2003 FORD MUSTANG ESP

Cleaning
1. Fabricate a cleaning tool from a 1/8 inch diameter brazing rod.
2. Cut an abrasive pad from maroon colored 3M Scotch Brite® with the dimensions corresponding to the coupling size.
3. Assemble the pad to the tool.
4. Coat the abrasive pad with PAG Refrigerant Compressor Oil (R- 134a Systems) or equivalent.
5. Roll the pad on the tool and install it in a variable speed drill motor.
6. CAUTION: Maintain low speed drill rotation when inserting or removing the cleaning Coupling Size Pad Size
3/8 inch 25 x 50 mm (1 x 2 inch)
1/2 inch 25 x 50 mm (1 x 2 inch)
5/8 inch 25 x 76 mm (1 x 3 inch)
3/4 inch 25 x 102 mm (1 x 4 inch) Klj . 3 ba
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COOL (blue) to WARM (red) causes a corresponding movement on the air temperature control
door and determines the temperature that the system will maintain.
z The A/C heater function selector switch combines a vacuum selector valve for direct control of
the vacuum control motors and electrical input to the instrument control module.
Control System Outputs
Blower Motor Switch Resistor
The heater blower motor switch resistor has the following features:
zThe assembly is located on the passenger side of the plenum assembly behind the glove
compartment (06010).
z Three resistance elements are mounted on the resistor board to provide four A/C blower motor
speeds.
z Depending on the heater blower motor switch position, series resistance is added or bypassed
in the A/C blower motor circuit to decrease or increase A/C blower motor speed.
z An overheating protective device (thermal limiter) will open the resistor coil circuit when the
temperature reaches 105°- 110°C (221°-230°F), interrupting the blower motor operation in all
speeds except HI.
z The thermal limiter cannot be reset and is not serviceable.
Control Actuators
Temperature Control Cable
The temperature control cable (19988) has the following features:
zThe cable assembly has a constant tension (pull- pull) dual cable design.
z The pull- pull design allows for constant smooth communication between the temperature control
knob and the air temperature blend door.
z The control cable can only be installed as an assembly.
Vacuum Control Motors
The vacuum control motors (18A318) control the position of the doors directing the air flow to the
different outlets. There are two types of vacuum control motors used in this system:
zSingle- diaphragm for air inlet and windshield defroster door operations.
z Double- diaphragm for air damper door operations.
Single- diaphragm motors have two positions:
z Shaft extended with no vacuum applied.
z Shaft retracted with vacuum applied.
Double- diaphragm motors have three positions:
z Shaft extended with no vacuum applied to either port.
z Shaft halfway retracted with vacuum applied to only one port. Klj . 3 ba
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3. If an obvious cause for an observed or reported concern is found, correct the cause (if possible)
before proceeding to the next step.
4. If the concern remains after the inspection, connect the diagnostic tool to the data link connector (DLC) located beneath the instrument panel and select the vehicle to be tested from the
diagnostic tool menu. If the diagnostic tool does not communicate with the vehicle:
zcheck that the program card is correctly installed.
z check the connections to the vehicle.
z check the ignition switch position.
5. If the diagnostic tool still does not power up, refer to the diagnostic tool operating manual.
6. Carry out the DATA LINK DIAGNOSTICS test. If the diagnostic tool responds with: zCKT914, CKT915 OR CKT70 = ALL ECUS NO RESP/NOT EQUIP, refer to Section 418 -
00 .
z NO RESP/NOT EQUIP for the instrument cluster, Go To Pinpoint Test A or for the
generic electronic module (GEM), Go To Pinpoint Test W .
z SYSTEM PASSED, retrieve and record the continuous diagnostic trouble codes (DTCs),
erase the continuous DTCs and carry out the self- test diagnostics for the instrument
cluster or the GEM.
7. If the DTCs retrieved are related to the concern, go to the Instrument Cluster Diagnostic Trouble Code (DTC) Index or the GEM Diagnostic Trouble Code Index to continue diagnostics.
8. If no DTCs related to the concern are retrieved, proceed to the Symptom Chart to continue diagnostics.
Instrument Cluster Self- Diagnostic Mode
To enter the instrument cluster self- diagnostic mode, press and hold the instrument cluster
SELECT/RESET button, turn the ignition switch to the RUN position, and then continue pressing the
SELECT/RESET button (five seconds) until tESt is displayed in the odometer. The SELECT/RESET
button must be released within three seconds of the odometer tESt display to begin the self- diagnostic
mode. Press the SELECT/RESET button to advance through the following steps until dtc is displayed.
Depressing the SELECT/RESET button will display any stored continuous DTCs before proceeding to
the next step. z
Engine coolant level
z Accessory drive belt
z Engine oil level
z Parking brake position switch
z Brake fluid level
z Boost gauge pressure line „
5 (15A)
„ 7 (15A)
„ 11 (15A)
„ 13 (15A)
„ 21 (5A)
„ 23 (15A)
„ 24 (30A)
„ 29 (15A)
„ 30 (15A)
„ 32 (15A)
„ 34 (20A)
„ 35 (15A)
„ 37 (5A)
„ 38 (20A)
„ 39 (5A)
z Circuitry Klj . 5 ba
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4. If the concern remains after the inspection, connect the diagnostic tool to the data link connector
(DLC) located beneath the instrument panel and select the vehicle to be tested from the
diagnostic tool menu. If the diagnostic tool does not communicate with the vehicle:
zcheck that the program card is correctly installed.
z check the connections to the vehicle.
z check the ignition switch position.
5. If the diagnostic tool still does not communicate with the vehicle, refer to the diagnostic tool manual.
6. Carry out the Data Link Diagnostic Test. If the diagnostic tool responds with: zCKT914, CKT915 or CKT70 = ALL ECUS NO RESP/NOT EQUIP, refer to Section 418 -
00 .
z NO RESP/NOT EQUIP for GEM, go to Pinpoint Test A.
z NO RESP/NOT EQUIP for RCM, refer to Section 501 - 20B .
z SYSTEM PASSED, retrieve and record the continuous diagnostic trouble codes (DTCs),
erase the continuous DTCs and carry out self- test diagnostics for the GEM.
7. If the DTCs retrieved are related to the concern, go to the GEM Diagnostic Trouble Code (DTC) Index to continue diagnostics.
8. If no DTCs related to the concern are retrieved, proceed to the Symptom Chart to continue diagnostics.
9. If the DTCs retrieved are for the RCM, refer to Section 501 - 20B .
Visual Inspection Chart Mechanical Electrical
z
Switch(es) z
Central junction box (CJB) fuses:
„28 (15A)
„ 32 (15A)
„ 39 (5A)
z Circuitry
GEM Diagnostic Trouble Code (DTC) Index DTC Description Source Action
B1340 Chime Input Request
Circuit Short to Ground GEM Go To Pinpoint Test C .
B1342 ECU Is Defective GEM CLEAR the DTCs. TEST the system for normal operation.
RETRIEVE the DTCs. If DTC B1342 is retrieved, INSTALL
a new GEM. REFER to
Section 419 - 10 .
B1353 Ignition Key-
In Circuit
Open GEM Go To Pinpoint Test B .
B1462 Safety Belt Switch
Circuit Failure GEM Go To Pinpoint Test F . Klj . 3 ba
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Battery—
Drain Tests
NOTE: No production vehicle should have more than a 50 mA (0.050 amp) continuous draw.
Check for current drains on the battery in excess of 50 milliamps (0.050 amp) with all the electrical
accessories off and the vehicle at rest. Current drains can be tested with the following procedure:
WARNING: Do not attempt this test on a lead- acid battery that has recently been
recharged. Explosive gases can cause personal injury.
CAUTION: To prevent damage to the meter, do not crank the engine or operate
accessories that draw more than 10A.
NOTE: Many modules draw 10 mA (0.010 amp) or more continuously.
NOTE: Use an in- line ammeter between the battery positive or negative post and its respective cable.
NOTE: Typically, a drain of approximately one amp can be attributed to an engine compartment lamp,
glove compartment lamp, or luggage compartment lamp staying on continually. Other component
failures or wiring shorts may be located by selectively pulling fuses to pinpoint the location of the
current drain. When the current drain is found, the meter reading will fall to an acceptable level. If the
drain is still not located after checking all the fuses, it may be due to the generator.
NOTE: To accurately test the drain on a battery, an in- line digital ammeter must be used. Use of a test
lamp or voltmeter is not an accurate method due to the number of electronic modules.
1. Make sure the junction box/fuse panels are accessible without turning on interior and underhood lights.
2. Drive the vehicle at least five minutes and over 48 km/h (30 mph) to turn on and exercise vehicle systems.
3. Allow the vehicle to sit with the key off for at least 40 minutes to allow modules to time out/power down.
4. Connect a fused jumper wire between the negative battery cable and the negative battery post to prevent modules from resetting and to catch capacitive drains.
5. Disconnect the negative battery cable from the post without breaking the connection of the jumper wire.
6. NOTE: It is very important that continuity is not broken between the battery and the negative
battery cable when connecting the meter. If this happens, the entire procedure must be
repeated.
Connect the tester between the negative battery cable and the post. The meter must be capable
of reading milliamps and should have a 10 amp capability.
7. NOTE: If the meter settings need to be switched or the test leads need to be moved to another
jack, the jumper wire must be reinstalled to avoid breaking continuity.
Remove the jumper wire.
NOTE: Amperage draw will vary from vehicle to vehicle depending on the equipment package.
Compare to a comparable vehicle for reference.
NOTE: No production vehicle should have more than a 50 mA (0.050 amp) draw. Klj . 11 ba
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8. If the draw is found to be excessive, pull fuses from the battery/central junction box one at a
time and note the current drop. Do not reinstall the fuses until you are finished testing.
9. Check the wiring schematic in the wiring diagram for any circuits that run from the battery without passing through the battery/central junction box. Disconnect these circuits if the draw is
still excessive.
Battery— Electronic Drains Which Shut Off When the Battery Cable is Disconnected
1. Repeat the steps of the battery drain testing.
2. Make sure all doors are closed and accessories are off. Without starting the engine, turn the ignition switch to RUN for a moment and then OFF. Wait a few minutes for the illuminated entry
lamps to turn off if equipped.
3. Connect the ammeter and read the amperage draw.
The current reading (current drain) should be less than 50 mA (0.05 amp). If the current drain exceeds
50 mA (0.05 amp) after a few minutes, and if this drain did not show in previous tests, the drain is most
likely caused by an inoperative electronic component. As in previous tests, remove the fuses from the
battery/central junction box one at a time to locate the problem circuit.
Generator On- Vehicle Tests
CAUTION: To prevent damage to the generator, do not make jumper wire connections
except as directed.
CAUTION: Do not allow any metal object to come in contact with the housing and the
internal diode cooling fins with key on or off. A short circuit will result and burn out the diodes.
NOTE: Battery posts and cable clamps must be clean and tight for accurate meter indications.
NOTE: Refer to the Battery Tester Procedure Manual for complete directions for testing the charging
system.
1. Turn off all lamps and electrical components.
2. Place the vehicle in transmission range NEUTRAL and apply the parking brake.
3. Carry out the Load Test and No- Load Test according to the following component tests:
Generator On- Vehicle Tests— Load Test
1. Switch the battery tester to the ammeter function.
2. Connect the positive and negative leads of the battery tester to the corresponding battery terminals.
3. Connect the current probe to the generator B+ output terminal, circuit 38 (BK/OG). Klj . 12 ba
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Pinpoint Tests speakers
zSubwoofer
amplifier.
z Circuitry. E .
z Poor quality sound from one or
more speakers (not all
speakers) z
Speaker(s).
z Circuitry.
z Audio unit.
z Subwoofer
amplifier. z
Go To Pinpoint Test F .
z Poor quality sound from all
speakers z
Audio unit.
z Speaker(s).
z Circuitry. z
Go To Pinpoint Test G .
z The subwoofer is inoperative zSubwoofer.
z Subwoofer
amplifier.
z Circuitry. z
Go To Pinpoint Test H .
z Loud popping when cycling the
ignition switch z
Audio unit.
z Circuitry. z
Go To Pinpoint Test I .
z One or more audio control
buttons (such as volume, seek,
tune and scan) are not
functional in either radio, tape,
or CD mode or all modes z
Audio unit. zREMOVE the audio
unit and SEND it to
an authorized Ford
audio system repair
facility. TEST the
system for normal
operation.
z When the headlamp switch is in
park or headlamp position and
the ignition switch is in the RUN
or ACC position, the audio unit
back lighting is inoperative — all
other I/P lighting functions are
normal z
Circuitry.
z Audio unit. z
REFER to Section 413 - 00 .
z The audio unit has two items
that can be dimmed— the audio
unit display and the control
buttons; one dims and the other
does not z
Audio unit. zREMOVE the audio
unit and SEND it to
an authorized Ford
audio system repair
facility. TEST the
system for normal
operation.
z Irregular operation of display
and indicator LEDs z
Audio unit. zREMOVE the audio
unit and SEND it to
an authorized Ford
audio system repair
facility. TEST the
system for normal
operation.
z Response time between
pressing any of the audio
control buttons and system
response is more than two
seconds z
Audio unit. zREMOVE the audio
unit and SEND it to
an authorized Ford
audio system repair
facility. TEST the
system for normal
operation. Klj . 3 ba
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z
Does the voltage vary as the volume is adjusted? D11 CHECK AUDIO SIGNAL CIRCUITS AT THE AFFECTED
SUBWOOFER AMPLIFIER FOR OPEN AND SHORT TO GROUND z
Key in OFF position.
z Disconnect: Audio Unit C290a.
z Measure the resistance between the affected subwoofer amplifier
and the audio unit C290a, and between the affected subwoofer
amplifier and ground as follows:
z Is the resistance less than 5 ohms between the audio unit and
subwoofer amplifier and greater that 10,000 ohms between the
subwoofer amplifier and ground? Speaker Circuits Audio Unit C290a Pin Subwoofer Amplifier Pin Circuit
2 8 172 (LB/RD)
8 7 169 (LG/BK) Yes
SEND the audio
unit to an
authorized Ford
audio system
repair facility.
TEST the system
for normal
operation.
No
REPAIR the circuit
(s) in question.
TEST the system
for normal
operation.
D12 CHECK FOR AN AUDIO SIGNAL AT THE AFFECTED
SUBWOOFER z
Key in OFF position.
z Connect: Affected Subwoofer Amplifier.
z Disconnect: Affected Subwoofer Speaker .
z Key in ON position.
z Turn on the audio unit and check for a fluctuating AC voltage
between affected subwoofer as follows: For right subwoofer pin 4,
circuit 187 (DB/OG) and pin 2, circuit 189 (LG/BK) harness side; and
between pin 3, circuit 179 (OR/RD) and pin 1, circuit 176 (PK/LG)
harness side. For left subwoofer pin 1, circuit 187 (DB/OR) and pin 3,
circuit 189 (LG/BK) harness side; and between pin 2, circuit 179
(OR/RD) and pin 4, circuit 176 (PK/LG) harness side.
z Does the voltage vary as the volume is adjusted? Yes
INSTALL a new
subwoofer
speaker.
No
GO to
D13 .
D13 CHECK FOR AN OPEN AND SHORT TO GROUND BETWEEN THE
AFFECTED SUBWOOFER AND ITS RESPECTIVE AMPLIFIERS z
Key in OFF position. Yes Klj . 11 ba
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