2003 FORD MUSTANG fuel

REMOVAL AND INSTALLATION
Charge Air Cooler
Removal and Installation
1. Drain the supercharger coolant. For additional information, refer to Section 303 - 03B .
2. Release the fuel pressure. For additional information, refer to Section 310 - 00 .
3. Disconnect the supercharger degas hose.
4. Disconnect the coolant hose.
5. Remove the supercharger belt. For additional information, refer to Section 303 - 05 .
6. Remove the air cleaner outlet tube. For additional information, refer to Section 303 - 12 .
7. Disconnect the throttle position (TP) sensor and the idle air control (IAC) valve electrical connectors.
SECTION 303-
12: Intake Air Distribution and Filtering 2003 Mustang Workshop Manual Material
Item Specification
Silicone Gasket and Sealant
F7AZ-
19554- EA or equivalent WSE-
M4G323- EA Klj . 1 ba
102003 Mustang Workshop Manual
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8. Disconnect the vacuum hose.
9. Disconnect the fuel supply spring lock coupler. For additional information, refer to
Section 310 -
00 .
10. Disconnect the accelerator controls. zDisconnect the accelerator cable.
z If equipped, disconnect the speed control cable. 11. Remove the accelerator cable bracket bolts. Klj . 2 ba
102003 Mustang Workshop Manual
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12. Remove the throttle body and spacer assembly.
13. Release the clip and position the accelerator cable bracket and the cables aside.
14. Disconnect the electrical connectors from the fuel pulse damper, EGR vacuum regulator
solenoid, supercharger bypass vacuum solenoid, and the differential pressure feedback EGR
system.
15. Disconnect the vacuum hoses from the differential pressure feedback EGR system. Klj . 3 ba
102003 Mustang Workshop Manual
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16. Disconnect the vacuum hoses from the supercharger bypass vacuum solenoid, and the
actuator.
17. Disconnect the vacuum hoses from the fuel pulse damper and the EGR vacuum regulator solenoid.
18. Disconnect the vacuum hose from the EGR valve.
19. Disconnect the vacuum hoses at the back of the supercharger and position the vacuum harness aside. Klj . 4 ba
102003 Mustang Workshop Manual
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24. Disconnect the positive crankcase ventilation (PCV) hose.
25. Separate the fuel charging wiring harness from the fuel injection supply manifold in four places
and position the harness aside.
26. Remove the ten bolts, the intake manifold, supercharger and fuel supply manifold as an assembly.
27. Disconnect and remove the PCV hoses. Klj . 6 ba
102003 Mustang Workshop Manual
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28. Remove the coolant supply and return manifold.
29. Remove the coolant supply and return tubes and seals.
30. Remove the fuel supply manifold mounting studs.
31. Remove the fuel supply manifold and fuel injectors as an assembly. Klj . 7 ba
102003 Mustang Workshop Manual
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DESCRIPTION AND OPERATION
Evaporative Emissions
Component Location
The evaporative emission system:
zis equipped with an on- board refueling vapor recovery (ORVR) system.
SECTION 303-
13: Evaporative Emissions 2003 Mustang Workshop Manual Item Part Number Description
1 9F980 Evaporative emission test port
2 9C915 Evaporative emission canister purge valve
3 9F945 Canister vent solenoid
4 9D653 Evaporative emission canister
5 9C047 Fuel vapor control valve tube assembly Klj . 1 ba
32003 Mustang Workshop Manual
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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
32003 Mustang Workshop Manual
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