2003 FORD MUSTANG service

REMOVAL AND INSTALLATION
Dual Converter H-
Pipe —4.6L (2V and 4V)
Removal
NOTE: The RH and LH catalytic converters are serviced separately.
1. Raise and support the vehicle. For additional information, refer to Section 100 - 02 .
2. CAUTION: When repairing exhaust system or removing the exhaust components,
disconnect all heated oxygen sensors (HO2S) (9F472) at the wiring connectors to prevent
damage to the heated oxygen sensors and wiring harness.
Disconnect the downstream RH and LH heated oxygen sensor connectors (9F472).
3. Disconnect the two upstream RH and LH catalyst monitor sensor connectors.
4. Remove the dual converter assembly nuts. (RH shown, LH similar.)
SECTION 309-
00: Exhaust System 2003 Mustang Workshop Manual Klj . 1 ba
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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
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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
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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
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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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SPECIFICATIONS
a
Manifold gauge set pressures may vary slightly depending on the distance between the service
SECTION 412-
00: Climate Control System - General Information 2003 Mustang Workshop Manual General Specifications
Item Specification
A/C Compressor
Type FS-
10 swashplate, 5 double- acting pistons Displacement 170 cc (10.4 cu in)
Rotation Clockwise
A/C Pressure Relief Valve
a Open pressures 3,792-
4,137 kPa (550- 600 psi) A/C Pressure Sensor Refer to the Powertrain Control/Emissions
Diagnosis (PC/ED) manual.
Coolant Hose Lubricant
MERPOL® ESE-
M99B144- B Evaporator Core Orifice
Color Orange
Diameter 1.45 mm (0.057 in)
Magnetic Clutch
Air gap clearance 0.35-
0.75 mm (0.014- 0.030 in) Dual Function Pressure Switch (V8)
a Fan on/open 2,137-
2,344 kPa (310- 340 psi) Fan off/close 1,655-
2,137 kPa (240- 310 psi) Clutch off/open 2,999-
3,275 kPa (435- 475 psi) Clutch on/closed 1,517-
1,931 kPa (220- 280 psi) Pressure Cutoff Switch (V6)
a Open 2,999-
3,275 kPa (435- 475 psi) Close 1,586-
1,999 kPa (230- 290 psi) A/C Cycling Switch Open and Closed Pressures
a Open pressure 145-
159 kPa (21- 23 psi) Close pressure 290 kPa (42 psi)
Refrigerant Lubricant and Capacity
PAG Refrigerant Compressor Oil (R-134a Systems)
F7AZ- 19589- DA (Motorcraft YN-12- C) WSH-
M1C231- B Capacity 254 ml (8.6 oz)
Refrigerant and Capacity
R134a Refrigerant YN-
19 WSH-
M17B19- A Capacity .96 kg (34 oz)
Refrigerant System Cleaner
A/C Systems Flushing Solvent F4AZ-19579-
A — Klj . 1 ba
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z
Refrigerant R- 134a must not be mixed with air for leak testing or used with air for any
other purpose above atmospheric pressure. R- 134a is combustible when mixed with high
concentrations of air and higher pressures.
z A number of manufacturers are producing alternative refrigerant products that are
designed to be used instead of R- 134a refrigerant. The use of any unauthorized
substitute refrigerant can severely damage the A/C components. If repair is required, use
only new or recycled refrigerant R- 134a.
CAUTION: To avoid contamination of the A/C system, always observe the following:
z Keep service tools and the work area clean.
z Never open or loosen a connection before discharging the system.
z When loosening a connection, if any residual pressure is evident, allow it to leak out
before opening the fitting.
z Evacuate a system that has been opened to install a new component or one that has
been discharged through leakage before charging.
z Seal an open fitting with a cap or plug immediately after disconnecting a component
from the system.
z Clean the outside of the fittings thoroughly before disconnecting a component from the
system.
z Do not remove the sealing caps from a new component until ready to install.
z Refrigerant oil will absorb moisture from the atmosphere if left uncapped. Do not open
an oil container until ready to use, and install the cap immediately after using. Store the
oil in a clean, moisture- free container.
z Install a new O- ring seal before connecting an open fitting. Coat the fitting and the O- ring
seal with refrigerant oil before connecting.
z When installing a refrigerant line, avoid sharp bends. Position the line away from the
exhaust or any sharp edges that can chafe the line.
z Do not open a refrigerant system or uncap a new component unless it is as close as
possible to room temperature. This will prevent condensation from forming inside a
component that is cooler than the surrounding air.
The manual climate control system heats or cools the vehicle depending on the function selector
switch position and the temperature selected.
zThe function selector switch position determines heating or cooling and air distribution.
z The temperature control setting determines the air temperature.
z The heater blower motor switch (18578) varies the blower motor speed.
Principles of Operation
There are four main principles involved with the basic theory of operation:
zheat transfer
z latent heat of vaporization
z relative humidity
z effects of pressure Heat Transfer Klj . 2 ba
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evaporator core or A/C condenser core. Then recheck for loss of vacuum.
z If a very small leak is suspected, allow the system to sit overnight with vacuum applied
and check for vacuum loss.
9. If the A/C evaporator core or A/C condenser core does leak, as verified by the above procedure, install a new A/C evaporator core or A/C condenser core. For additional information, refer to
Section 412 - 03 .
A/C Compressor— External Leak Test
1. Install the A/C pressure test adapter on the rear head of the A/C compressor using the existing manifold retaining bolt.
2. Connect the high and low pressure lines of a manifold gauge set or a refrigerant recovery/recycling station such as the R- 134a A/C Service Center to the corresponding fittings
on the A/C pressure test adapter.
3. Attach the center hose of the manifold gauge set to a refrigerant container standing in an upright position.
4. Hand- rotate the compressor shaft 10 complete revolutions to distribute the oil inside the A/C
compressor.
5. Open the low pressure gauge valve, the high pressure gauge valve and the valve on the refrigerant container to allow the refrigerant vapor to flow into the A/C compressor.
6. Using the Refrigerant Leak Detector, check for leaks at the compressor shaft seal and the compressor center seal.
7. If a shaft seal leak is found, install a new shaft seal. For additional information, refer to Section 412 - 03 . If an external leak is found at the center joint of the A/C compressor, install a new A/C
compressor.
8. When the leak test is complete, recover the refrigerant. For additional information, refer to Air Conditioning (A/C) System Recovery, Evacuation and Charging in this section. Klj . 40 ba
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