
shock absorbers/struts if
damaged. TEST the system
for normal operation.
No
GO to
H4 .
H4 CHECK THE FRONT SPRINGS
z
Check the front spring and front spring mounts/brackets for
wear or damage.
z Are the front springs or spring mounts/brackets worn
or damaged? Yes
REPAIR or INSTALL new
components as necessary.
TEST the system for normal
operation.
No
GO to
H5 .
H5 CHECK THE CONTROL ARMS/RADIUS ARMS
z
Inspect the control arm bushings for wear or damage.
z Inspect for twisted or bent control/radius arm.
z Are the control/radius arms damaged or worn? Yes
REPAIR or INSTALL new
components as necessary.
TEST the system for normal
operation.
No
GO to
H6 .
H6 CHECK THE STABILIZER BAR/TRACK BAR
z
Check the stabilizer bar/track bar bushings and links for
damage or wear.
z Check the stabilizer bar/track bar for damage.
z Check for loose or damaged stabilizer bar isolators or
brackets.
z Are the stabilizer bar/track bar components loose, worn
or damaged? Yes
REPAIR or INSTALL new
components as necessary.
TEST the system for normal
operation.
No
Suspension system OK.
CONDUCT diagnosis on
other suspect systems.
Test Step Result / Action to Take Klj . 54 ba
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Page 102 of 4378

FORD MUSTANG 2003 Workshop Manual PINPOINT TEST J: WHEEL AND TIRE I1 ROAD TEST THE VEHICLE
�z
Test drive the vehicle.
�z NOTE: An assistant will be needed for this road test.
�z During the road test, drive the vehicle over a roug

PINPOINT TEST J: WHEEL AND TIRE I1 ROAD TEST THE VEHICLE
z
Test drive the vehicle.
z NOTE: An assistant will be needed for this road test.
z During the road test, drive the vehicle over a rough road.
Using ChassisEARs, determine from which
area/component the noise is originating.
z Is there a squeak, creak or rattle noise? Yes
GO to
I2 .
No
The suspension system is
OK. Conduct a diagnosis on
other suspect systems. I2 REAR SHOCK ABSORBER/STRUT CHECK
z
WARNING: The electrical power to the air
suspension system must be shut off prior to hoisting,
jacking or towing an air suspension vehicle. This can
be accomplished by turning off the air suspension
switch. Failure to do so can result in unexpected
inflation or deflation of the air springs, which can result
in shifting of the vehicle during these operations.
z Raise and support the vehicle.
z Check the rear shock absorber/strut mounts for loose bolts
or nuts.
z Check the rear shock absorbers/struts for damage. Carry
out a shock absorber check.
z Are the rear shock absorbers/struts loose or damaged? Yes
TIGHTEN to specifications if
loose. INSTALL new rear
shock absorbers/struts if
damaged. TEST the system
for normal operation.
No
GO to
I3 .
I3 CHECK THE REAR SPRINGS
z
Check the rear springs and rear spring mounts/brackets for
wear or damage.
z Are the rear springs or spring mounts/brackets worn or
damaged? Yes
REPAIR or INSTALL new
components as necessary.
TEST the system for normal
operation.
No
GO to
I4 .
I4 CHECK THE CONTROL ARMS/TRAILING ARMS
z
Inspect the control arm/trailing arm bushings for wear or
damage. Check for loose control arm/trailing arm bolts.
z Inspect for twisted or bent control arm/trailing arms.
z Are the control arm/trailing arms loose, damaged or
worn? Yes
REPAIR or INSTALL new
components as necessary.
TEST the system for normal
operation.
No
GO to
I5 .
I5 CHECK THE STABILIZER BAR/TRACK BAR
z
Check the stabilizer bar/track bar bushings and links for
damage or wear.
z Check the stabilizer bar/track bar for damage.
z Check for loose or damaged stabilizer bar isolators or
brackets.
z Are the stabilizer bar/track bar components loose, worn
or damaged? Yes
REPAIR or INSTALL new
components as necessary.
TEST the system for normal
operation.
No
Suspension system OK.
CONDUCT diagnosis on
other suspect systems.
Test Step
Result / Action to Klj . 55 ba
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Page 103 of 4378

FORD MUSTANG 2003 Workshop Manual Take
J1 ROAD TEST THE VEHICLE
�z
NOTE: Wheel or tire vibrations felt in the steering wheel are most
likely related to the front wheel or tire. Vibration felt through the
seat are most likely rela

Page 104 of 4378

FORD MUSTANG 2003 Workshop Manual �z
Are there signs of visual runout? J5 RADIAL RUNOUT CHECK ON THE TIRE
�z
Measure the radial runout of the wheel and tire assembly. A
typical specification for total radial runout is 0.045 inch.

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