2003 FORD MUSTANG service indicator

GENERAL PROCEDURES
Disc Check
WARNING: Dust and dirt present on wheel brake and clutch assemblies may contain
asbestos fibers that are hazardous to health when made airborne by cleaning with compressed
air or by dry brushing. Failure to follow these instructions may result in personal injury.
WARNING: Wheel brake assemblies and clutch facings should be cleaned using a vacuum
cleaner recommended for use with asbestos fibers such as the brake automobile brake drum
system with vacuum. Dust and dirt from the vacuum should be disposed of in a manner that
prevents dust exposure such as sealed bags. The bag must be labeled according to OSHA
instructions and the trash hauler notified as to the bag's contents. Failure to follow these
instructions may result in personal injury.
WARNING: If a vacuum suitable for asbestos is not available, cleaning should be done
wet. If dust generation is still possible, technicians should wear government- approved toxic
dust purifying respirators. Failure to follow these instructions may result in personal injury.
WARNING: Grinding or sanding on the brake linings, pads, rotors, drums or clutch
facings should be done only while using correct exhaust- ventilated equipment. Failure to
follow these instructions may result in personal injury.
WARNING: OSHA requires areas where asbestos dust generation is possible to be
isolated and posted with warning signs. Only technicians concerned with carrying out brake or
clutch service should be present in the area. Failure to follow these instructions may result in
personal injury.
1. Check the clutch disc lining surface for hardening or the presence of oil.
2. Check for a worn clutch disc lining. Measure the minimum allowable depth to the rivet heads with a slide caliper.
SECTION 308-
00: Manual Transaxle/Transmission and Clutch — General
Information 2003 Mustang Workshop
Manual Special Tool(s)
Brake/Automobile Brake Drum
System with Vacuum
164-
R3622 or equivalent Dial Indicator/Magnetic Base
100-
D002 (D78P-4201- B) or
equivalent Klj . 1 ba
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The spring lock coupling is a refrigerant line coupling held together by a garter spring inside a circular
cage.
zWhen the coupling is connected together, the flared end of the female fitting slips behind the
garter spring inside the cage of the male fitting.
z The garter spring and cage then prevent the flared end of the female fitting from pulling out of
the cage.
z Three O- ring seals are used to seal between the two halves of the A/C condenser core
couplings. All other couplings have two O- ring seals.
z Use only the O- ring seals listed in the Ford Master Parts Catalog for the spring lock coupling.
z A plastic indicator ring is used on the spring lock couplings of the A/C evaporator core to
indicate, during vehicle assembly, that the coupling is connected. Once the coupling is
connected, the indicator ring is no longer necessary but will remain captive by the coupling near
the cage opening.
z The indicator ring may also be used during repair operations to indicate connection of the
coupling.
z An A/C tube lock coupling clip (19E746) may be used to secure the coupling but is not required.
Service Gauge Port Valves
The high- pressure service gauge port valve is located on the A/C manifold and tube.
The low pressure service gauge port valve is located on the suction accumulator. 2 — Female fitting (part of 19860)
3 19E746 A/C tube lock coupling clip
4 19E576 A/C tube lock coupling spring
5 — Cage (part of 19D690)
6 — O-
ring seals (part of 19D690) 7 — Male fitting (part of 19835)
Item Part
Number Description
1 19D702 A/C charging valve cap
2 19D701 Low pressure service gauge port valve (part of
19C836)
3 19D701 Schrader-
type valve 4 — O-
ring seal (part of 19D701) 5 19D701 High pressure service gauge port valve (part of Klj . 9 ba
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Instrument Cluster—
Base 4.6L Engine transmission)
16 — LOW FUEL level indicator
17 — SERVICE ENGINE SOON indicator
18 — THEFT indicator
19 — AIR BAG warning indicator
20 — Charging system indicator
21 — Safety belt warning indicator
Item Part
Number Description
1 — Fuel gauge
2 — Engine coolant temperature gauge
3 — Speedometer
4 — Turn signal/hazard indicator
5 — High beam indicator
6 — Tachometer
7 — Odometer
8 — Trip odometer reset button
9 — Voltmeter gauge
10 — Oil pressure gauge
11 — CHECK FUEL CAP indicator
12 — BRAKE warning indicator
13 — ABS warning indicator Klj . 2 ba
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Instrument Cluster—
Cobra 14 — Traction control indicator
15 — Overdrive off (O/D OFF) indicator (automatic
transmission)
16 — LOW FUEL level indicator
17 — SERVICE ENGINE SOON indicator
18 — THEFT indicator
19 — AIR BAG warning indicator
20 — Charging system indicator
21 — Safety belt warning indicator
Item Part
Number Description
1 — Fuel gauge
2 — Engine coolant temperature gauge
3 — Speedometer
4 — Turn signal/hazard indicator
5 — High beam indicator
6 — Tachometer
7 — Odometer
8 — Trip odometer reset button
9 — Boost gauge
10 — Oil pressure gauge
11 — CHECK FUEL CAP indicator
12 — BRAKE warning indicator Klj . 3 ba
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13 — ABS warning indicator
14 — Traction control indicator
15 — Overdrive off (O/D OFF) indicator (automatic
transmission)
16 — LOW FUEL level indicator
17 — SERVICE ENGINE SOON indicator
18 — THEFT indicator
19 — AIR BAG warning indicator
20 — Charging system indicator
21 — Safety belt warning indicator Klj . 4 ba
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The boost pressure gauge on the instrument cluster receives and measures the boost pressure
directly from the intake manifold. The boost pressure gauge will display between 0.0-
0.48 kpa (0.0-10
psi) boost pressure dependent upon accelerator position, engine load, and engine rpm.
LOW FUEL Level Indicator
The low fuel level indicator is hardwired from the fuel sender to the instrument cluster. The instrument
cluster will illuminate the low fuel indicator when the usable fuel quantity is less than 1/8 tank (15%) of
fuel tank capacity.
Oil Pressure Gauge
The oil pressure gauge is hardwired from the oil pressure switch to the instrument cluster. The oil
pressure gauge will indicate either normal or no oil pressure.
CHECK FUEL CAP
The CHECK FUEL CAP indicator is used to indicate significant leaks in the fuel tank evaporative
system due to a loose fuel cap. Fuel tank pressure is monitored by the PCM. If a leak is detected the
PCM signals a fault to the instrument cluster via the SCP network. Once the PCM has detected a
loose fuel cap and the CHECK FUEL CAP indicator is illuminated, the indicator will remain illuminated
until the fuel cap is secured and the vehicle has been running for several minutes. For additional
information, refer to the Powertrain Control/Emissions Diagnosis (PC/ED) manual.
BRAKE Warning Indicator
The BRAKE warning indicator activates when the generic electronic module (GEM) detects the ignition
switch circuits are in the RUN state, when the GEM detects low brake fluid level, or that the parking
brake is applied. The BRAKE warning indicator will prove out starting when the GEM detects that the
ignition circuits have made a transition to RUN or START from OFF, ACC, or keyout and ending when
either three seconds have elapsed or when the GEM detects the ignition circuits have made a
transition to OFF, ACC, or keyout.
Safety Belt Warning Indicator
The safety belt switch is hardwired to the GEM. The safety belt warning indicator will be illuminated
when the GEM sends a ground signal to the instrument cluster.
ABS Warning Indicator
The ABS warning indicator will be illuminated when the anti- lock brake control module sends a ground
signal to the instrument cluster. The prove- out of the ABS indicator is controlled by the anti- lock brake
control module.
SERVICE ENGINE SOON Indicator
The SERVICE ENGINE SOON indicator receives its signal from the PCM over the SCP network. If the
instrument cluster does not receive a message from the PCM within five seconds, the instrument
cluster will illuminate the SERVICE ENGINE SOON indicator and log a diagnostic trouble code (DTC).
High Beam Indicator
The high beam indicator will illuminate when the steering column multifunction switch is in the high
beam position by sending a battery signal to the instrument cluster. Right and Left Turn Indicator Klj . 3 ba
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Pinpoint Tests
PINPOINT TEST A: NO COMMUNICATION WITH THE INSTRUMENT
CLUSTER z
The SERVICE ENGINE
SOON indicator is
never/always on z
Circuitry.
z SERVICE
ENGINE
SOON
indicator bulb.
z Powertrain
control module
(PCM).
z Instrument
cluster. z
Go To Pinpoint Test S .
z The turn/hazard
indicator is never/always
on z
Circuitry.
z Turn/hazard
bulb(s).
z Instrument
cluster. z
Go To Pinpoint Test T .
z The THEFT indicator is
never/always on z
Circuitry.
z THEFT
indicator LED.
z Instrument
cluster. z
REFER to Section 419 - 01 .
z The traction control
indicator is never/always
on z
Circuitry.
z Traction control
switch.
z Standard
corporate
protocol (SCP)
network.
z Powertrain
control module
(PCM).
z ABS module.
z Instrument
cluster. z
Go To Pinpoint Test U .
z The integrated circuit
display is
inoperative/erratic z
Instrument
cluster. z
Go To Pinpoint Test V .
z The instrument cluster is
inoperative z
Central junction
box (CJB) fuse
(s):
„11
(15A).
„ 21 (5A).
„ 34
(20A).
z Circuitry.
z Instrument
cluster. z
Go To Pinpoint Test V .
Test Step Result / Action to
Take Klj . 13 ba
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PINPOINT TEST S: THE SERVICE ENGINE SOON INDICATOR IS
NEVER/ALWAYS ON side and ground.
z Key in ON position.
z Does the ABS indicator illuminate? No
GO to
R3 .
R3 CHECK CIRCUIT 603 (DG) FOR AN OPEN
z
Key in OFF position.
z Disconnect: Instrument Cluster C220b.
z Measure the resistance between the instrument cluster
C220b pin 15, circuit 603 (DG), harness side and the anti-
lock brake control module C135 pin 16, circuit 603 (DG),
harness side.
z Is the resistance less than 5 ohms? Yes
GO to
R4 .
No
REPAIR the circuit. TEST
the system for normal
operation. R4 CHECK FOR CORRECT INSTRUMENT CLUSTER
OPERATION z
Disconnect all instrument cluster connectors.
z Check for:
zcorrosion
z pushed- out pins
z Connect all instrument cluster connectors and make sure
they seat correctly.
z Operate the system and verify the concern is still present.
z Is the concern still present? Yes
INSTALL a new instrument
cluster. REFER to
Instrument Cluster
in this
section. TEST the system
for normal operation.
No
The system is operating
correctly at this time.
Concern may have been
caused by a loose or
corroded connector.
CLEAR the DTCs.
REPEAT the self- test. Test Step Result / Action to Take
S1 CARRY OUT THE INSTRUMENT Klj . 35 ba
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