2003 FORD MUSTANG maintenance

DESCRIPTION AND OPERATION
Engine
WARNING: Do not operate the engine with the hood open until the fan blade has been first
examined for possible cracks and separation.
The 4.6L (4V) (281 CID) is a V- 8 engine with the following features:
z dual overhead camshafts
z four valves per cylinder
z sequential multiport fuel injection (SFI)
z an aluminum intake manifold
z aluminum cylinder heads
z a cast aluminum, 90-degree V- cylinder block
z individually chain- driven camshafts with a hydraulic timing chain tensioner on each timing chain
z the electronic ignition system with eight ignition coils
Identification
Always refer to these labels when replacement parts are necessary or when checking engine
calibrations. The engine parts often differ within a CID family. Verification of the identification codes will
ensure that the correct parts are obtained. These codes contain all the pertinent information relating to
the dates, optional equipment and revisions. The Ford Master Parts Catalog contains a complete
listing of the codes and their application.
Code Information
The engine code information label, located on the side of the valve cover and the front side of the
valve cover, contains the following:
zengine build date
z engine plant code
z engine code
Exhaust Emission Control System
Operation and necessary maintenance of the exhaust emission control devices used on this engine is
covered in the Powertrain Control/Emissions Diagnosis (PC/ED) manual.
Induction System
The sequential multiport fuel injection (SFI) provides the fuel/air mixture needed for combustion in the
cylinders. The eight solenoid- operated fuel injectors:
z are mounted in the lower intake manifold.
z meter fuel into the air intake stream in accordance with engine demand.
z are positioned so that their tips direct fuel just ahead of the engine intake valves.
SECTION 303-
01D: Engine — Mach I 4.6L (4V) 2003 Mustang Workshop Manual Klj . 1 ba
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z
prevents hydrocarbon emissions from reaching the atmosphere.
z stores fuel vapors in the evaporative emission (EVAP) canister that are generated during
vehicle operation or hot soak, or vehicle refueling, until they can be consumed by the engine.
z routes the stored fuel vapors to the engine during engine operation.
z is controlled by the powertrain control module (PCM) which uses various sensor inputs to
calculate the desired amount of purge flow. The PCM regulates the purge flow, induced by the
application of intake manifold vacuum, by varying the duty cycle applied to the EVAP canister
purge valve.
z has an evaporative emission test port for test purposes.
The fuel vapors are routed:
zfrom the fuel tank through the fuel vapor control valve and fuel vapor vent valve.
z to the EVAP canister through a vapor line.
z to the engine when the EVAP canister purge valve is opened by the PCM.
The fuel tank pressure (FTP) sensor:
zmonitors the pressure levels in the fuel tank.
z communicates the pressure reading to the PCM during the OBDII leak test.
z is located in- line above the fuel tank and is serviced as part of the fuel vapor control valve tube
assembly.
The evaporative emission canister:
zis located in the left rear quarter panel.
z contains activated carbon.
z stores fuel vapor.
The fuel tank filler cap:
zrelieves system pressure above 14 kPa (56.21 inches H
2 O).
z relieves system vacuum below 3.8 kPa (15.26 inches H
2 O).
The canister vent solenoid: zis normally open.
z seals the EVAP system for the inspection and maintenance (I/M 240) test and OBDII leak and
pressure tests.
z is mounted to the evaporative emission canister.
z is repaired as a separate item.
The evaporative emission (EVAP) canister purge valve:
zis normally closed.
z regulates purging of the EVAP canister.
z is controlled by the PCM. Klj . 2 ba
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Principles of Operation
Evaporative Emission (EVAP) Canister Purge Valve
The EVAP canister purge valve is controlled by the powertrain control module (PCM). The EVAP
canister purge valve controls the flow of fuel vapors from the EVAP canister to the engine intake
manifold during various engine operating modes. The EVAP canister purge valve is normally closed.
Evaporative Emission (EVAP) Canister
Fuel vapors from the fuel tank are stored in the EVAP canister. When the engine is running, the vapors
are purged from the EVAP canister for combustion.
Canister Vent Solenoid
During the Evaporative Emission (EVAP) System Test Monitor, Evaporative Emissions Repair
Verification Drive Cycle, and the Evaporative Emission System Leak Test, the canister vent solenoid is
closed to allow a vacuum to be drawn on the fuel tank at a specific level. The canister vent solenoid is
normally open.
Fuel Tank Pressure (FTP) Sensor
The fuel tank pressure sensor is used to measure the fuel tank pressure during the Evaporative
Emissions Monitor Test. The fuel tank pressure sensor is mounted in the fuel vapor control valve tube
as it crosses over the fuel tank.
Fuel Vapor Control Valve
The fuel vapor control valve is normally between the EVAP canister and the fuel vapor vent valve. Its
function is to prevent the flow of liquid fuel into the EVAP canister or up to the canister purge valve
during refueling, and to prevent the collection of liquid fuel in the fuel vapor hoses by overfilling the fuel
tank.
Fuel Vapor Vent Valve (FVV) Assembly
The fuel vapor vent valve (FVV) assembly is mounted on the top of the fuel tank. It is used to control
the flow of fuel vapors entering the EVAP system. The head portion of the assembly prevents the fuel
tank from overfilling during refueling. The assembly also has a spring float, which prevents liquid fuel
from entering the vapor delivery system under severe handling or vehicle rollover conditions. In the
upright position, the open bottom of the float will lift and shut off the orifice. Under severe handling
conditions, the spring will push the float closed when angles allow liquid fuel to reach the orifice. In a
rollover condition, the weight of the open bottom float and spring pressure will close the orifice.
Fuel Filler Pipe Check Valve
The fuel filler pipe check valve is an intricate part of the fuel filler pipe. It is intended to prevent liquid
fuel from re-entering the fuel filler pipe from the fuel tank on refueling or roll over conditions.
Fuel Filler Cap
The fuel filler cap is used to prevent fuel spill and to close the EVAP system to the atmosphere.
Evaporative Emission System Monitor
When a fault occurs, the EVAP system monitor is reset to NO and a diagnostic trouble code (DTC) is
set in the PCM memory. After the DTC is repaired, the vehicle drive cycle must be completed to reset
the monitor in preparation for inspection and maintenance testing. EVAP Emission System Leak Test Klj . 2 ba
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GENERAL PROCEDURES
Evaporative Emission Repair Verification Drive Cycle
Drive Cycle Recommendations
NOTE:
The following procedure is designed to execute and complete the evaporative emission repair
verification drive cycle and to clear the Ford P1000, inspection and maintenance (I/M) readiness code.
When the ambient air temperature is below 4.4°C (40°F) or above 37.8°C (100°F), or the altitude is
above 2,438 meters (8,000 feet), the EVAP monitor will not run. If the P1000 must be cleared in these
conditions, the powertrain control module (PCM) must detect them once (twice on some applications)
before the EVAP monitor can be bypassed and the P1000 cleared. The EVAP bypassing procedure is
described in the following drive cycle.
1. Most OBD II monitors will complete more readily using a steady foot driving style during cruise or acceleration modes. Operating the throttle in a smooth fashion will minimize the time
necessary for monitor completion.
2. Fuel tank level should be between one- half and three-quarters full with three- quarters full being
the most desirable.
3. The evaporative monitor can only operate during the first 30 minutes of engine operation. When executing the procedure for this monitor, stay in part throttle mode and drive in a smooth
fashion to minimize fuel slosh.
Drive Cycle Preparation
NOTE: For best results, follow each of the following steps as accurately as possible.
4. NOTE: This step bypasses the engine soak timer and resets OBD II monitor status.
Install the scan tool. Turn the key ON with the engine OFF. Cycle the key off, then on. Select
the appropriate vehicle and engine qualifier. Clear all diagnostic trouble codes (DTCs) and carry
out a PCM reset.
5. Begin to monitor the following PIDs: ECT, EVAPDC, FLI (if available) and TP MODE. Press Diagnostic Data Link, PCM, PID/Data monitor and record, press trigger to select each PID, then
start.
6. Start the engine without returning the key to the OFF position.
Preparation for Monitor Entry
WARNING: Strict observance of posted speed limits and attention to driving conditions
SECTION 303-
13: Evaporative Emissions 2003 Mustang Workshop Manual Special Tool(s)
Worldwide Diagnostic System
(WDS)
418-
F224,
New Generation STAR (NGS)
Tester
418- F052, or equivalent scan
tool Klj . 1 ba
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CAUTION: The vehicle should not be driven if the fluid level indicator shows the fluid
below the DO NOT DRIVE mark or internal failure could result.
NOTE: If the vehicle has been operated for an extended period, at high highway speeds, in city traffic,
during hot weather, or while pulling a trailer, the fluid needs to cool down to obtain an accurate
reading.
NOTE: The fluid level reading on the indicator will differ from operating and ambient temperatures. The
correct reading should be within the normal operating temperature range.
Under normal circumstances the fluid level should be checked during normal maintenance. If the
transmission starts to slip, shifts slowly, or shows signs of fluid leaking, the fluid level should be
checked.
1. With the transmission in P (PARK), the engine at idle, foot pressed on the brake, move the range selector lever through each gear and allow engagement of each gear. Place the
transmission range selector lever in the P position.
2. Wipe the fluid level indicator cap and remove the indicator.
3. Wipe the indicator with a clean cloth.
4. Install the indicator back in the filler tube until it is fully seated, then remove the indicator. The fluid level should be within the normal operating temperature range.
High Fluid Level
A fluid level that is too high may cause the fluid to become aerated due to the churning action of the
rotating internal parts. This will cause erratic control pressure, foaming, loss of fluid from the vent tube,
and possible transmission failure. If an overfill reading is indicated, drain and refill the transmission.
Low Fluid Level
A low fluid level could result in poor transmission engagement, slipping, or failure. This could also
indicate a leak in one of the transmission seals or gaskets. Adding Fluid Item Description
1 Fluid level at room temperature 10°-
35°C (50°-95°F) 2 Fluid level at operating temperature 66°-
77°C (150°-170°F) 3 Do not drive mark Klj . 2 ba
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GENERAL PROCEDURES
Transmission Fluid Drain and Refill
Draining
CAUTION: Always refer to the instructions supplied with the flush and fill machine.
NOTE: Draining fluid from the transmission by removing only the fluid pan is acceptable for vehicles
that do not have a torque converter drain plug, for normal or severe duty fluid maintenance.
NOTE: A new procedure for draining and adding transmission fluid using a suitable transmission flush
and fill machine has been added. The following procedure has different methods for draining and
refilling the listed vehicles:
zAll vehicles using a suitable flush and fill machine.
z Vehicles equipped with a torque converter drain plug.
z Vehicles without a torque converter drain plug.
Use the method that is applicable to your vehicle.
All vehicles using a suitable flush and fill machine 1. With the vehicle in NEUTRAL, position on a hoist. For additional information, refer to Section 100 - 02 .
2. Use a suitable flush and fill machine to change the fluid.
3. When connecting the flush and fill machine, connect the machine to the fluid cooler tube after the fluid cooler on the cooler return line. This will help remove any foreign material trapped in
the fluid coolers. Refill SECTION 307-
01: Automatic Transaxle/Transmission 2003 Mustang Workshop Manual Special Tool(s)
Automatic Transmission Flush
and Fill Machine
211-
00018
Automatic Transmission Flush
and Fill Machine
199- 00010 or equivalent
Material Item Specification
MERCON® V Automatic
Transmission Fluid
XT
-5-QM MERCON®
V Klj . 1 ba
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4. Use only clean automatic transmission fluid.
5. Once the fluid exchange has been completed, disconnect the flush and fill machine. Reconnect
any disconnected fluid cooler tubes.
6. With the engine running and the transmission at normal operating temperature 66- 77°C (150-
170°F), check and adjust the transmission fluid level, and check for any leaks. If fluid is needed,
add fluid in increments of 0.24- liter (0.5-pint) until the correct level is achieved (fluid should be in
the cross- hatched area of the fluid level indicator).
Draining
Vehicles equipped with a torque converter drain plug 1. With the vehicle in NEUTRAL, position on a hoist. For additional information, refer to Section 100 - 02 .
2. Loosen the transmission fluid pan bolts and allow the fluid to drain.
3. After the fluid has drained, remove the transmission fluid pan.
4. Do not remove the fluid filter. It is not necessary to change the fluid filter during a normal maintenance fluid change.
5. Remove the torque converter drain plug cover. Klj . 2 ba
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170°F), check and adjust the transmission fluid level, and check for any leaks. If fluid is needed,
add fluid in increments of 0.24-
liter (0.5-pint) until the correct level is achieved (fluid should be in
the cross- hatched area of the fluid level indicator).
Draining
Vehicles without a torque converter drain plug 1. With the vehicle in NEUTRAL, position on a hoist. For additional information, refer to Section 100 - 02 .
2. Loosen the transmission fluid pan bolts and allow the fluid to drain.
3. After the fluid has drained, remove the transmission fluid pan.
4. Do not remove the fluid filter. It is not necessary to change the fluid filter during a normal maintenance fluid change.
5. Clean and inspect the transmission fluid pan, transmission fluid pan gasket and magnet.
6. Thoroughly flush the cooler tubes. For additional information, refer to Transmission Fluid Cooler — Backflushing and Cleaning in this section. Klj . 5 ba
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