2003 FORD MUSTANG test G

Component Tests
Steering Linkage
1. NOTE: Excessive vertical motion of the studs relative to the sockets may indicate excessive
wear.
With the parking brake applied, perform the following:
zHave an assistant rotate the steering wheel back and forth 360 degrees and watch for
relative motion of the studs in the tie- rod end ball sockets.
z Watch for loose steering gear mounting.
2. Another method is to raise the front wheels (1007) off the ground, grasp the wheel at the front and rear and watch for excessive play or binding in the joints while trying to steer the wheels.
3. Install new steering components as necessary. For additional information, refer to the appropriate Group 2 steering section.
Turning Effort Test
NOTE: Make sure that the front wheels are properly aligned and the tire pressure is correct before
checking the effort.
1. Park the vehicle on dry concrete and set the parking brake.
2. Insert a thermometer into the power steering pump reservoir.
3. CAUTION: Do not hold the steering wheel against the stops for more than three to
five seconds at a time. Damage to the power steering pump will occur.
Idle the engine for two to three minutes. Turn the steering wheel from stop- to-stop several times
to warm the fluid to 50- 60°C (122-140°F).
4. With the engine running, attach special tool 211- 034 (T74P-3504-Y) to the rim of the steering
wheel.
5. Measure the pull required to turn the steering wheel one complete revolution in each direction. Refer to Steering Wheel Turning Effort under General Specifications in this section.
Pump Flow and Pressure Test WARNING: Do not touch the flowmeter during the test procedure, or severe burns and
serious injury may occur.
1. CAUTION: Make sure that the connection point will not interfere with any of the
engine accessory drive components or drive belts.
Install special tool 211- F001 (014-00207) at the high pressure port of the power steering pump.
Make sure the power steering analyzer gate valve is fully open. Klj . 8 ba
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On some vehicles, the power steering pump high pressure port is inaccessible and the
special tool should then be installed either at the steering gear or at a point in the high
pressure line between the power steering pump and the steering gear.
2. Place a dial thermometer in the power steering pump reservoir.
3. Check the power steering fluid level. If necessary, add power steering fluid. zUse Motorcraft MERCON® Multi-Purpose ATF XT -2-QDX or MERCON® equivalent.
4. Install a digital tachometer.
5. CAUTION: Do not hold the steering wheel against the stops for more than three to
five seconds at a time. Damage to the power steering pump will occur.
Start the engine. Place the transmission in neutral. Set the parking brake. Raise the power
steering fluid temperature to 74- 80°C (165-175°F) by rotating the steering wheel fully to the left
and right several times.
6. Set the engine speed to 1500 rpm. Record the flow rate and pressure readings. zIf the flow rate is below the flow rate specification, a new power steering pump may need
to be installed. Continue with the test procedure.
z If the pressure reading is above the maximum pressure specification, then check power
steering hoses for kinks and restrictions.
7. Partially close the gate valve to obtain 750 psi. Set the engine speed at idle. Record the flow rate.
zIf the flow is less than the specified flow rate, then install a new power steering pump. For
additional information, refer to Section 211 - 02 .
8. CAUTION: Do not allow the gate valve to remain closed for more than 5 seconds.
Completely close and partially open the gate valve 3 times. Record the pressure relief valve
actuation pressure reading. zIf the pressure does not meet the relief pressure specification, install a new power
steering pump. For additional information, refer to Section 211 - 02 .
9. Set engine speed to 1500 rpm. Record the flow rate. zIf the flow rate varies more than 3.785 liters/minute (1 gallon/minute) from the initial flow
rate reading, install a new power steering pump. For additional information, refer to
Section 211 - 02 .
10. CAUTION: Do not hold the steering wheel against the stops for more than three to
five seconds at a time. Damage to the power steering pump will occur.
Set the engine speed at idle. Turn (or have an assistant turn) the steering wheel to the left and
right stops. Record flow rate and pressure readings at the stops.
zThe pressure reading at both stops should be nearly the same as the maximum pump
relief pressure.
z The flow rate should drop below 1.9 liters/minute (0.5 gallons/minute).
z If the pressure does not reach the maximum pump relief pressure or the flow rate does
not drop below the specified value, excessive internal leakage is occurring. Install a new
steering gear as necessary. For additional information, refer to Section 211 - 02 . Klj . 9 ba
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DIAGNOSIS AND TESTING
Steering Column Switches
Refer to Wiring Diagrams Cell
13 , Power Distribution for schematic and connector information.
Refer to Wiring Diagrams Cell 81 , Interval Wiper/Washer for schematic and connector information.
Refer to Wiring Diagrams Cell 85 , Headlamps for schematic and connector information.
Refer to Wiring Diagrams Cell 90 , Turn/Stop/Hazard Lamps for schematic and connector information.
Inspection and Verification 1. Verify the customer concern by operating the multifunction or ignition switch.
2. Visually inspect for obvious signs of mechanical and electrical damage.
3. If the concern remains after the inspection, connect the scan tool to the data link connector (DLC) located beneath the instrument panel and select the vehicle to be tested from the scan
tool menu. If the scan tool does not communicate with the vehicle:
zcheck that the program card is correctly installed.
SECTION 211-
05: Steering Column Switches 2003 Mustang Workshop Manual Special Tool(s)
Worldwide Diagnostic System
(WDS)
418-
F224,
New Generation STAR (NGS)
Tester
418- F052, or equivalent scan
tool 73 Digital Multimeter
105-
R0051 or equivalent
Visual Inspection Chart Mechanical Electrical
z
Ignition key
z Ignition switch
z Multifunction switch
z Turn signal switch
z Hazard/flasher switch z
Battery junction box (BJB) Fuses:
„(3) IGN (40A)
z Central junction box (CJB) Fuses:
„6 (25A)
„ 39 (5A)
z Damaged wiring harness
z Loose or corroded connections Klj . 1 ba
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check the connections to the vehicle.
z check the ignition switch position.
4. If the scan tool still does not communicate with the vehicle, refer to the scan tool manual.
5. Carry out the DATA LINK DIAGNOSTIC TEST. If the scan tool responds with: zCKT914, CKT915 or CKT70 =ALL ECUS NO RESP/NOT EQUIP, refer to Section 418 -
00 .
z NO RESP/NOT EQUIP for GEM, go to Pinpoint Test A.
z SYSTEM PASSED, retrieve and record the continuous diagnostic trouble codes (DTCs),
erase the continuous DTCs and carry out self- test diagnostics for the GEM.
6. If the DTCs retrieved are related to the concern, go to the GEM Diagnostic Trouble Code (DTC) Index to continue diagnostics.
7. If no DTCs related to the concern are retrieved, proceed to the Symptom Chart to continue diagnostics.
GEM Diagnostic Trouble Code (DTC) Index GEM Diagnostic Trouble Code (DTC) Index DTC Description Source Action
B1217 Horn Relay Coil Circuit Failure GEM REFER to
Section 413 - 06 .
B1218 Horn Relay Coil Circuit Short to
Vbatt GEM REFER to
Section 413 - 06 .
B1312 Lamp Headlamp Input Circuit
Short to Battery GEM REFER to
Section 417 - 01 .
B1317 Battery Voltage High GEM REFER to
Section 414 - 00 .
B1318 Battery Voltage Low GEM REFER to
Section 414 - 00 .
B1322 Driver Door Ajar Circuit Short to
Ground GEM REFER to
Section 417 - 02 .
B1330 Passenger Door Ajar Circuit
Short to Ground GEM REFER to
Section 417 - 02 .
B1334 Decklid Ajar Rear Door Circuit
Short to Ground GEM REFER to
Section 417 - 02 .
B1339 Chime Input Request Circuit
Short to Battery GEM REFER to
Section 413 - 09 .
B1340 Chime Input Request Circuit
Short to Ground GEM REFER to
Section 413 - 09 .
B1342 ECU Is Defective GEM CLEAR the DTC. Retrieve the DTCs. If DTC
B1342 is retrieved, INSTALL a new GEM. REFER to Section 419 - 10 .
B1353 Ignition Key-
In Circuit Open GEM REFER to
Section 413 - 09 .
B1359 Ignition Run/Acc Circuit Failure GEM GO to
Pinpoint Test E .
B1396 Power Door Lock Circuit Short
to Battery GEM REFER to
Section 501 - 14B .
B1397 Power Door Unlock Circuit
Short to Battery GEM REFER to
Section 501 - 14B . Klj . 2 ba
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B1405 Driver Power Window Down
Circuit Short to Battery GEM REFER to
Section 501 - 11 .
B1408 Driver Power Window Up
Circuit Short to Battery GEM REFER to
Section 501 - 11 .
B1410 Driver Power Window Motor
Circuit Failure GEM REFER to
Section 501 - 11 .
B1426 Lamp Safety Belt Circuit Short
to Battery GEM REFER to
Section 413 - 01 .
B1428 Lamp Safety Belt Circuit Failure GEM REFER to
Section 413 - 01 .
B1431 Wiper Brake/Run Relay Circuit
Failure GEM REFER to
Section 501 - 16 .
B1432 Wiper Brake/Run Relay Circuit
Short to Battery GEM REFER to
Section 501 - 16 .
B1434 Wiper Hi/Low Speed Relay Coil
Circuit Failure GEM REFER to
Section 501 - 16 .
B1436 Wiper Hi/Low Speed Relay Coil
Circuit Short to Battery GEM REFER to
Section 501 - 16 .
B1438 Wiper Mode Select Switch
Circuit Failure GEM REFER to
Section 501 - 16 .
B1441 Wiper Mode Select Switch
Circuit Short to Ground GEM REFER to
Section 501 - 16 .
B1446 Wiper Park Sense Circuit
Failure GEM REFER to
Section 501 - 16 .
B1448 Wiper Park Sense Circuit Short
to Battery GEM REFER to
Section 501 - 16 .
B1450 Wiper Wash/Delay Switch
Circuit Failure GEM REFER to
Section 501 - 16 .
B1453 Wiper Wash/Delay Switch
Circuit Short to Ground GEM REFER to
Section 501 - 16 .
B1458 Wiper Washer Pump Motor
Relay Circuit Failure GEM REFER to
Section 501 - 16 .
B1460 Wiper Washer Pump Motor
Relay Coil Circuit Short to Battery GEM REFER to
Section 501 - 16 .
B1462 Safety Belt Switch Circuit
Failure GEM REFER to
Section 413 - 09 .
B1466 Wiper Hi/Low Speed Not
Switching GEM REFER to
Section 501 - 16 .
B1473 Wiper Low Speed Circuit Motor
Failure GEM REFER to
Section 501 - 16 .
B1476 Wiper High Speed Circuit Motor
Failure GEM REFER to
Section 501 - 16 .
B1551 Decklid Release Circuit Failure GEM REFER to
Section 501 - 14B .
B1553 Decklid Release Circuit Short
to Battery GEM REFER to
Section 501 - 14B .
B1555 Ignition Run/Start Circuit
Failure GEM GO to
Pinpoint Test D .
B1687 Lamp Dome Input Circuit Short
to Battery GEM REFER to
Section 417 - 02 .
B2486 LF Side Repeater Lamp Output GEM REFER to
Section 417 - 01 . Klj . 3 ba
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Symptom Chart
Pinpoint Tests
PINPOINT TEST A: NO COMMUNICATION WITH THE GENERIC
ELECTRONIC MODULE Circuit Failure
B2488 RF Side Repeater Lamp Output
Circuit Failure GEM REFER to
Section 417 - 01 .
C1189 Brake Fluid Level Sensor Input
Short Circuit to Ground GEM REFER to
Section 413 - 01 .
C1223 Lamp Brake Warning Output
Circuit Failure GEM REFER to
Section 413 - 01 .
C1225 Lamp Brake Warning Output
Circuit Short to Battery GEM REFER to
Section 413 - 01 .
Symptom Chart Condition
Possible Sources Action
z No communication with
the generic electronic
module z
CJB Fuse 39
(5A).
z Circuitry.
z GEM. z
Go To Pinpoint Test A .
z The ignition switch is
inoperative z
BJB Fuse IGN
SW (40A).
z Ignition switch.
z Circuitry. z
Go To Pinpoint Test B .
z No power in ACC zIgnition switch.
z Circuitry. z
Go To Pinpoint Test C .
z No power in RUN zIgnition switch.
z Circuitry. z
Go To Pinpoint Test D .
z No power in START zIgnition switch.
z Circuitry. z
Go To Pinpoint Test E .
z The multifunction
switch/hazard switch
does not operate
correctly z
Multifunction
switch. z
Carry out the multifunction
switch component test.
REFER to Wiring Diagrams,
Cell 149, Component
Testing. Test Step Result / Action to Take
CAUTION: Use the correct probe adapter(s) when making measurements. Filaure to
use the correct probe adapter(s) may damage the connector. A1 CHECK THE GENERIC ELECTRONIC MODULE (GEM)
POWER SUPPLY z
Key in OFF position.
z Disconnect: Generic Electronic Module (GEM) C201a. Yes
GO to
A2 . Klj . 4 ba
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PINPOINT TEST B: THE IGNITION SWITCH IS INOPERATIVE z
Disconnect: GEM C201b.
z Key in ON position.
z Using the following table. measure the voltage between the
GEM, harness side and ground.
z Are the voltages greater than 10 volts? Connector Pin Circuit
C201a 2 400 (LB/BK)
C201a 3 1006 (DG/WH)
C201b 1 1001 (WH/YE)
C201b 4 193 (YE/LG) No
REPAIR the circuit(s) in
question. TEST the system
for normal operation.
A2 CHECK THE GEM GROUND CIRCUIT 397 (BK/WH) FOR
OPEN z
Key in OFF position.
z Measure the resistance between the GEM C201b pin 2,
circuit 397 (BK/WH), harness side and ground.
z Is the resistance less than 5 ohms? Yes
GO to
A3 .
No
REPAIR the circuit(s) in
question. TEST the system
for normal operation. A3 CHECK CIRCUIT 397 (BK/WH) FOR SHORT TO POWER
z
Measure the voltage between GEM C201b pin 2, circuit 397
(BK/WH), harness side and ground.
z Is any voltage present? Yes
REPAIR the circuit. TEST
the system for normal
operation.
No
REFER to
Section 418 - 00 .
Test Step Result / Action to Take
B1 CHECK THE IGNITION SWITCH
z
Carry out the ignition switch component test.
REFER to Wiring Diagrams Cell 149,
Component Testing.
z Is the ignition switch OK ? Yes
INSTALL a new BJB. TEST the system for
normal operation. Klj . 5 ba
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PINPOINT TEST C: NO POWER IN ACC
PINPOINT TEST D: NO POWER IN RUN
PINPOINT TEST E: NO POWER IN START No
INSTALL a new ignition switch. REFER to
Ignition Switch
. TEST the system for
normal operation. Test Step Result / Action to Take
C1 CHECK THE RADIO FOR NORMAL OPERATION
z
Key in ON position.
z Check the radio for normal operation.
z Does the radio operate correctly? Yes
GO to
C2 .
No
Go To Pinpoint Test D .
C2 CHECK THE VOLTAGE AT THE IGNITION SWITCH
z
Disconnect: Ignition Switch C250 .
z Measure the voltage between ignition switch C250 Pin B5,
Circuit 1050 (LG/VT), harness side and ground.
z Is the voltage greater than 10 volts? Yes
INSTALL a new ignition
switch. REFER to
Ignition Switch . TEST the system for
normal operation.
No
REPAIR the circuit. TEST the
system for normal operation. Test Step Result / Action to Take
D1 CHECK THE IGNITION SWITCH
z
Carry out the ignition switch component test.
REFER to Wiring Diagrams Cell 149,
Component Testing.
z Is the ignition switch OK ? Yes
INSTALL a new BJB. TEST the system for
normal operation.
No
INSTALL a new ignition switch. REFER to
Ignition Switch
. TEST the system for
normal operation. Test Step Result / Action to Take
E1 CHECK THE VOLTAGE TO THE IGNITION SWITCH
z
Key in OFF position.
z Disconnect: Ignition Switch C250 . Yes
GO to
E2 . Klj . 6 ba
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