2003 FORD MUSTANG air filter

z
If equipped, inspect automatic transmission fluid level with dipstick.
z Inspect brake pads, shoes, rotors, drums, brake lines, hoses and parking brake system.
z Inspect wheel ends for end play and noise.
z Inspect engine cooling system and hoses.
z Inspect steering linkage, suspension and (if equipped) driveshaft and ball joints.
z Rotate tires and inspect for wear.
z Install a new cabin air filter.
z If filled with green engine coolant, change coolant.
224,000 Km (140,000 Miles)
zChange engine oil and install a new oil filter.
z Inspect tires for wear. Rotation recommended for optimal tire life.
232,000 Km (145,000 Miles)
zChange engine oil and install a new oil filter.
z Inspect tires for wear. Rotation recommended for optimal tire life.
240,000 Km (150,000 Miles)
zChange engine oil and install a new oil filter.
z Inspect brake pads, shoes, rotors, drums, brake lines, hoses and parking brake system.
z Inspect wheel ends for end play and noise.
z Inspect engine cooling system and hoses.
z Inspect exhaust system and heat shields.
z Inspect steering linkage, suspension and (if equipped) driveshaft and ball joints.
z Rotate tires and inspect for wear.
z Install a new engine air filter.
z Install a new fuel filter. (See ADDITIONAL INFORMATION below.)
z If equipped, install a new cabin air filter.
z If filled with yellow engine coolant, change coolant or at 8 years, whichever comes first.
z Change automatic transmission/transaxle fluid and filter.
z Change rear axle lubricant on all rear wheel (RWD) vehicles.
z Install a new accessory drive belt(s) (if a new belt has not been installed within the last 100,000
miles).
z If equipped, install new climate controlled seat filters (Navigator, Lincoln LS and Aviator).
ADDITIONAL INFORMATION: If vehicle is registered in California, the California Air Resources Board
(CARB) has determined that failure to install a new fuel filter at this interval will not nullify the emission
warranty or limit recall liability prior to completion of the vehicle's useful life. It is, however
recommended that maintenance checks be carried out and recorded at the indicated intervals.
Additional checks for natural gas and propane vehicles include inspecting fuel tanks, as well as
draining and installing a new filter. Klj . 9 ba
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z
Generator electrical
field or bearings. z
CARRY OUT generator
load test. REPAIR or
INSTALL a new generator
as necessary. REFER to
Section 414 - 02 .
z Drone type noise zExhaust system. zCARRY OUT the Exhaust System Neutralizing in this
section. REPAIR as
necessary.
z A/C compressor. zCHECK for noise with
vehicle at constant speeds.
CYCLE the compressor on
and off and listen for a
change in pitch. REPAIR as
necessary. REFER to
Section 412 - 03 .
z Powertrain mounts. zCARRY OUT the
Powertrain/Drivetrain Mount Neutralizing in this
section.
z Sputter type
noise— noise
worse when cold,
lessens or
disappears when
vehicle is at
operating
temperature z
Damaged or worn
exhaust system
components. z
INSPECT the exhaust
system for leaks or
damage. REPAIR as
necessary. REFER to
Section 309 - 00 .
z Rattling noise—
noise from the
upper engine
(valve train).
Worse when
engine is cold z
Low oil level. zCHECK oil level. FILL as
necessary.
z Thin or diluted oil. zINSPECT the oil for
contamination. If oil is
contaminated, CHECK for
the source. REPAIR as
necessary. CHANGE the oil
and filter.
z Low oil pressure. zCARRY OUT an oil
pressure test. If not within
specifications, REPAIR as
necessary. REFER to
Section 303 - 00 .
z Worn rocker
arms/fulcrums or
followers. z
CARRY OUT a valve train
analysis. INSTALL new
valve train components as
necessary. REFER to
Section 303 - 01A for 3.8L
engines or Section 303 - 01B
for 4.6L (2V) engines.
z Worn valve guides. zCARRY OUT a valve train
analysis. INSTALL new
valve guides as necessary.
REFER to Section 303 - 01A
for 3.8L engines or
Section 303 - 01B for 4.6L (2V)
engines. Klj . 26 ba
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flange runout.
Symptom Chart—
Transmission (Automatic) Noise/Vibration Condition
Possible Sources Action
z Rattle— occurs
at idle or at
light
acceleration
from a stop z
Damaged engine or
transmission mounts. z
CHECK the
powertrain/drivetrain mounts
for damage. REPAIR or
INSTALL new mounts as
necessary.
z A loose front exhaust
pipe heat shield. z
REPAIR or INSTALL a new
heat shield as necessary.
z Loose inspection
plate or dust cover
plate. z
CHECK for loose bolts.
TIGHTEN to specifications.
REFER to Section 307 - 01 .
z Loose flex plate to
converter nuts. z
CHECK for loose nuts.
TIGHTEN to specifications.
REFER to Section 307 - 01 .
z Whine— pitch
increases with
vehicle speed.
Starts in first
and second
gear,
decreases or
goes away at
higher gears z
Damaged or worn low
one- way clutch.
z Damaged or worn
intermediate one- way
clutch.
z Friction elements.
z Damaged or worn
planetary or sun gear. z
INSPECT the transmission
for wear or damage. REPAIR
or INSTALL new components
as necessary. REFER to
Section 307 - 01 .
z Whine— the
pitch changes
with engine
speed z
A worn or damaged
accessory drive
component. z
CARRY OUT the Engine
Accessory Test. REPAIR or
INSTALL new components as
necessary.
z Incorrect fluid level. zCHECK that the transmission
is filled to the correct level.
ADD fluid as necessary.
REFER to Section 307 - 01 .
z Partially blocked filter. zINSPECT the filter. CLEAN or
INSTALL a new filter as
necessary. REFER to Section 307 - 01 .
z Worn or damaged
torque converter. z
CARRY OUT the torque
converter service and
replacement check. REFER
to Section 307 - 01 .
z Worn or damaged
front pump. z
INSPECT the front pump.
INSTALL a new front pump
as necessary. REFER to
Section 307 - 01 .
z Whine— pitch
changes with
vehicle speed z
Speedometer cable
or gears. z
REPAIR or INSTALL new
cables or gears as necessary.
z Whine/moan
type noise—
pitch increases
or changes
with vehicle
speed z
Damaged engine or
transmission mount. z
CHECK the
powertrain/drivetrain mounts
for damage. CARRY OUT
Powertrain/Drivetrain Mount Neutralizing in this section.
z U-joints worn or zINSPECT the U- joints for Klj . 45 ba
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z
Is the ticking noise gone? CHECK for TSB for applicable vehicle.
REPAIR as necessary. TEST the system
for normal operation.
No
GO to
B2 .
B2 CHECK FOR TICKING NOISE AT THE FUEL
INJECTOR z
Using an EngineEAR, listen at the fuel
injectors by placing a probe on each injector.
To isolate the faulty injector, disconnect the
injector electrical connector and listen for the
noise.
z Is the fuel injector the source of the ticking
noise? Yes
INSTALL a new fuel injector. REFER to
Section 303
- 04A for 3.8L engines or
Section 303 - 04B for 4.6L (2V) engines.
TEST the system for normal operation.
No
GO to B3 .
B3 CHECK THE BELT TENSIONER FOR TICKING
NOISE z
Inspect the accessory drive. Check for the belt
tensioner bottoming at end of travel or not at
end of stroke.
z Using an EngineEAR, listen at the belt
tensioner.
z Is the belt tensioner the source of the
noise? Yes
INSTALL a new belt tensioner. TEST the
system for normal operation.
No
GO to
B4 .
B4 CHECK THE WATER PUMP FOR TICKING
NOISE z
Using an EngineEAR, listen at the water pump
for ticking noise.
z Is the water pump the source of the noise? Yes
INSTALL a new water pump. REFER to
Section 303
- 03A . TEST the system for
normal operation.
No
GO to B5 .
B5 CHECK FOR AN OBSTRUCTION OF THE
COOLING FAN z
Inspect the cooling fan for obstructions.
z Check the cooling fan and shroud for wear or
damage.
z Was there an obstruction or does the
cooling fan show signs of damage? Yes
REPAIR or INSTALL a new cooling fan.
REFER to
Section 303 - 03A . TEST the
system for normal operation.
No
GO to B6 .
B6 CHECK THE OIL PUMP FOR TICKING NOISE
z
Check the oil pump using EngineEARs and
probe at the oil filter adapter to verify the oil
pump as a source.
z Is the oil pump the source of the noise? Yes
INSTALL a new oil pump. REFER to
Section 303
- 01A for 3.8L engines or
Section 303 - 01B for 4.6L (2V) engines.
TEST the system for normal operation.
No
GO to B7 .
B7 CHECK VALVE LIFTERS OR LASH
ADJUSTERS FOR CORRECT OPERATION z
Check valve lifter/lash adjuster for correct
operation, using EngineEARs.
z Are the valve lifters/lash adjusters Yes
VERIFY customer concern. CONDUCT a
diagnosis of other suspect components. Klj . 50 ba
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PINPOINT TEST F: HYDRO-
BOOST ERRATIC OPERATION, STICKS,
BINDS OR GRABS z
Check accessory drive belt tension and
condition. Refer to Section 303 - 05 .
z Is the accessory drive belt OK? Yes
GO to
E3 .
No
INSTALL a new accessory drive belt.
REFER to Section 303 - 05 .
E3 CHECK POWER STEERING HOSES
z
Check power steering pressure hoses, power
steering gear pressure hoses and power
steering return hose for cracks or leaks.
z Do power steering pressure hose, power
steering gear hose and power steering
return hose check OK? Yes
GO to
E4 .
No
INSTALL new hoses as necessary.
REFER to Section 211 - 00 .
E4 CHECK BRAKE PEDAL LINKAGE
z
Check brake pedal linkage for binding or
sticking operation.
z Does pedal linkage check OK? Yes
GO to
E5 .
No
INSTALL new pedal linkage as necessary.
REFER to Section 206 - 06 .
E5 CHECK POWER STEERING PUMP SPEED
z
Check engine idle speed against
specifications.
z Is engine idle speed OK? Yes
GO to
E6 .
No
SET engine idle speed to specification.
REFER to Powertrain Control/Emissions
Diagnosis (PC/ED) manual. E6 CHECK FOR PLUGGED RETURN HOSE
z
NOTE: The return hose from the oil cooler to
the power steering reservoir has an in- line
filter in the hose.
z Disconnect power steering return hose from
power steering fluid cooler and power
steering pump reservoir.
z Pass air through hose from the oil cooler end.
z Is hose plugged? Yes
INSTALL a new power steering return
hose.
No
GO to
E7 .
E7 CHECK POWER STEERING PUMP FLOW
AND RELIEF z
Test power steering pump for correct flow
and relief pressure. Refer to Section 211 - 00 .
z Is power steering pump operating
correctly? Yes
INSTALL a new power brake hydro-
boost
unit. REFER to Section 206 - 07 .
No
INSTALL a new power steering pump.
REFER to Section 211 - 02 .
Test Step Result / Action to
Take F1 CHECK SUPPLY HOSE
z
Check for obstructions in power steering return hose and Yes Klj . 11 ba
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6. Carry out an oil consumption test:
a. Drain the engine oil, remove the oil bypass filter (6714) and refill with one liter (quart) less than
the recommended amount.
b. Run the engine for three minutes (10 minutes if cold), and allow the oil to drain back for at least five minutes with the vehicle on a level surface.
c. Remove oil level dipstick and wipe clean. (Do not wipe with anything contaminated with silicone compounds.) Reinstall the oil level dipstick, being sure to seat it firmly in the oil level indicator
tube (6754). Remove the oil level dipstick and draw a mark on the back (unmarked) surface at
the indicated oil level. This level should be about the same as the MIN or ADD mark on the face
of the oil level dipstick.
d. Add one liter (quart) of oil. Restart the engine and allow to idle for at least two minutes. Shut off the engine and allow the oil to drain back for at least five minutes. Mark the oil level dipstick,
using the procedure above.
e. Record the vehicle mileage. f. Instruct the customer to drive the vehicle as usual and perform the following:
„Check the oil level regularly at intervals of 160 to 240 km (100- 150 miles).
„ Return to the service point when the oil level drops below the lower (MIN or ADD) mark
on the oil level dipstick.
„ Add only full liters (quarts) of the same oil in an emergency. Note the mileage at which
the oil is added.
g. Check the oil level under the same conditions and at the same location as in Steps 6c and 6d.
„Measure the distance from the oil level to the UPPER mark on the oil level dipstick and
record.
„ Measure the distance between the two scribe marks and record.
„ Divide the first measurement by the second.
„ Divide the distance driven during the oil test by the result. This quantity is the
approximate oil consumption rate in kilometers per liter or in miles per quart.
h. If the oil consumption rate is unacceptable, go to Step 7.
7. Check the positive crankcase ventilation (PCV) system. Make sure the system is not plugged.
8. Check for plugged oil drain- back holes in the cylinder heads and cylinder block.
9. If the condition still exists after performing the above steps, go to Step 10.
10. Perform a cylinder compression test or perform a cylinder leak detection test with Engine Cylinder Leak Detection/Air Pressurization Kit. This can help determine the source of oil
consumption such as valves, piston rings or other areas.
11. NOTE: After determining if new parts should be installed, make sure correct parts are used.
Check valve guides for excessive guide clearance. Install new all valve stem seals (6571) after
verifying valve guide clearance.
12. Worn or damaged internal engine components can cause excessive oil consumption. Small deposits of oil on the tips of spark plugs can be a clue to internal oil consumption. If internal oil
consumption still persists, proceed as follows:
a. Remove the engine from the vehicle and place it on an engine work stand. Remove the intake manifolds (9424), cylinder heads, oil pan (6675) and oil pump (6600).
b. Check piston ring clearance, ring gap and ring orientation. Repair as necessary.
c. Check for excessive bearing clearance. Repair as necessary.
13. Repeat the oil consumption test (Step 6) to confirm the oil consumption concern has been resolved. Klj . 10 ba
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9 6161 Piston ring
10 6200 Connecting rod assy.
11 6100 Piston and rod assy (8 req'd)
12 N806164 Washer
13 6256 Camshaft sprocket
14 6265 Camshaft sprocket spacer
15 6766 Oil filler cap
16 6C324 Crankcase vent connector and hose
17 6582 Valve cover
18 6B280 Camshaft bearing cap
19 6250 Camshaft
20 9H308 Idle air control valve inlet tube
21 N806155 Bolt (2 req'd)
22 9F715 Idle air control valve
23 N806154 Bolt (4 req'd)
24 9F670 Idle air control gasket
25 9E926 Throttle body
26 9E936 Throttle body gasket
27 9A589 Throttle body gasket
28 N807309 Bolt (3 req'd)
29 9728 Bracket
30 N806154 Bolt (5 req'd)
31 9D476 EGR valve gasket
32 9D460 EGR valve
33 W701625 Bolt (2 req'd)
34 N811017 Stud bolt (4 req'd)
35 9F792 Fuel injection supply manifold
36 9D477 EGR valve to exhaust manifold tube
37 9E498 Main emission vacuum control connector
38 12A522 Engine control sensor extension wire
39 N806459 Dowel (4 req'd)
40 8555 Water bypass tube
41 N646419 Dowel (2 req'd)
42 W623454 Washer (2 req'd)
43 N806040 Dowel (2 req'd)
44 N806007 Dowel (2 req'd)
45 6A636 Oil filter adapter gasket
46 6881 Oil filter adapter (manual transmission)
47 N806156 Bolt (4 req'd)
48 6714 Oil bypass filter
49 N87838 Dowel
50 Klj . 4 ba
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IN-
VEHICLE REPAIR
Oil Filter Adapter
Removal and Installation 1. Drain the cooling system. For additional information, refer to Section 303 - 03A or
Section 303 -
03B .
2. Disconnect the lower radiator hose.
3. Raise and support the vehicle. For additional information, refer to Section 100 - 02 .
4. Drain the engine oil.
5. Disconnect the oil pressure sensor electrical connector.
SECTION 303-
01B: Engine — 4.6L (2V) 2003 Mustang Workshop Manual Material
Item Specification
Super Premium SAE 5W-20
Motor Oil
XO- 5W20 QSP or equivalent WSS-
M2C153-
H Premium Engine Coolant
VC-
4A (In Canada CXC- 10; In
Oregon VC- 5) or equivalent ESE-
M97B44-
A Klj . 1 ba
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