2003 FORD MUSTANG open hood

pressure reading. Release pressure and repeat the test. Install a new radiator cap if the
pressure is not 99.3-
121.4 kPa (14.4-17.6 psi).
Cap — 4.6L
WARNING: Never remove the pressure relief cap while the engine is operating or when the
cooling system is hot. Failure to follow these instructions can result in damage to the cooling
system or engine or personal injury. To avoid having scalding hot coolant or steam blow out of
the degas bottle when removing the pressure relief cap, wait until the engine is cooled, then
wrap a thick cloth around the pressure relief cap and turn it slowly. Step back while the
pressure is released from the cooling system. When you are sure all the pressure has been
released, turn and remove the pressure relief cap (still with a cloth).
1. Remove the pressure relief cap from the degas bottle.
2. Follow the instructions from the pressure tester.
3. NOTE: If the plunger of the pump is depressed too quickly, an erroneous pressure reading will
result.
Slowly depress the plunger of the pressure test pump until the pressure gauge reading stops
increasing and note the highest pressure reading obtained.
4. If the pressure test gauge readings are not within specifications, install a new pressure relief cap. If the pressure test gauge readings are within specifications, carry out the cooling system
Pressure Test.
Thermostat — Water
A new water thermostat should be installed only after the following electrical and mechanical tests
have been carried out.
Thermostat — Electrical Test
CAUTION: Always vent the exhaust to the outside when carrying out this test.
NOTE: The electrical thermostat test is most accurate if carried out at less than 37.8°C (100°F)
ambient air. This test may be carried out with or without the hood open and with the engine warm or
cold.
1. Check the engine coolant level. Fill as needed.
2. With the ignition OFF, remove the engine coolant temperature (ECT) (4.6L) or cylinder head temperature (CHT) (3.8L) sensor harness connector and attach ECT (4.6L) or CHT (3.8L)
Sensor "T" Cable as a jumper between the powertrain control module (PCM) (12A650) and the
ECT (4.6L) or CHT (3.8L) sensor. Attach the 73III Automotive Meter to the ECT (4.6L) or CHT
(3.8L) Sensor "T" Cable. Voltage values (0- 5 V) may now be monitored while the sensor retains
its connection to the wiring harness.
An appropriate diagnostic tool may be used to monitor the ECT on vehicles equipped with data link connector (DLC). Klj . 8 ba
102003 Mustang Workshop Manual
17. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_4464/S3B~us~en~ ...

3. Remove the pressure cap from the cooling system reservoir and the fill plug from the engine
crossover tube.
4. CAUTION: Do not fill the cooling system through the reservoir only. Coolant will not
enter the engine. Only the reservoir and the radiator will be filled and engine overheating
will occur.
Add coolant into the fill neck on the engine crossover tube until coolant reaches the top of the fill
neck on the cooling system reservoir.
5. Install the cooling system pressure cap on the reservoir.
6. Continue to fill the cooling system at the engine crossover fill neck until full.
7. Install the engine crossover tube fill plug.
8. WARNING: To avoid the possibility of personal injury or damage to the vehicle, do
not operate the engine with the hood open until the fan has been first examined for
possible cracks and separation.
CAUTION: If the engine temperature gauge does not move, coolant level is low in
the engine and must be filled. Stop the engine, allow to cool, and fill the cooling system
as outlined.
Run the engine until the thermostat opens (coolant flowing through the radiator lower hose
becomes hot).
9. Stop the engine and allow to cool.
10. Add coolant to the engine crossover tube fill neck until the cooling system is full.
11. Install the fill plug.
12. Repeat the fill procedure if necessary.
Filling — Mach I
CAUTION: Vehicle cooling systems are filled with Motorcraft Premium Gold Engine
Coolant VC -7-A (in Oregon VC -7-B) or equivalent meeting Ford specification WSS- M97B51-A1
(yellow color). Always fill the cooling system with the same coolant that is present in the
system. Do not mix coolant types.
CAUTION: Engine coolant provides freeze protection, boil protection, cooling efficiency,
and corrosion protection to the engine and cooling components. In order to obtain these
protections, the engine coolant must be maintained at the correct concentration and fluid level
in the degas bottle.
When adding engine coolant, use a 50/50 mixture of engine coolant and deionized water.
To maintain the integrity of the coolant and the cooling system:
zAdd Motorcraft Premium Gold Engine Coolant VC -7-A (in Oregon VC -7-B) or equivalent
meeting Ford specification WSS- M97B51-A1 (yellow color). Use the same coolant that Klj . 5 ba
72003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_4464/S3B~us~en~ ...

was drained from the cooling system. Do not mix coolant types.
z Do not add/mix orange- colored Motorcraft Speciality Orange Engine Coolant VC- 2 or
equivalent meeting Ford specification WSS- M97B44-D. Mixing coolants may degrade the
coolant's corrosion protection.
z Do not add alcohol, methanol, or brine, or any engine coolants mixed with alcohol or
methanol antifreeze. These can cause engine damage from overheating or freezing.
z Do not mix with recycled coolant unless it meets the requirements of Ford specification
WSS- M97B51- A1. Not all coolant recycling processes meet these Ford specifications.
Use of such coolants can harm the engine and cooling system components. Do not mix
coolant types
NOTE: The addition of Motorcraft Cooling System Stop Leak Pellets, VC- 6, darkens Motorcraft
Premium Gold Engine Coolant from yellow to golden tan.
1. Remove the air intake scoop. For additional information, refer to Section 303 - 12 .
2. Check all hose clamps for correct tightness. Make sure the radiator draincock is closed.
3. Place the heater temperature selector in maximum cool position.
4. Remove the pressure cap from the cooling system reservoir and the fill plug from the engine crossover tube.
5. CAUTION: Do not fill the cooling system through the reservoir only. Coolant will not
enter the engine. Only the reservoir and the radiator will be filled and engine overheating
will occur.
Add coolant into the fill neck on the engine crossover tube until coolant reaches the top of the fill
neck on the cooling system reservoir.
6. Install the cooling system pressure cap on the reservoir.
7. Continue to fill the cooling system at the engine crossover fill neck until full.
8. Install the engine crossover tube fill plug.
9. WARNING: To avoid the possibility of personal injury or damage to the vehicle, do
not operate the engine with the hood open until the fan has been first examined for
possible cracks and separation.
CAUTION: If the engine temperature gauge does not move, coolant level is low in
the engine and must be filled. Stop the engine, allow to cool, and fill the cooling system
as outlined.
Run the engine until the thermostat opens (coolant flowing through the radiator lower hose
becomes hot).
10. Stop the engine and allow to cool.
11. Add coolant to the engine crossover tube fill neck until the cooling system is full.
12. Install the fill plug.
13. Repeat the fill procedure if necessary. Klj . 6 ba
72003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_4464/S3B~us~en~ ...

4. Remove the front seat. For additional information, refer to
Section 501 - 10 .
5. Unhook the clutch release lever cable (7K553) from the clutch pedal adjuster quadrant (7L583).
6. Open the hood, remove the screws and the clutch release cable (7K553).
7. NOTE: On 4.6L vehicles only
Remove the bolt and the clutch release lever cable bracket from the brake master cylinder
(2140).
8. Raise the vehicle. For additional information, refer to Section 100 - 02 .
9. Remove the screw from the clutch release lever cable clamp. Klj . 2 ba
52003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_2308/S3B~us~en~ ...

GENERAL PROCEDURES
Air Conditioning (A/C) System Check —
Retail Procedure
NOTE: This Retail Procedure is not eligible for claiming on Ford paid repairs (warranty and ESP).
NOTE: The engine should be run at idle for 10 minutes with the air conditioning on and set to MAX A/C
before carrying out this retail procedure.
NOTE: Read and follow all of the Warnings, Cautions and Notes at the beginning of this section before
continuing.
1. Visual inspection
Open the hood and visually inspect the heating and air conditioning systems for the following:
zCoolant reservoir for correct coolant level
z Heater hoses for deterioration or loose connections
z Radiator and condenser for debris or damaged fins restricting airflow, loose mounting or
connections
z Accessory drive belt(s) and cooling fan(s) for wear or physical damage
z Refrigerant lines and connections for physical damage or loose connections
z Compressor for physical damage or loose connections
z Suction accumulator/drier for physical damage or loose connections
z Wiring and connectors for excessive wear, loose or damaged connections, or incorrect
routing
2. A/C refrigerant analysis
zCarry out air conditioning refrigerant analysis. For additional information, refer to
Refrigerant Identification Testing in this section.
z If the refrigerant fails the analysis, discontinue diagnosis and make recommendations for
repairs.
z If the refrigerant passes the analysis, carry out the air conditioning system check.
3. Air conditioning system check
zConnect manifold gauge set or charging station with gauges to refrigerant system.
z With the vehicle in park, parking brake set, thermometer installed in center panel vent,
and air conditioning system on and set to MAX A/C, start the engine.
z Record air refrigerant system pressures while running the engine at 1,500 rpm and allow
engine to return to idle.
z Operate the blower motor in all control positions and check for correct blower speed
changes.
z With the blower motor on HI, operate air discharge mode selector in all positions and
check for correct airflow in each position.
z Operate the temperature blend selector in all positions and check for correct change in
discharge temperature. Check the air discharge temperature with the selector in the
coolest position and the air conditioning on and set to MAX A/C to determine if the air
discharge temperature is acceptable for the current ambient air temperature.
z Carry out the EATC self- test (if applicable).
If the refrigerant system pressures were low, carry out the refrigerant system leak test.
SECTION 412-
00: Climate Control 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~ ...

z
Check that the vehicle is on level ground.
z If the vehicle is equipped with air suspension, make sure that the switch is on.
2. NOTE: The vertical wall or screen must be a minimum of 2.4 meters (8 feet) wide.
Park the vehicle on a level surface approximately 7.6 meters (25 feet) from the vertical wall or
screen directly in front of it.
3. NOTE: The center of the lamp is marked by a 3 mm (0.12 in) circle on the headlamp lens.
Mark a horizontal reference line on the vertical wall or screen. 1. Measure the center of the headlamp height to ground and record.
2. Make a 2.4 meter (8 foot) horizontal mark (masking tape) on the vertical wall or screen at the same distance from the ground as previously recorded.
4. NOTE: This procedure should be done in a dark environment to effectively see the headlamp
beam pattern.
Turn on the low beam headlamps to illuminate the wall or screen and open the hood.
5. NOTE: For SAE type headlamps, the appearance of the beam pattern may vary between
vehicles.
On the wall or screen, locate the high intensity area of the beam pattern. Place the top edge of
the high intensity zone even with the horizontal reference line.
VOR type headlamps 6. NOTE: The appearance of the VOR beam pattern may vary between vehicles.
Identify at the top edge of this high intensity area a distinct horizontal cutoff in the beam pattern.
If the top edge of this cutoff is not even with the horizontal reference line, the headlamp beam will need to be adjusted. Klj . 2 ba
42003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_5108/S3B~us~en~ ...

DESCRIPTION AND OPERATION
Body
Body and Sheet Metal
The body:
zIs a unibody open cowl structure.
z Is constructed of a lightweight, all- steel material with removable bolted hood (16612), front
fenders (16005), doors, and luggage compartment lid.
SECTION 501-
00: Body System — General Information 2003 Mustang Workshop Manual Klj . 1 ba
12003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_5108/S3B~us~en~ ...

SPECIFICATIONS
SECTION 501-
02: Front End Body Panels 2003 Mustang Workshop Manual Torque Specifications
Description Nm lb-
ft lb-
in Hood latch support screws 12 9 —
Hood latch retaining screws 12 9 —
Hood latch control handle and cable retaining screws 3 — 27
Hood latch support nuts 10 — 89
Fender bolts 12 9 —
Grille opening panel bolts 3 — 27
Rear hood hinge to body bolts 9 — 80
Front hood hinge to body bolts 13 10 — Klj . 1 ba
12003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_5108/S3B~us~en~ ...