2003 FORD MUSTANG warning

GENERAL PROCEDURES
Pressure Relief
WARNING: Do not smoke or carry lighted tobacco or open flame of any type when
working on or near any fuel- related components. Highly flammable mixtures are always present
and may be ignited, resulting in possible personal injury.
WARNING: Fuel in the fuel system remains under high pressure even when the engine is
not running. Before servicing or disconnecting any of the fuel lines or fuel system components,
the fuel system pressure must be relieved to prevent accidental spraying of fuel, causing
personal injury or a fire hazard.
1. Remove the Schrader valve cap and install the Fuel Pressure Gauge.
2. CAUTION: Open the manual valve slowly on the Fuel Pressure Gauge.
Relieve the fuel pressure. zPlace the fuel in a suitable container.
SECTION 310-
00: Fuel System — General Information 2003 Mustang Workshop Manual Special Tool(s)
Fuel Pressure Gauge
310-
012 (T80L-9974- B) Klj . 1 ba
22003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_2308/S3B~us~en~ ...

GENERAL PROCEDURES
Fuel Tank Draining
WARNING: Do not smoke or 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, resulting in possible personal injury.
1. Disconnect the battery ground cable. For additional information, refer to Section 414 - 01 .
2. Remove the fuel tank filler cap.
3. Insert the hose guide into the filler neck.
4. NOTE: Insert the hose until the stop contacts the guide tube. If the stop does not contact the
guide tube, remove the hose and repeat the procedure.
Insert the chamfered end of the hose into the filler neck through the guide tube.
SECTION 310-
00: Fuel System — General Information 2003 Mustang Workshop Manual Special Tool(s)
Fuel Storage Tanker
164-R3202 or equivalent
Fuel Tank Drain Hose
310-
F013 Klj . 1 ba
22003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_2308/S3B~us~en~ ...

GENERAL PROCEDURES
Spring Lock Couplings
Disconnect
WARNING: Do not smoke or carry lighted tobacco or open flame of any type when
working on or near any fuel- related components. Highly flammable mixtures are always present
and may be ignited, resulting in possible personal injury.
WARNING: Fuel in the fuel system remains under high pressure even when the engine is
not running. Before servicing or disconnecting any of the fuel lines or fuel system components,
the fuel system pressure must be relieved to prevent accidental spraying of fuel, causing
personal injury or a fire hazard.
1. Relieve the fuel system pressure. For additional information, refer to Pressure Relief in this
section.
2. Remove the fuel tube clip.
SECTION 310-
00: Fuel System — General Information 2003 Mustang Workshop Manual Special Tool(s)
Disconnect Tool, Spring Lock
Coupling (3/8 inch yellow)
310-
D004 (D87L-9280- A) or
equivalent Disconnect Tool, Spring Lock
Coupling (1/2 inch green)
310-
D005 (D87L-9280- B) or
equivalent
Material Item Specification
SAE 5W-
20 Super Premium
Synthetic Blend Motor Oil
XO- 5W20- QSP or equivalent WSS-
M2C153-
H Klj . 1 ba
32003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_2308/S3B~us~en~ ...

GENERAL PROCEDURES
Fuel Line Fittings —
Push Connect
Disconnect WARNING: Do not smoke or carry lighted tobacco or open flame of any type when
working on or near any fuel- related components. Highly flammable mixtures are always present
and may be ignited, resulting in possible personal injury.
WARNING: Fuel in the fuel system remains under high pressure even when the engine is
not running. Before servicing or disconnecting any of the fuel lines or fuel system components,
the fuel system pressure must be relieved to prevent accidental spraying of fuel, causing
personal injury or a fire hazard.
1. Relieve the fuel system pressure. For additional information, refer to Pressure Relief in this
section.
2. Disconnect the safety clip from the male hose.
3. Install the Fuel Line Disconnect Set and push into the fitting.
SECTION 310-
00: Fuel System — General Information 2003 Mustang Workshop Manual Special Tool(s)
Disconnect Tool, Spring Lock
Coupling
310-
S039 (T90T-9550- S)
Material Item Specification
SAE 5W-
20 Super Premium
Blend Motor Oil
XO- 5W20-QSP or equivalent WSS-
M2C153-
H Klj . 1 ba
32003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_2308/S3B~us~en~ ...

GENERAL PROCEDURES
Fittings
—R-Clip
Disconnect WARNING: Do not smoke or carry lighted tobacco or open flame of any type when
working on or near any fuel- related components. Highly flammable mixtures are always present
and may be ignited, resulting in possible personal injury.
WARNING: Fuel in the fuel system remains under high pressure even when the engine is
not running. Before servicing or disconnecting any of the fuel lines or fuel system components,
the fuel system pressure must be relieved to prevent accidental spraying of fuel, causing
possible personal injury or a fire hazard.
CAUTION: Do not use any tools. The use of tools may cause a deformity in the clip
components which may cause fuel leaks.
1. Relieve the fuel system pressure. For additional information, refer to Pressure Relief in this
section.
2. Remove the shipping tab by bending.
3. Spread the R- clip legs and push the clip into the fitting.
SECTION 310-
00: Fuel System — General Information 2003 Mustang Workshop Manual Material
Item Specification
SAE 5W-
20 Super Premium
Synthetic Blend Motor Oil
XO- 5W20- QSP or equivalent WSS-
M2C153-
H Klj . 1 ba
32003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_2308/S3B~us~en~ ...

GENERAL PROCEDURES
Fittings —
Vapor Tube
Disconnect
1. WARNING: The evaporative emission system contains fuel vapor and condensed
fuel vapor. Although not present in large quantities, it still presents the danger of
explosion or fire. Disconnect the battery ground cable from the battery to minimize the
possibility of an electrical spark occurring, possibly causing a fire or explosion if fuel
vapor or fuel liquid is present in the area.
Disconnect the battery ground cable.
2. Disconnect the vapor tube from the fitting. 1. Squeeze the fitting.
2. Disconnect the vapor tube from the fitting.
Connect 1. Clean and inspect the fitting and the tube for damage.
2. Push the tube into the fitting until it snaps in place.
3. Pull on the connection to make sure the fitting is secure.
SECTION 310-
00: Fuel System — General Information 2003 Mustang Workshop Manual Klj . 1 ba
22003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_2308/S3B~us~en~ ...

DESCRIPTION AND OPERATION
Fuel Tank And Lines
WARNING: Do not smoke, carry lighted tobacco or an open flame of any type when
working on or near any fuel- related component. Highly flammable mixtures are always present
and may be ignited, possibly resulting in personal injury.
The vehicle utilizes a returnless fuel system consisting of:
zthe fuel tank.
z a fuel tank filler pipe which contains a restrictor plate to permit only unleaded fuel to be pumped
into the fuel tank.
z a 1/8 turn fuel tank filler cap.
z a fuel filter providing filtration to protect the fuel injectors.
z a single fuel line accommodating the returnless fuel system.
z a fuel injection supply manifold which contains a differential pressure sensor and a fuel
temperature sensor.
z a fuel pump and sender assembly which provides pressurized fuel to the engine and contains:
„an inlet filter.
„ a check valve which maintains system pressure after the pump is shut off.
„ a pressure relief valve for overpressure protection in the event of restricted flow.
The fuel pump is controlled by an electronic fuel pump driver module which is enabled by the
powertrain control module (PCM). Electrical power to the fuel pump is provided through the inertia fuel
shutoff (IFS) switch, which is located in the luggage compartment. SECTION 310-
01: Fuel Tank and Lines 2003 Mustang Workshop Manual Klj . 1 ba
12003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_2308/S3B~us~en~ ...

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
52003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_2308/S3B~us~en~ ...