2003 FORD MUSTANG belt

z
Drive the vehicle over a bump or rough surface one wheel at a time to determine if the noise is
coming from the front or the back and the left or the right side of the vehicle.
z Proceed as necessary.
Neutral Engine Run- Up (NERU) Test
To carry out this test, proceed as follows:
zInstall a tachometer.
z Increase the engine rpm up from an idle to approximately 4000 rpm while in PARK on front
wheel drive vehicles with automatic transmissions, or NEUTRAL for all other vehicles. Note the
engine rpm and, if possible, determine the vibration frequency.
z Attempt to identify what part of the vehicle the concern is coming from.
z Attempt to identify the source of the concern.
z Proceed as necessary.
Drive Engine Run- Up (DERU) Load Test
To carry out this test, proceed as follows:
z WARNING: Block the front and rear wheels, and apply the parking brake and the
service brake, or injury to personnel can result.
CAUTION: Do not carry out the Engine Load Test for more than five seconds or
damage to the transmission or transaxle can result.
Block the front and rear wheels.
z Apply the parking brake and the service brake.
z Install a tachometer.
z Shift the transmission into DRIVE, and increase and decrease the engine rpm between an idle
to approximately 2000 rpm. Note the engine rpm and, if possible, determine the vibration
frequency.
z Repeat the test in REVERSE.
z If the vibration/noise is duplicated when carrying out this test, inspect the engine and
transmission or transaxle mounts.
z If the concern is definitely engine speed- related, carry out the Engine Accessory Test to narrow
down the source.
z Proceed as necessary.
Engine Accessory Test
To carry out this test, proceed as follows:
z WARNING: Block the front and rear wheels, and apply the parking brake and the
service brake, or injury to personnel can result.
CAUTION: Limit engine running time to one minute or less with belts removed or
serious engine damage will result. Klj . 8 ba
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NOTE:
A serpentine drive belt decreases the usefulness of this test. In these cases, use a
vibration analyzer, such as the VA, to pinpoint accessory vibrations. An electronic listening
device, such as an EngineEAR, will also help to identify noises from specific accessories.
Remove the accessory drive belts.
z Increase the engine rpm to where the concern occurs.
z If the vibration/noise is duplicated when carrying out this test, the belts and accessories are not
sources.
z If the vibration/noise was not duplicated when carrying out this test, install each accessory belt,
one at a time, to locate the source.
Vehicle Cold Soak Procedure
To carry out this procedure, proceed as follows:
zTest preparations include matching customer conditions (if known). If not known, document the
test conditions: gear selection and engine rpm. Monitor the vibration/noise duration with a watch
for up to three minutes.
z Park the vehicle where testing will occur. The vehicle must remain at or below the concern
temperature (if known) for 6- 8 hours.
z Before starting the engine, conduct a visual inspection under the hood.
z Turn the key on, but do not start the engine. Listen for the fuel pump, anti- lock brake system
(ABS) and air suspension system noises.
z Start the engine.
z CAUTION: Never probe moving parts.
Isolate the vibration/noise by carefully listening. Move around the vehicle while listening to find
the general location of the vibration/noise. Then, search for a more precise location by using a
stethoscope or EngineEAR.
z GO to Symptom Chart — Idle Noise/Vibration to assist with the diagnosis.
6: Check OASIS/TSBs/Repair History
After verifying the customer concern, check for OASIS reports, TSBs and the vehicle repair history for
related concerns. If information relating to a diagnosis/repair is found, carry out the procedure(s)
specified in that information.
If no information is available from these sources, carry out the vehicle preliminary inspection to
eliminate any obvious faults.
7: Diagnostic Procedure
Qualifying the concern by the particular sensation present can help narrow down the concern. Always
use the "symptom" to "system" to "component" to "cause" diagnosis technique. This diagnostic method
divides the problem into related areas to correct the customer concern.
zVerify the "symptom".
z Determine which "system(s)" can cause the "symptom".
„If a vibration concern is vehicle speed related, the tire and wheel rpm/frequency or
driveshaft frequency should be calculated.
„ If a vibration concern is engine speed related, the engine, engine accessory or engine
firing frequencies should be calculated. Klj . 9 ba
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„
A wobble or shudder. GO to Symptom Chart — Tire Noise/Vibration .
2. Depends more on where the vehicle is operated 1. Bump/pothole, rough road or smooth road. GO to Symptom Chart — Suspension
Noise/Vibration .
„ Noise is random or intermittent occurring from road irregularities. GO to Symptom Chart — Squeak and Rattle .
„ Noise or vibration changes from one road surface to another. Normal sound
changes.
„ Noise or vibration associated with a hard/firm ride. GO to Symptom Chart —
Suspension Noise/Vibration .
Symptom Charts Symptom Chart — Air Leak and Wind Noise Condition
Possible Sources Action
z Air leak around
door perimeter z
Loose fit seal. zPINCH the seal carrier to
improve retention on the
seal flange.
z Seal installed
incorrectly. z
REINSTALL the seal.
z Door misaligned. zREALIGN the door.
CHECK door gaps and fit
in the door opening and
ADJUST as necessary.
z Scuff plate installed
incorrectly. z
REINSTALL the scuff
plate.
z Seal or seal push pins
damaged. z
INSTALL a new seal.
z Air leak around
glass run z
Door glass misaligned. zADJUST the door glass.
z Glass run installed
incorrectly. z
ADJUST the glass run.
INSERT foam in the glass
run carrier.
z Leak path behind glass
run. z
INSTALL foam rope
behind the glass run.
z Glass run channel
spread wide. z
PINCH the glass run
channel to reduce the size
of the opening.
z Blow- out clip bent or
contacting door glass. z
ADJUST the blow- out clip
or INSTALL a new glass
run/blow- out clip molding
assembly.
z Glass run damaged. zINSTALL a new glass run.
z Air leak at inner
belt line z
Belt line seal installed
incorrectly on flange. z
ADJUST the seal. (Do not
bend the flange.)
z Belt line seal integrated
with door trim installed
incorrectly (no glass
contact). z
REINSTALL the door trim. Klj . 12 ba
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z
No contact with side
glass. z
ADJUST the door glass.
z No contact with glass
runs at both ends of
belt line seal. z
ADJUST the belt line seal
or ADD foam at the seal
ends.
z Belt line seal damaged. zINSTALL a new seal.
z Air leak at outer
belt line z
Belt line seal installed
incorrectly on flange
(no glass contact). z
ADJUST the seal.
z Belt line seal does not
contact the glass. z
ADJUST the door glass.
z No contact with glass
runs at both ends of
belt line seal. z
ADJUST the belt line
seal/ADD foam at the seal
ends.
z Belt line seal damaged. zINSTALL a new seal.
z Draft at inner
door
handle/speaker
opening z
Hole in watershield. zSEAL the hole with a
suitable tape.
z Watershield
misaligned. z
REALIGN the watershield.
INSTALL a new
watershield if the pressure
sensitive adhesive fails.
z Exterior door handle
seal
misaligned/damaged. z
REALIGN or INSTALL a
new seal as necessary.
z Wind noise from
side view mirror z
Outside mirror housing
misaligned. z
REALIGN with the edges
shingled correctly and no
gaps.
z Mirror sail gasket
folded/misaligned. z
REINSTALL with the
gasket unfolded and
aligned correctly.
z Mirror housing trim cap
installed incorrectly. z
REINSTALL with the
edges shingled to the air
flow.
z Air leak through mirror
housing hinge. z
Fully ENGAGE the mirror
into its operating
position/USE foam to
block the air path through
the hinge.
z Inner sail trim installed
incorrectly. z
REINSTALL the sail
trim/ADJUST the door
trim.
z Inner sail gasket/barrier
installed incorrectly. z
REINSTALL the trim
cover with the
gasket/barrier aligned
correctly.
z Air path through wiring
bundle/fastener access
holes. z
BLOCK the air path(s)
with foam/tape.
z Exposed fastener
access hole on mirror
housing/sail. z
INSTALL a new cap if it is
missing.
z Air leak around
perimeter of fixed z
Gaps in the sealant
bead. z
APPLY approved sealant. Klj . 13 ba
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CARRY OUT a driveline
vibration test. REFER to
Section 205
- 00 . REPAIR as
necessary.
z Binding or
damaged
splines on the
driveshaft slip-
yoke. z
CLEAN and INSPECT the
splines of the slip- yoke,
driveshaft and coupling
shaft for wear or damage.
INSTALL a new slip- yoke or
driveshaft assembly as
necessary. REFER to
Section 205 - 01 . REPAIR as
necessary.
z Driveshaft
runout. z
CARRY OUT a Runout
Check. REFER to Section 205 - 00 . REPAIR as
necessary.
z Incorrect lateral
and radial
tire/wheel
runout. z
INSPECT the tire and
wheels. MEASURE tire
runouts. REPAIR or
INSTALL new components
as necessary. REFER to
Section 204 - 04 .
z Driveline angles
out of
specification. z
CHECK for correct driveline
angles. REPAIR as
necessary. REFER to
Section 205 - 00 .
z Incorrectly
seated CV joint
in the front
wheel hub. z
CHECK the outer CV joint
for correct seating into the
hub. REPAIR as necessary. Symptom Chart —
Engine Noise/Vibration Condition
Possible Sources Action
z Grinding noise—
occurs during
engine cranking z
Incorrect starter
motor mounting. z
INSPECT the starter motor
for correct mounting.
REPAIR as necessary.
REFER to Section 303 - 06 .
z Starter motor. zCHECK the starter motor.
REPAIR or INSTALL a new
starter motor as necessary.
REFER to Section 303 - 06 .
z Incorrect starter
motor drive
engagement. z
INSPECT the starter motor
drive and flexplate/flywheel
for wear or damage.
INSTALL a new starter
motor drive or flywheel as
necessary. REFER to
Section 303 - 06 .
z Engine ticking
noise z
Fuel injector.
z Fuel line.
z Oil pump.
z Valve lifter.
z Belt tensioner.
z Water pump.
z Obstruction of cooling
fan. z
Go To Pinpoint Test B .
z Engine drumming zPowertrain mount. zCARRY OUT Klj . 23 ba
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noise—
normally
accompanied by
vibration Powertrain/Drivetrain Mount Neutralizing in this
section.
z Damaged or
misaligned exhaust
system. z
INSPECT the exhaust
system for loose or broken
clamps and brackets.
CARRY OUT Exhaust System Neutralizing in this
section.
z Whistling noise—
normally
accompanied
with poor idle
condition z
Air intake system. zCHECK the air intake
ducts, air cleaner, throttle
body and vacuum hoses for
leaks and correct fit.
REPAIR or ADJUST as
necessary. REFER to
Section 303 - 12
z
Clunking noise zWater pump has
excessive end play or
imbalance. z
CHECK the water pump for
excessive end play.
INSPECT the water pump
with the drive belt off for
imbalance. INSTALL a new
water pump as necessary.
REFER to Section 303 -
03A .
z Generator has
excessive end play. z
CHECK the generator for
excessive end play.
REPAIR or INSTALL a new
generator. REFER to
Section 414 - 02 .
z Pinging noise zExhaust system leak. zINSPECT the exhaust
system for leaks. REPAIR
as necessary.
z Gasoline octane too
low. z
VERIFY with customer the
type of gasoline used.
CORRECT as necessary.
z Knock sensor
operation. z
CHECK the knock sensor.
INSTALL a new knock
sensor as necessary.
REFER to Section 303 - 14 .
z Incorrect spark
timing. z
CHECK the spark timing.
REPAIR as necessary.
z High operating
temperature. z
INSPECT cooling system
for leaks. CHECK the
coolant level. REFILL as
necessary. CHECK the
coolant for the correct mix
ratio. DRAIN and REFILL
as needed. CHECK engine
operating temperature is
within specifications.
REPAIR as necessary.
z Foul- out spark plug. zCHECK the spark plugs.
REPAIR or INSTALL new
spark plugs as necessary.
z Catalytic converter. zAcceptable noise.
z Knocking noise—
light knocking
noise, also z
Excessive clearance
between the piston
and the cylinder wall. z
Engine cold and at high
idle. Using an EngineEAR,
pull a spark plug or fuel Klj . 24 ba
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as necessary.
z Accelerator pedal
vibration— felt
through the pedal
as a buzz z
Throttle cable loose
or misrouted. z
INSPECT the throttle cable.
REPAIR as necessary.
REFER to Section 310 - 02 .
z Engine
vibration— mostly
at coast/neutral
coast. Condition
improves with
vehicle
accelerating z
Combustion
instability. z
CHECK the ignition system.
INSTALL new components
as necessary.
z Engine vibration
or shudder—
occurs with light
to medium
acceleration
above 56 km/h
(35 mph) z
Worn or damaged
spark plugs. z
INSPECT the spark plugs
for cracks, high resistance
or broken insulator.
INSTALL a new spark plug
(s) as necessary.
z Plugged fuel injector. zREPAIR or INSTALL a new
injector as necessary.
REFER to Section 303 - 04A
for 3.8L engines or
Section 303 - 04B for 4.6L (2V)
engines.
z Damaged spark plug
wire. z
INSPECT the spark plug
wires for damage. INSTALL
a new spark plug wire(s) as
necessary.
z Contaminated fuel. zINSPECT the fuel for
contamination. DRAIN the
fuel system and refill.
z Worn or damaged
torque converter. z
CHECK the torque
converter. INSTALL a new
torque converter as
necessary. REFER to
Section 307 - 01 .
Symptom Chart—
Idle Noise/Vibration Condition
Possible Sources Action
z Idle air control (IAC)
valve moan — occurs
on throttle tip- out z
IAC valve is
contaminated
with oil. z
GO to Component Tests in
this section.
z Accessory drive belt
chirp — occurs at idle
or high idle, cold or
hot. Most common
occurrence is during
humid weather z
Accessory drive
belt worn, or
pulley is
misaligned or
loose. z
INSPECT for loose or
misaligned pulleys. CHECK
the drive belt for wear or
damage. INSTALL new
pulley(s)/drive belt, or
accessory drive components
as necessary. REFER to
Section 303 - 05 .
z Accessory drive
bearing hoot —
occurs at idle or high
idle in cold
temperatures of
approximately +4°C z
Accessory drive
idler or
tensioner pulley
bearing is
experiencing
stick/slip z
Go To Pinpoint Test C . Klj . 28 ba
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port. DISCARD the leaking
parts, and INSTALL a new
component.
z Vehicles with a
plastic intake
manifold. z
Acceptable condition. Some
plastic manifolds exhibit this
noise, which is the effect of
the plastic manifold.
z Automatic
transmission buzz or
hiss z
Incorrect
driveline
angles. z
CHECK for correct driveline
angles. REPAIR as
necessary. REFER to
Section 205 - 00 .
z Worn or
damaged main
control
solenoids or
valves. z
Using a transmission tester,
activate the solenoids to
duplicate sound. INSTALL
new components as
necessary. REFER to
Section 307 - 01 .
z Manual Transmission
Clutch throw- out
bearing whine. A
change in noise pitch
or loudness while
depressing the clutch
pedal z
Worn throw- out
bearing. z
INSTALL a new throw- out
bearing. REFER to Section 308 - 01 .
z Heating, vacuum and
air conditioning
(HVAC) system chirp
— most audible inside
the vehicle. Listen for
a change in noise
pitch or loudness
while changing the
HVAC system blower
speed z
Damaged or
worn HVAC
blower bearing. z
INSTALL a new blower
motor. REFER to Section 412 - 02 .
z Air conditioning (A/C)
clutch ticking —
occurs when the
compressor clutch
engages z
Acceptable
noise.
z Incorrect air
gap. z
LISTEN to the clutch to
determine if the noise occurs
with clutch engagement. A
small amount of noise is
acceptable. If the noise is
excessive, CHECK the A/C
clutch air gap. INSPECT the
A/C clutch for wear or
damage. INSTALL a new
clutch as necessary. REFER
to Section 412 - 03 .
z Intermittent rattle, or
scraping/rubbing
noise z
Loose exhaust
heat shield(s). z
INSPECT the exhaust
system for loose parts using
a glove or clamps to verify
cause. REPAIR as
necessary. REFER to
Section 309 - 00 .
z Wiring, hose or
other part
interfering with
accessory drive
belt or pulley. z
INSPECT accessory drive
system closely verifying
there is adequate clearance
to all rotating components.
REPAIR as necessary.
z Engine ticking or
knocking noise —
occurs during idle or z
Piston noise or
valvetrain noise
(bled down z
Go To Pinpoint Test G . Klj . 30 ba
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