2003 FORD MUSTANG test G

operating. Failure to follow these instructions could result in damage to the cooling system or
engine and/or personal injury. To avoid having scalding hot coolant or steam blow out of the
cooling system, use extreme care when removing the pressure relief cap from a hot degas
bottle. Wait until the engine has cooled, then wrap a thick cloth around the pressure relief cap
and turn it slowly one turn (counterclockwise). Step back while the pressure is released from
the cooling system. When certain all the pressure has been released, remove pressure relief
cap (still with a cloth).
1. Immerse the pressure relief cap in water and install it on the shallow filler neck of Radiator/Heater Core Pressure Tester and Radiator Cap Adapter, part of Radiator/Heater Core
Pressure Tester.
2. Immerse the filler neck seal in water and install it in the filler neck adapter.
3. Install the filler neck adapter with the filler neck seal to the Radiator Cap Adapter.
4. Connect the female quick- connect fitting of the pressure test pump to the male quick- connect
fitting of the filler neck adapter.
5. NOTE: If the plunger of the pump is depressed too fast, 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.
6. Release the pressure by turning the relief screw counterclockwise. Then tighten the pressure relief screw and repeat Step 6 (at least twice) to make sure the reading is repeatable within the
specifications of the pressure relief cap.
7. 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.
Radiator Leak Test, Removed From the Vehicle CAUTION: Never leak test an aluminum radiator or intercooler in the same water that
copper/brass radiators are tested in. Flux and caustic cleaners may be present in the cleaning
tank and they will damage aluminum radiators and intercoolers.
NOTE: Clean the radiator or intercooler before leak testing to avoid contamination of tank.
1. Leak test the radiator or intercooler in clean water with 138 kPa (20 psi) air pressure. Klj . 6 ba
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DIAGNOSIS AND TESTING
Fuel Charging And Controls
Refer to the Powertrain Control/Emissions Diagnosis (PC/ED) manual.
SECTION 303-
04A: Fuel Charging and Controls — 3.8L 2003 Mustang Workshop Manual Klj . 1 ba
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DIAGNOSIS AND TESTING
Fuel Charging And Controls
Refer to the Powertrain Control/Emissions Diagnosis (PC/ED) manual.
SECTION 303-
04B: Fuel Charging and Controls — 4.6L (2V) 2003 Mustang Workshop Manual Klj . 1 ba
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DIAGNOSIS AND TESTING
Fuel Charging and Controls
Refer to the Powertrain Control/Emissions Diagnosis (PC/ED) manual.
SECTION 303-
04C: Fuel Charging and Controls — Cobra 4.6L (4V) 2003 Mustang Workshop Manual Klj . 1 ba
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DIAGNOSIS AND TESTING
Fuel Charging and Controls
Refer to the Powertrain Control/Emissions Diagnosis (PC/ED) manual.
SECTION 303-
04D: Fuel Charging and Controls — Mach I 4.6L (4V) 2003 Mustang Workshop Manual Klj . 1 ba
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DIAGNOSIS AND TESTING
Accessory Drive
Inspection and Verification
1. Verify customer concern by running the engine.
2. Inspect the drive belt for chunking, fraying and wear.
3. Check the drive belt for correct routing.
Drive Belt Cracking/Chunking/Wear
V Ribbed Serpentine Drive Belt With Cracks Across Ribs
The accessory drive:
zhas a single serpentine drive belt.
z has an automatic drive belt tensioner.
z does not require adjustment.
V Ribbed Belt With Chunks of Rib Missing
Symptom Chart SECTION 303-
05: Accessory Drive 2003 Mustang Workshop Manual Klj . 1 ba
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Component Tests
Drive Belt Noise/Flutter
Drive belt chirp occurs due to pulley misalignment or excessive pulley runout. It can be the result of a
damaged pulley or an incorrectly aligned pulley.
To correct, determine the area where the noise comes from. Check each of the pulleys in that area
with a straightedge to the crankshaft pulley, looking for accessory pulleys out of position in the fore/aft
direction or at an angle to the straightedge.
Drive belt squeal is an intermittent noise that occurs when the drive belt slips on a pulley during certain
conditions, such as: engine start up, rapid engine acceleration, or A/C clutch engagement.
Drive belt squeal can occur:
zif any of the accessories are damaged, have a worn or damaged bearing, internal torsional
resistance above normal. All accessories should be rotatable by hand in the unloaded condition.
If not, inspect the accessory.
z if fluid gets on the drive belt. This includes power steering fluid, engine coolant, engine oil or air
conditioning system lubricant. If fluid does get on the drive belt during service, clean the drive
belt with soap and water and thoroughly rinse with clean water.
z NOTE: The drive belt tensioner arm should rotate freely without binding.
if the drive belt is too long. A drive belt that is too long will allow the drive belt tensioner arm to
go all the way to the arm travel stop under certain load conditions, which will release tension to
the drive belt. If the drive belt tensioner indicator is outside the installation wear range window,
install a new drive belt.
z if the drive belt tensioner is worn or damaged.
Belt Tension
NOTE: Drive belt tension is not adjustable.
The drive belt tensioner automatically adjusts drive belt tension. Symptom Chart Condition
Possible Sources Action
z Drive belt
noise, chirping,
flutter z
Defective/worn drive
belt.
z Misaligned pulley.
z Pulley runout.
z Damaged
accessories.
z Fluid contamination
of drive belt. z
GO to Component Tests, Drive
Belt, Noise/Flutter.
z Damaged or worn
drive belt tensioner. z
GO to Component Tests, Belt
Tensioner, Automatic.
z Premature
drive belt wear z
Defective drive belt.
z Misaligned pulley.
z Pulley runout.
z Damaged
accessories.
z Incorrectly installed
drive belt. z
GO to Component Tests, Drive
Belt Noise/Flutter and Drive
Belt Misalignment diagnosis. Klj . 2 ba
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DIAGNOSIS AND TESTING
Starting System
Refer to Wiring Diagrams Cell
20 , Starting System for schematic and connector information.
Inspection and Verification WARNING: When servicing starter motor or carrying out other underhood work in the
vicinity of the starter motor, be aware that the heavy gauge battery input lead at the starter
solenoid is "electrically hot" at all times. A protective cap or boot is provided over this terminal
that must be installed after servicing. Be sure to disconnect the battery negative cable before
servicing the starter. Failure to follow these instructions may result in personal injury.
WARNING: When working in area of the starter motor, be careful to avoid touching hot
exhaust components. Failure to follow these instructions may result in personal injury.
WARNING: When using a remote starter switch or jumper wire, be sure the ignition switch
is in the OFF position and the transmission is in PARK (A/T) or Neutral (M/T) with the parking
brake control fully applied.
1. Verify the customers concern by operating the starting system to duplicate the conditions.
2. Inspect to determine if any of the following mechanical or electrical concerns apply.
3. If the inspection reveals an obvious concern that can be readily identified, repair as necessary.
4. If the concern remains after the inspection, determine the symptom. GO to Symptom Chart .
SECTION 303-
06: Starting System 2003 Mustang Workshop Manual Special Tool(s)
Digital Multimeter
105-
R0051 or equivalent Visual Inspection Chart
Mechanical Electrical
z
Starter motor
z Brackets z
Battery
z Battery junction box (BJB) fuse ignition switch (40A)
z Central junction box (CJB) Fuse 6 (20A)
z Fuse 24 (10A)
z Damaged wiring harness
z Starter Relay
z Loose or corroded connections Klj . 1 ba
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