2003 FORD MUSTANG power steering

Component Tests
Drive Belt Noise/Flutter
Drive belt chirp occurs due to pulley misalignment or excessive pulley runout. It can be the result of a
damaged pulley or an incorrectly aligned pulley.
To correct, determine the area where the noise comes from. Check each of the pulleys in that area
with a straightedge to the crankshaft pulley, looking for accessory pulleys out of position in the fore/aft
direction or at an angle to the straightedge.
Drive belt squeal is an intermittent noise that occurs when the drive belt slips on a pulley during certain
conditions, such as: engine start up, rapid engine acceleration, or A/C clutch engagement.
Drive belt squeal can occur:
zif any of the accessories are damaged, have a worn or damaged bearing, internal torsional
resistance above normal. All accessories should be rotatable by hand in the unloaded condition.
If not, inspect the accessory.
z if fluid gets on the drive belt. This includes power steering fluid, engine coolant, engine oil or air
conditioning system lubricant. If fluid does get on the drive belt during service, clean the drive
belt with soap and water and thoroughly rinse with clean water.
z NOTE: The drive belt tensioner arm should rotate freely without binding.
if the drive belt is too long. A drive belt that is too long will allow the drive belt tensioner arm to
go all the way to the arm travel stop under certain load conditions, which will release tension to
the drive belt. If the drive belt tensioner indicator is outside the installation wear range window,
install a new drive belt.
z if the drive belt tensioner is worn or damaged.
Belt Tension
NOTE: Drive belt tension is not adjustable.
The drive belt tensioner automatically adjusts drive belt tension. Symptom Chart Condition
Possible Sources Action
z Drive belt
noise, chirping,
flutter z
Defective/worn drive
belt.
z Misaligned pulley.
z Pulley runout.
z Damaged
accessories.
z Fluid contamination
of drive belt. z
GO to Component Tests, Drive
Belt, Noise/Flutter.
z Damaged or worn
drive belt tensioner. z
GO to Component Tests, Belt
Tensioner, Automatic.
z Premature
drive belt wear z
Defective drive belt.
z Misaligned pulley.
z Pulley runout.
z Damaged
accessories.
z Incorrectly installed
drive belt. z
GO to Component Tests, Drive
Belt Noise/Flutter and Drive
Belt Misalignment diagnosis. Klj . 2 ba
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SPECIFICATIONS
SECTION 303-
14: Electronic Engine Controls 2003 Mustang Workshop Manual General Specifications
Item Specification
Lubricants
Super premium SAE 5W-
20 Engine Oil XO-5W20-DSP WSS-
M2C914- A Penetrating and Lock Lubricant E8AZ-19A501-
B N/A
Pipe Sealant with Teflon D8AZ-19554-
A WSK-
M26350- A2
Torque Specifications Description Nm lb-
ft lb-
in Cylinder head temperature (CHT) sensor —
3.8L 10 — 89
Engine coolant temperature (ECT) sensor —
4.6L (2V) 20 — 15
Engine coolant temperature (ECT) sensor —
4.6L (4V) 24 18 —
Heated oxygen sensors (HO2S) 41 30 —
Catalyst monitor sensors 41 30 —
Crankshaft position (CKP) sensor bolts —
3.8L 6 — 53
Crankshaft position (CKP) sensor bolts —
4.6L 10 — 89
Power steering reservoir bolts 10 — 89
Camshaft position (CMP) sensor bolt —
4.6L 10 — 89
PCM connector to module bolt 6 — 53
Idle air control (IAC) valve bolts 10 — 89
Camshaft synchronizer housing bolt 25 18 —
Throttle position (TP) sensor screws 3 — 27
Fuel pressure sensor bolts 4 — 35
Air intake scoop bolts 25 18 —
Air intake scoop bracket bolt 25 18 —
Air intake scoop bracket nuts 25 18 —
Air intake scoop bracket throttle body nut 9 — 80
Exhaust gas recirculation (EGR) vacuum regulator solenoid bolts 10 — 89 Klj . 1 ba
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REMOVAL AND INSTALLATION
Camshaft Position (CMP) Sensor —
4.6L
Removal and Installation 1. Disconnect the battery ground cable. For additional information, refer to Section 414 - 01 .
2. Remove the bolts and position aside the power steering pump reservoir.
3. Remove the camshaft position (CMP) sensor. zDisconnect the connector.
z Remove the bolt and the sensor.
4. To install, reverse the removal procedure.
SECTION 303-
14: Electronic Engine Controls 2003 Mustang Workshop Manual Klj . 1 ba
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z
Other
component
leaking. z
IDENTIFY leaking fluid
as engine, power
steering, or transmission
fluid. REPAIR as
necessary.
z False report. zREMOVE all traces of
lube on the exposed
transmission surfaces.
CHECK the vent for free
breathing. OPERATE
the transmission and
INSPECT for new
leakage. REPAIR as
necessary. REFER to
Section 308 - 03A or
Section 308 - 03B .
z Internal
components. z
INSPECT for leaks at
the input shaft bearing
retainer seal and the
shift rail expansion plug.
REFER to Section 308 -
03A or
Section 308 -
03B . INSPECT for leaks
at the top cover gasket.
INSPECT the case for
sand holes or cracks.
REPAIR or INSTALL a
new case as necessary.
REFER to Section 308 -
03A or
Section 308 -
03B .
z Fill and drain
plugs. z
CHECK fill and drain
plugs and bore threads.
REPAIR as necessary.
TIGHTEN plugs to
specified torque value.
REFER to Section 308 -
03A or
Section 308 -
03B .
z Bearing failure zOther part
failure.
z Raceways or
rollers.
z Lubricant.
z Towing vehicle
further than 80
km (50 miles)
with driveshaft
installed.
Mainshaft
tapered bearing
and needle
caged bearings
are especially
susceptible to
damage. z
REMOVE,
DISASSEMBLE and
CLEAN the
transmission. Inspect for
damaged parts and
install new components
as necessary. (Note:
RESET the bearing
preload if any new
tapered bearings are
installed). REFER to
Section 308 - 03A or
Section 308 - 03B .
z Vibration break-
up of retainer
and brinelling of
races.
z Bearing(s). z
DETERMINE the cause
of vibration and
CORRECT. Otherwise
PROCEED as above. Klj . 6 ba
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DIAGNOSIS AND TESTING
Speed Control
Refer to Wiring Diagrams Cell
31 , Speed Control for schematic and connector information.
Principles of Operation
The speed control system is designed to maintain vehicle speed above 48 km/h (30 mph). After the
ON switch is depressed, depressing the SET/ACCEL switch will activate the speed control servo. To
increase a set speed, either depress and hold for continuous acceleration, or momentarily tap the
SET/ACCEL switch for 1.6 km/h (1 mph) acceleration increments. To decrease a set speed, depress
and hold the COAST switch until the target speed is reached, or momentarily tap the COAST switch
for 1.6 km/h (1 mph) deceleration increments. When the speed control system has been disabled by
tapping the brake pedal, the RESUME switch can be depressed and the vehicle will return to the
original set speed if the vehicle is traveling over 48 km/h (30 mph) and the OFF switch has not been
depressed.
NOTE: The deactivator switch is provided as an additional safety feature. Normally, when the brake
pedal is depressed, an electrical signal from the brake lamp circuit to the speed control servo will
deactivate the system. Under increased brake pedal effort, the deactivator switch will open and
remove power to the speed control servo, releasing the throttle independent of the speed control
servo.
NOTE: The air bag sliding contract provides the electrical interface between the steering column wiring
and the speed control actuator switches in the steering wheel.
The inputs to the speed control servo are the:
zvehicle speed signal.
SECTION 310-
03: Speed Control 2003 Mustang Workshop Manual Special Tool(s)
Worldwide Diagnostic System
(WDS)
418-
F224,
New Generation STAR (NGS)
Tester
418- F052, or equivalent
diagnostic tool 73 Digital Multimeter or
equivalent
105-
R0051 Breakout Box, EEC-V Control
System 418-049, or equivalent
014- 00950 Klj . 1 ba
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The boost pressure gauge on the instrument cluster receives and measures the boost pressure
directly from the intake manifold. The boost pressure gauge will display between 0.0-
0.48 kpa (0.0-10
psi) boost pressure dependent upon accelerator position, engine load, and engine rpm.
LOW FUEL Level Indicator
The low fuel level indicator is hardwired from the fuel sender to the instrument cluster. The instrument
cluster will illuminate the low fuel indicator when the usable fuel quantity is less than 1/8 tank (15%) of
fuel tank capacity.
Oil Pressure Gauge
The oil pressure gauge is hardwired from the oil pressure switch to the instrument cluster. The oil
pressure gauge will indicate either normal or no oil pressure.
CHECK FUEL CAP
The CHECK FUEL CAP indicator is used to indicate significant leaks in the fuel tank evaporative
system due to a loose fuel cap. Fuel tank pressure is monitored by the PCM. If a leak is detected the
PCM signals a fault to the instrument cluster via the SCP network. Once the PCM has detected a
loose fuel cap and the CHECK FUEL CAP indicator is illuminated, the indicator will remain illuminated
until the fuel cap is secured and the vehicle has been running for several minutes. For additional
information, refer to the Powertrain Control/Emissions Diagnosis (PC/ED) manual.
BRAKE Warning Indicator
The BRAKE warning indicator activates when the generic electronic module (GEM) detects the ignition
switch circuits are in the RUN state, when the GEM detects low brake fluid level, or that the parking
brake is applied. The BRAKE warning indicator will prove out starting when the GEM detects that the
ignition circuits have made a transition to RUN or START from OFF, ACC, or keyout and ending when
either three seconds have elapsed or when the GEM detects the ignition circuits have made a
transition to OFF, ACC, or keyout.
Safety Belt Warning Indicator
The safety belt switch is hardwired to the GEM. The safety belt warning indicator will be illuminated
when the GEM sends a ground signal to the instrument cluster.
ABS Warning Indicator
The ABS warning indicator will be illuminated when the anti- lock brake control module sends a ground
signal to the instrument cluster. The prove- out of the ABS indicator is controlled by the anti- lock brake
control module.
SERVICE ENGINE SOON Indicator
The SERVICE ENGINE SOON indicator receives its signal from the PCM over the SCP network. If the
instrument cluster does not receive a message from the PCM within five seconds, the instrument
cluster will illuminate the SERVICE ENGINE SOON indicator and log a diagnostic trouble code (DTC).
High Beam Indicator
The high beam indicator will illuminate when the steering column multifunction switch is in the high
beam position by sending a battery signal to the instrument cluster. Right and Left Turn Indicator Klj . 3 ba
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PINPOINT TEST T: THE TURN/HAZARD INDICATOR IS
NEVER/ALWAYS ON CLUSTER SERVICE ENGINE SOON
INDICATOR ACTIVE COMMAND
z
Connect the diagnostic tool.
z Key in ON position.
z Enter the following diagnostic mode
on the diagnostic tool: Instrument
Cluster Active Command.
z Trigger the instrument cluster active
command MIL.
z Did the SERVICE ENGINE SOON
indicator illuminate? Yes
REFER to the Powertrain Control/Emissions
Diagnosis (PC/ED) manual.
No
GO to
S2 .
S2 CHECK FOR CORRECT
INSTRUMENT CLUSTER OPERATION z
Disconnect all instrument cluster
connectors.
z Check for:
zcorrosion
z pushed- out pins
z Connect all instrument cluster
connectors and make sure they seat
correctly.
z Operate the system and verify the
concern is still present.
z Is the concern still present? Yes
INSTALL a new instrument cluster. REFER to
Instrument Cluster
in this section. TEST the
system for normal operation.
No
The system is operating correctly at this time.
Concern may have been caused by a loose or
corroded connector. CLEAR the DTCs. REPEAT
the self- test. Test Step Result / Action to
Take T1 CHECK THE TURN SIGNAL AND HAZARD LAMPS OPERATION
CAUTION: Use the correct probe adapter(s) when making
measurements. Failure to use the correct probe adapter(s) may
damage the connector.
z Key in ON position.
z Operate the left and right turn signals.
z Operate the hazard lamps.
z Do the turn signals and hazard lamps operate correctly? Yes
GO to
T2 .
No
REFER to Section 417 - 01 .
T2 CHECK THE CIRCUIT IN QUESTION —
CIRCUIT 2 (WH/LB) (RH)
OR CIRCUIT 3 (LG/WH) (LH) z
Key in OFF position.
z Disconnect: Instrument Cluster C220a (RH) or C220b (LH).
z Key in ON position.
z Measure the voltage between the instrument cluster C220a pin 3,
circuit 3 (LG/WH), harness side and ground, while the steering
column multifunction switch is placed in the left turn position (LH); or
between the instrument cluster C220b pin 3, circuit 2 (WH/LB),
harness side and ground, while the steering column multifunction
switch is placed in the right turn position (RH). Yes
GO to
T3 .
No
REPAIR the circuit
(s) in question.
TEST the system for
normal operation. Klj . 36 ba
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DIAGNOSIS AND TESTING
Communications Network
Refer to Wiring Diagrams Cell
14 , Multiplex Communication Network for schematic and connector
information.
Principles of Operation
The vehicle has two module communications networks. The standard corporate protocol (SCP) which
is an unshielded twisted pair cable (data bus plus, Circuit 914 [TN/OG] and data bus minus, Circuit 915
[PK/LB]), and the international standards organization (ISO) 9141 network which is a single wire
(Circuit 70 [LB/WH]). The diagnostic tool can connect to both networks through the data link connector
(DLC). This makes diagnosis and testing of these systems easier by allowing one smart tester to be
able to diagnose and control any module on the two networks from one connector. The DLC can be
found under the instrument panel between the steering column and the radio.
The ISO 9141 communication network does not permit inter- module communication. When the
diagnostic tool communicates to modules on the ISO 9141 communication network, the diagnostic tool
must ask for all information; the modules cannot initiate communications.
The SCP network will remain operational even with the severing of one of the bus wires.
Communications will also continue if one of the bus wires is shorted to ground or battery positive
voltage (B+) or if some, but not all, termination resistors are lost.
Unlike the SCP communication network, the ISO 9141 communication network will not function if the
wire is shorted to chassis ground or battery positive voltage (B+). Also, if one of the modules on the
ISO 9141 network loses power or shorts internally, communications to that module will fail.
The powertrain control module (PCM) is on the SCP communication network. The PCM controls the
engine for better fuel economy, emissions control, and failure mode detection and storage. Refer to
Powertrain Control/Emissions Diagnosis (PC/ED) manual Section 3 for diagnosis and testing of the
PCM.
The restraint control module (RCM) is on the ISO 9141 network. The RCM controls the deployment of
the air bags based on sensor input. For additional information, refer to Section 501 - 20B .
SECTION 418-
00: Module Communications Network 2003 Mustang Workshop Manual Special Tool(s)
73 Digital Multimeter or
equivalent
105-
R0051 Worldwide Diagnostic System
(WDS)
418-
F224,
New Generation STAR (NGS)
Tester
418- F052, or equivalent
diagnostic tool Klj . 1 ba
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