2003 FORD MUSTANG brake

z
Seized or heat
damaged
crankshaft main
bearing. z
INSTALL a new crankshaft main
bearing.
z Excessive
crankshaft end
play. z
INSTALL a new thrust bearing or
crankshaft (6303).
z Excessive
connecting rod
bearing clearance. z
INSTALL a new connecting rod
bearing or connecting rod
(6200).
z Heat damaged
connecting rod
bearing (6211). z
INSTALL a new connecting rod
bearing.
z Damaged
connecting rod
bushing (6207). z
INSTALL a new connecting rod
bushing.
z Worn cylinder. zREPAIR or INSTALL a new
cylinder block (6010).
z Worn piston (6108)
or piston pin
(6135). z
INSTALL a new piston or piston
pin.
z Damaged piston
rings. z
INSTALL new piston rings.
z Bent connecting
rod. z
INSTALL a new connecting rod.
z Malfunctioning
valve tappet (6500)
or lash adjuster. z
INSTALL a new valve tappet or
lash adjuster.
z Excessive valve
tappet or lash
adjuster clearance. z
ADJUST clearance or INSTALL
a new valve tappet guide or
valve tappet.
z Broken valve spring
(6513). z
INSTALL a new valve spring.
z Excessive valve
guide clearance. z
ADJUST clearance or INSTALL
a new valve guide (6510) or
valve.
z Insufficient
power z
Malfunctioning or
damaged ignition
system. z
Refer to the appropriate section
in Group 303 for the procedure.
REFER to the Powertrain
Control/Emissions Diagnosis
(PC/ED) manual.
z Malfunctioning or
damaged fuel
system. z
Refer to the appropriate section
in Group 303 for the procedure.
REFER to the Powertrain
Control/Emissions Diagnosis
(PC/ED) manual.
z Malfunctioning or
damaged air intake
system. z
Refer to the appropriate section
in Group 303 for the procedure.
REFER to the Powertrain
Control/Emissions Diagnosis
(PC/ED) manual.
z Damaged or
plugged exhaust
system. z
INSPECT exhaust system.
z Incorrect tire size. zREFER to Section 204 - 04 .
z Dragging brakes. zREFER to Section 206 - 00 . Klj . 5 ba
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4. WORN RINGS OR DILUTED OIL: When the engine is accelerated (dotted needle), the needle
drops to 0 kPa (0 in- Hg). Upon deceleration, the needle runs slightly above 74 kPa (22 in- Hg).
5. STICKING VALVES: When the needle (dotted) remains steady at a normal vacuum but occasionally flicks (sharp, fast movement) down and back about 13 kPa (4 in- Hg), one or more
valves may be sticking.
6. BURNED OR WARPED VALVES: A regular, evenly- spaced, downscale flicking of the needle
indicates one or more burned or warped valves. Insufficient hydraulic lash adjuster or hydraulic
lash adjuster (HLA) clearance will also cause this reaction.
7. POOR VALVE SEATING: A small but regular downscale flicking can mean one or more valves are not seating.
8. WORN VALVE GUIDES: When the needle oscillates over about a 13 kPa (4 in- Hg) range at idle
speed, the valve guides could be worn. As engine speed increases, the needle will become
steady if guides are responsible.
9. WEAK VALVE SPRINGS: When the needle oscillation becomes more violent as engine rpm is increased, weak valve springs are indicated. The reading at idle could be relatively steady.
10. LATE VALVE TIMING: A steady but low reading could be caused by late valve timing.
11. IGNITION TIMING RETARDING: Retarded ignition timing will produce a steady but somewhat low reading.
12. INSUFFICIENT SPARK PLUG GAP: When spark plugs are gapped too close, a regular, small pulsation of the needle can occur.
13. INTAKE LEAK: A low, steady reading can be caused by an intake manifold or throttle body gasket leak.
14. BLOWN HEAD GASKET: A regular drop of fair magnitude can be caused by a blown head gasket or warped cylinder head- to-cylinder block surface.
15. RESTRICTED EXHAUST SYSTEM: When the engine is first started and is idled, the reading may be normal, but as the engine rpm is increased, the back pressure caused by a clogged
muffler (5230), kinked tail pipe or other concerns will cause the needle to slowly drop to 0 kPa
(0 in-Hg). The needle then may slowly rise. Excessive exhaust clogging will cause the needle to
drop to a low point even if the engine is only idling.
16. When vacuum leaks are indicated, search out and correct the cause. Excess air leaking into the system will upset the fuel mixture and cause concerns such as rough idle, missing on
acceleration or burned valves. If the leak exists in an accessory unit such as the power brake
booster (2005), the unit will not function correctly. Always fix vacuum leaks.
Excessive Engine Oil Consumption
The amount of oil an engine uses will vary with the way the vehicle is driven in addition to normal
engine- to-engine variation. This is especially true during the first 16,100 km (10,000 miles) when a new
engine is being broken in or until certain internal engine components become conditioned. Vehicles
used in heavy- duty operation may use more oil. The following are examples of heavy- duty operation:
z trailer towing applications
z severe loading applications
z sustained high speed operation Klj . 12 ba
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IN-
VEHICLE REPAIR
Valve Cover LH
Removal and Installation 1. Remove the Hydro Boost brake booster. For additional information, refer to Section 206 - 07 .
2. Remove the LH ignition coils. For additional information, refer to Section 303 - 07C .
3. Disconnect the engine coolant temperature (ECT) sensor and unclip the wiring harness from the stud.
4. Unclip the wiring harness from the power steering bracket.
5. Disconnect the electrical connectors from the fuel pulse damper, EGR vacuum regulator solenoid, supercharger bypass vacuum solenoid, and the differential pressure feedback EGR
system.
SECTION 303-
01C: Engine — Cobra 4.6L (4V) 2003 Mustang Workshop Manual Material
Item Specification
Silicone Gasket and Sealant
F7AZ-
19554- EA WSE-
M4G323- A4 Metal Surface Cleaner
F4AZ-
19A536- RA WSE-
M5B392- A Klj . 1 ba
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IN-
VEHICLE REPAIR
Valve Cover LH
Removal
All vehicles 1. Remove the air intake scoop. For additional information, refer to Section 303 - 12 .
2. Remove the Hydro- Boost brake booster. For additional information, refer to Section 206 - 07 .
3. Raise and support the vehicle. For additional information, refer to Section 100 - 02 .
Manual transmission vehicles
4. Remove the screw and the dust shield.
5. Disengage the clutch release cable from the clutch release fork.
SECTION 303-
01D: Engine — Mach I 4.6L (4V) 2003 Mustang Workshop Manual Material
Item Specification
Metal Surface Cleaner
F4AZ-
19A536- RA or
equivalent WSE-
M5B392- A Silicone Gasket and Sealant
F7AZ-
19554- EA or equivalent WSE-
M4G323-
A4 Klj . 1 ba
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14. Lower the vehicle.
All vehicles 15. Install the Hydro- Boost brake booster. For additional information, refer to Section 206 - 07 .
16. Install the air intake scoop. For additional information, refer to Section 303 - 12 . Klj . 8 ba
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IN-
VEHICLE REPAIR
Engine Front Cover
Removal
All vehicles 1. Remove the air intake scoop bracket. For additional information, refer to Section 303 - 12 .
2. Remove the RH valve cover. For additional information, refer to Valve Cover RH in this section.
3. Remove the Hydro- Boost brake booster. For additional information, refer to Section 206 - 07 .
Manual transmission vehicles
4. Remove the two clutch release cable retaining screws.
All vehicles 5. Remove the LH ignition coil cover bolts and the cover.
SECTION 303-
01D: Engine — Mach I 4.6L (4V) 2003 Mustang Workshop Manual Material
Item Specification
Metal Surface Cleaner
F4AZ-
19A536- RA or equivalent WSE-
M5B392-
A Silicone Gasket and Sealant
F7AZ-
19554- EA or equivalent WSE-
M4G323-
A4 SAE 5W-
30 Premium Synthetic
Blend Motor Oil
XO- 5W30-QSP or equivalent WSS-
M2C153-
G Klj . 1 ba
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Manual transmission vehicles
36. Install the clutch release cable screws.
All vehicles 37. Install the RH valve cover. For additional information, refer to Valve Cover RH in this section.
38. Install the Hydro- Boost brake booster. For additional information, refer to Section 206 - 07 .
39. Install the air intake scoop bracket. For additional information, refer to Section 303 - 12 .
40. Fill the crankcase with clean engine oil. Klj . 20 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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