2003 FORD MUSTANG vacuum

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.
z 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 DIAGNOSTICS test. If the scan tool responds with:
z CKT914, CKT915 or CKT70 = ALL ECUS NO RESP/NOT EQUIP, refer to Section 418 - 00 .
z NO RESP/NOT EQUIP for PCM, refer to the Powertrain Control/Emissions Diagnosis (PC/ED)
manual.
z SYSTEM PASSED, retrieve and record the continuous diagnostic trouble codes (DTCs), erase
the continuous DTCs and carry out the PCM KOEO self- test.
6. If the DTCs retrieved are related to the concern, go to the PCM Diagnostic Trouble Code (DTC) Index to continue diagnostics.
7. If the concern remains after the inspection, determine the symptom. GO to Symptom Chart .
PCM Diagnostics Trouble Code (DTC) Index
Symptom Chart z
EVAP lines or hoses
z Vacuum lines or hoses DTC Description Source Action
P0442 Small leak detected in EVAP system
(As small as 1.02 mm [0.040 inch]) PCM Go To Pinpoint Test A .
P0455 Major leak or no flow detected PCM Go To Pinpoint Test B .
P0457 Check for missing or leaking fuel filter
cap PCM Go To Pinpoint Test A .
P1443 Very small or no purge flow detected PCM Go To Pinpoint Test B .
P1450 Excessive vacuum detected in the fuel
tank PCM Go To Pinpoint Test C .
— Any other PCM DTC PCM REFER to the Powertrain
Control/Emissions Diagnosis (PC/ED)
manual.
SYMPTOM CHART Condition
Possible Sources Action
z Hissing sound when
removing fuel cap z
Canister vent solenoid.
z Evaporative emissions
canister.
z Fuel vapor control valve z
Go To Pinpoint Test D . Klj . 4 ba
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PINPOINT TEST B: DTC P0455 MAJOR LEAK OR NO FLOW
DETECTED OR DTC P1443 VERY SMALL OR NO PURGE FLOW
DETECTED IN SYSTEM Procedure in this section.
z Pressurize the EVAP system to 3.48
kPa (14 inches H
2 O).
z Using the ultrasonic leak detector,
check the fuel vapor control valve tube
to the fuel tank for leaks. Check the
fuel tank pressure sensor, fuel vapor
control valve tube and the fuel filler
pipe. Check fuel tank to EVAP canister
-canister vent solenoid.
z Is a leak detected? A10 CHECK EVAP SYSTEM AT FUEL
FILLER PIPE z
Reconnect the EVAP canister purge
outlet tube to the fuel vapor tee.
z Complete the evaporative emission
system leak test. Refer to Evaporative Emission System Leak Test in this
section.
z Does the EVAP system pass the
leak test? Yes
RESTORE the system to normal operation.
CARRY OUT the evaporative emission system
leak test. REFER to
Evaporative Emission System Leak Test in this section. If the system
passes the leak test, CARRY OUT the
evaporative emissions repair verification drive
cycle. REFER to Evaporative Emission Repair Verification Drive Cycle in this section.
No
GO to A6 .
Test Step Result / Action to Take
NOTE:
Condition DTC P0455 set: – 1.74 kPa (-7.0 inches H
2 O) over 30 seconds. NOTE:
Condition DTC P1443 set: – 1.74 kPa (-7.0 inches H
2 O) over 30 seconds with more than
0.02 lb/min vapor flow. B1 CHECK FOR DIAGNOSTIC
TROUBLE CODE P0455 OR
P1443 z
Use the recorded results
from the PCM DTCs.
z Is DTC P0455 present? Yes
GO to
B2 .
No
GO to B3 .
B2 VISUALLY CHECK FOR
GROSS EVAP SYSTEM LEAKS z
Check for the presence of a
fuel filler cap. Do not tighten
or check for correct
installation at this time.
z Check the input port
vacuum and EVAP return
tube are connected to the
EVAP canister purge valve.
z Check that the canister vent
solenoid is correctly
attached to the EVAP Yes
REPAIR or INSTALL new EVAP components as necessary.
GO to
B3 .
No
GO to B3 . Klj . 8 ba
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PINPOINT TEST C: DTC P1450 EXCESSIVE VACUUM DETECTED IN
THE FUEL TANK Tester to the fuel filler pipe.
z Pressurize the EVAP
system to 6.47 to 6.97 kPa
(26 to 28 inches H
2 O).
z Does the pressure drop
immediately? No
INSTALL new fuel tank vapor line(s). REPEAT pinpoint test
Step B5 to verify the repair. CARRY OUT the evaporative
emission system leak test. REFER to
Evaporative Emission System Leak Test in this section. If the system passes the
leak test, CARRY OUT the evaporative emission repair
verification drive cycle. REFER to Evaporative Emission Repair Verification Drive Cycle in this section.
B6 CHECK FOR FAILED EVAP
CANISTER PURGE VALVE OR
FUEL TANK PRESSURE
SENSOR z
Use the recorded results
from the PCM DTCs.
z Are DTC codes P0455 and
P1443 present? Yes
INSTALL a new EVAP canister purge valve. REFER to
Evaporative Emission Canister Purge Valve
in this section.
CARRY OUT the evaporative emission system leak test.
REFER to Evaporative Emission System Leak Test in this
section. If no leak is detected, CARRY OUT the evaporative
emissions repair verification drive cycle. REFER to
Evaporative Emission Repair Verification Drive Cycle in this
section.
No
INSTALL a new fuel tank pressure sensor. REFER to Fuel Tank Pressure Sensor in this section. CARRY OUT the
evaporative emission system leak test. REFER to
Evaporative Emission System Leak Test in this section. If
the system passes the leak test, CARRY out the
evaporative emission repair verification drive cycle. REFER
to Evaporative Emission Repair Verification Drive Cycle in
this section. Test Step Result / Action to Take
NOTE:
Condition P1450 DTC set: more than - 1.79 kPa (-7.2 inches H
2 O) over 30 seconds. C1 CHECK FOR VISUAL CAUSES OF EXCESSIVE
FUEL TANK VACUUM z
Check for kinks or bends in the fuel vapor hoses
and tubes.
z Visually check the EVAP canister inlet port,
canister vent solenoid filter or outlet hose for
contamination or foreign material.
z Check the canister vent solenoid for blockage or
contamination.
z Is a concern with a hose, tube, connection or
component visually evident? Yes
REMOVE any contamination or foreign
material around fuel vapor hoses and
tubes. REPAIR the hoses, tubes or
components as necessary. After all
visual concerns are repaired, GO to
C2
.
No
GO to C2 .
C2 CHECK FOR BLOCKAGE BETWEEN EVAP
TEST PORT AND CANISTER VENT SOLENOID z
Disconnect and plug the EVAP return tube at the
intake manifold.
z Connect the Evaporative Emissions System Leak
Tester to the EVAP test port. Yes
GO to
C3 .
No Klj . 10 ba
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REMOVAL AND INSTALLATION
Evaporative Emission Canister Purge Valve
Removal and Installation
1. WARNING: The evaporative emission system contains fuel vapor and condensed
fuel vapor. Although not 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. Failure to follow these instructions may result in personal
injury.
Disconnect the battery ground cable. For additional information, refer to Section 414 - 01 .
2. Raise and support the vehicle. For additional information, refer to Section 100 - 02 .
3. Remove the RH front wheel. For additional information, refer to Section 204 - 04 .
4. Remove the right front splash shield. 1. Remove the three screws.
2. Remove the five pin- type retainers.
5. Disconnect the connector.
6. Disconnect the main emission vacuum control connector.
SECTION 303-
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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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DESCRIPTION AND OPERATION
Electronic Engine Controls —
Cobra
Most of the Cobra engine electronic controls are similar to that of the non- supercharged 4.6L (2V)
engine. These components are as follows:
zCrankshaft position (CKP) sensor
z Throttle position (TP) sensor
z Idle air control (IAC) valve
z Mass air flow (MAF) sensor
z Heated oxygen sensors (HO2S)
z Engine coolant temperature (ECT) sensor
There are also three controls that are unique to the Cobra engine. These are as follows:
zIntegrated temperature and manifold absolute pressure (T- MAP) sensor
z Supercharger bypass vacuum solenoid
z Supercharger bypass vacuum solenoid — actuator
Supercharger Bypass Vacuum Solenoid and Actuator
The Supercharger bypass vacuum solenoid will bleed off boost under the following conditions:
zheavy engine misfire
z engine coolant over- temperature
z loss of intercooler fluid
z pump failure
This prevents damage that can occur if boost were allowed under these conditions. The solenoid is
located on the upper LH side of the engine. The solenoid uses engine vacuum to operate a actuator
and linkage that connects to the pressure bleed off valve. The actuator is located near the solenoid
and is connected to it by a vacuum line.
Integrated Temperature and Manifold Absolute Pressure (TMAP) Sensor
The TMAP sensor is located on the upper LH side of the engine and is used to measure current
manifold absolute pressure and manifold air charge temperature. SECTION 303-
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REMOVAL AND INSTALLATION
Mass Air Flow (MAF) Sensor —
Cobra
Removal and Installation 1. Disconnect the intake air temperature (IAT) sensor.
2. Disconnect the breather hose.
3. Disconnect the vacuum hose. 4. Loosen the clamps and remove the air cleaner outlet pipe. SECTION 303-
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REMOVAL AND INSTALLATION
Fuel Pressure Sensor
Removal
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. Failure to follow these instructions may result in personal injury.
WARNING: Fuel in the fuel system remains under high pressure even when the engine is
not running. Before working on or disconnecting any of the fuel lines or fuel system
components, the fuel system pressure must be relieved. Failure to follow these instructions
may result in personal injury.
Mach I
1. Remove the air intake scoop. For additional information, refer to Section 303 - 12 .
All engines 2. Relieve the fuel pressure. For additional information, refer to Section 310 - 00 .
3. NOTE: The 4.6L (4V) Cobra engine is shown, the other engines are similar.
Disconnect the connector and the vacuum line. 4. Remove the bolts and the sensor. SECTION 303-
14: Electronic Engine Controls 2003 Mustang Workshop Manual Material
Item Specification
Super Premium SAE 5W-20
Motor Oil
XO- 5W20- DSP or equivalent WSS-
M2C914-
A Klj . 1 ba
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