2003 FORD MUSTANG service

Power Steering Pump —
CII
Power Steering Pump — CIII
Power Steering Gear Identification CAUTION: Always use the ID code when ordering service parts. The steering gear identification code is stamped into the housing. 2 — To left turn port
3 — To right turn port
4 — Return port (out)
5 — Pressure port (in)
6 — Oil flow —
right turn 7 — Air transfer tube (between bellows) Klj . 4 ba
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Power Steering Pump Identification
CAUTION: Always use the ID code when ordering service parts.
The pump identification code is located on a tag attached to the power steering pump. Item Part Number Description
1 — Steering gear housing
2 — Mounting boss
3 — Shift code
4 — Day code
5 — Month code
6 — Build year
7 — Steering gear model code
Item Part
Number Description
1 — Model code
2 — For manufacturing purposes only
3 — Day of the month (A = Jan., B = Feb., etc., I is not
used)
4 — Shift
5 — Month
6 — Year Klj . 5 ba
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DISASSEMBLY AND ASSEMBLY
Gear
Disassembly
NOTE:
The steering gear is serviceable as either a long or short rack assembly. This procedure covers
the removal and installation of the components not supplied with a short rack assembly. On short rack
assembly only the front wheel spindle tie- rods and front suspension steering ball stud dust seals are
serviced separately.
All steering gears
1. Remove the steering gear mounting bracket housing insulators. zDiscard worn or damaged steering gear mounting bracket housing insulators.
SECTION 211-
02: Power Steering 2003 Mustang Workshop Manual Special Tool(s)
Head Mounting Fixture
303-
D041 (D83L-500- B1) or
Equivalent Inner Tie Rod Socket Tool
211-
D025 (D90P-3290- A) or
Equivalent Steering Gear Holding Fixture
211-
D011 (D87P-3504- B) or
Equivalent
Material Item Specification
Multi-
Purpose Grease
XG- 4 ESR-
M1C159-
A Silicone Brake Caliper Grease
and Dielectric Compound
D7AZ-
19A331- A ESE-
M1C171-
A Klj . 1 ba
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GENERAL PROCEDURES
Supplemental Restraint System (SRS) Deactivation and
Reactivation
Deactivation
WARNING: Always wear safety glasses when repairing an air bag supplemental restraint
system (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury
in the event of an accidental deployment.
WARNING: After deployment, the air bag surface can contain deposits of sodium
hydroxide, a product of the gas generant combustion that is irritating to the skin. Wash your
hands with soap and water afterwards.
WARNING: Never probe the connectors on the air bag module. Doing so can result in air
bag deployment, which can result in personal injury.
WARNING: Air bag modules with discolored or damaged trim covers must be installed
new, not repainted.
WARNING: The restraint system diagnostic tool is for restraint system service only.
Remove from vehicle prior to road use. Failure to remove could result in injury and possible
violation of vehicle safety standards.
1. WARNING: To avoid accidental deployment and possible personal injury, the
backup power supply must be depleted before repairing or replacing any front or side air
bag supplemental restraint system (SRS) components and before servicing, replacing,
adjusting or striking components near the front or side air bag sensors, such as doors,
instrument panel, console, door latches, strikers, seats and hood latches.
Please refer to the appropriate vehicle shop manual to determine location of the front air
bag sensors.
The side air bag sensors are located at or near the base of the B- pillar.
To deplete the backup power supply energy, disconnect the battery ground cable and
wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). SECTION 211-
04: Steering Column 2003 Mustang Workshop Manual Special Tool(s)
Diagnostic Tool, Restraint
System (2 Req'd)
418-
F088 (105- R0012) Klj . 1 ba
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10. Connect the battery ground cable. For additional information, refer to
Section 414 - 01 .
11. WARNING: The restraint system diagnostic tool is for restraint system service only.
Remove from vehicle prior to road use. Failure to remove could result in injury and
possible violation of vehicle safety standards.
With all the restraint system diagnostic tools removed, prove out the supplemental restraint
system (SRS). For additional information, refer to Section 501 - 20B . Klj . 6 ba
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1. If compression improves considerably, piston rings are faulty.
2. If compression does not improve, valves are sticking or seating incorrectly.
3. If two adjacent cylinders indicate low compression pressures and squirting oil on each piston
does not increase compression, the head gasket may be leaking between cylinders. Engine oil
or coolant in cylinders could result from this condition.
Use the Compression Pressure Limit Chart when checking cylinder compression so that the
lowest reading is within 75 percent of the highest reading.
Cylinder Leakage Detection
When a cylinder produces a low reading, use of the Engine Cylinder Leak Detection/Air Pressurization
Kit will be helpful in pinpointing the exact cause.
The leakage detector is inserted in the spark plug hole, the piston is brought up to dead center on the
compression stroke, and compressed air is admitted.
Once the combustion chamber is pressurized, a special gauge included in the kit will read the
percentage of leakage. Leakage exceeding 20 percent is excessive.
While the air pressure is retained in the cylinder, listen for the hiss of escaping air. A leak at the intake
valve (6507) will be heard in the throttle body (9E926). A leak at the exhaust valve (6505) can be
heard at the tail pipe. Leakage past the piston rings will be audible at the positive crankcase ventilation
(PCV) connection. If air is passing through a blown head gasket to an adjacent cylinder, the noise will
be evident at the spark plug hole of the cylinder into which the air is leaking. Cracks in the cylinder
block or gasket leakage into the cooling system may be detected by a stream of bubbles in the radiator
(8005).
Oil Consumption Test
The following diagnostic procedure is used to determine the source of excessive internal oil
consumption. 1. NOTE: Oil use is normally greater during the first 16,100 km (10,000 miles) of service. As
mileage increases, oil use generally decreases. Vehicles in normal service should get at least
1,450 km per liter (900 miles per quart) after 16,000 km (10,000 miles) of service. High speed
driving, towing, high ambient temperature and other factors may result in greater oil use.
Define excessive oil consumption, such as the number of miles driven per liter (quart) of oil
used. Also determine customer's driving habits, such as sustained high speed operation,
towing, extended idle and other considerations.
2. Verify that the engine has no external oil leak as described under Engine Oil Leaks in the Diagnosis and Testing portion of this section.
3. Verify that the engine has the correct oil level dipstick (6750).
4. Verify that the engine is not being run in an overfilled condition. Check the oil level at least five minutes after a hot shutdown with the vehicle parked on a level surface. In no case should the
level be above MAX or the letter F in FULL. If significantly overfilled, carry out Steps 6a through
6d.
5. Verify the spark plugs are not oil saturated. If the spark plugs are oil saturated and compression is good it can be assumed the valve seals or valve guides are at fault. Klj . 9 ba
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6. Carry out an oil consumption test:
a. Drain the engine oil, remove the oil bypass filter (6714) and refill with one liter (quart) less than
the recommended amount.
b. Run the engine for three minutes (10 minutes if cold), and allow the oil to drain back for at least five minutes with the vehicle on a level surface.
c. Remove oil level dipstick and wipe clean. (Do not wipe with anything contaminated with silicone compounds.) Reinstall the oil level dipstick, being sure to seat it firmly in the oil level indicator
tube (6754). Remove the oil level dipstick and draw a mark on the back (unmarked) surface at
the indicated oil level. This level should be about the same as the MIN or ADD mark on the face
of the oil level dipstick.
d. Add one liter (quart) of oil. Restart the engine and allow to idle for at least two minutes. Shut off the engine and allow the oil to drain back for at least five minutes. Mark the oil level dipstick,
using the procedure above.
e. Record the vehicle mileage. f. Instruct the customer to drive the vehicle as usual and perform the following:
„Check the oil level regularly at intervals of 160 to 240 km (100- 150 miles).
„ Return to the service point when the oil level drops below the lower (MIN or ADD) mark
on the oil level dipstick.
„ Add only full liters (quarts) of the same oil in an emergency. Note the mileage at which
the oil is added.
g. Check the oil level under the same conditions and at the same location as in Steps 6c and 6d.
„Measure the distance from the oil level to the UPPER mark on the oil level dipstick and
record.
„ Measure the distance between the two scribe marks and record.
„ Divide the first measurement by the second.
„ Divide the distance driven during the oil test by the result. This quantity is the
approximate oil consumption rate in kilometers per liter or in miles per quart.
h. If the oil consumption rate is unacceptable, go to Step 7.
7. Check the positive crankcase ventilation (PCV) system. Make sure the system is not plugged.
8. Check for plugged oil drain- back holes in the cylinder heads and cylinder block.
9. If the condition still exists after performing the above steps, go to Step 10.
10. Perform a cylinder compression test or perform a cylinder leak detection test with Engine Cylinder Leak Detection/Air Pressurization Kit. This can help determine the source of oil
consumption such as valves, piston rings or other areas.
11. NOTE: After determining if new parts should be installed, make sure correct parts are used.
Check valve guides for excessive guide clearance. Install new all valve stem seals (6571) after
verifying valve guide clearance.
12. Worn or damaged internal engine components can cause excessive oil consumption. Small deposits of oil on the tips of spark plugs can be a clue to internal oil consumption. If internal oil
consumption still persists, proceed as follows:
a. Remove the engine from the vehicle and place it on an engine work stand. Remove the intake manifolds (9424), cylinder heads, oil pan (6675) and oil pump (6600).
b. Check piston ring clearance, ring gap and ring orientation. Repair as necessary.
c. Check for excessive bearing clearance. Repair as necessary.
13. Repeat the oil consumption test (Step 6) to confirm the oil consumption concern has been resolved. Klj . 10 ba
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Valve Train Analysis—
Engine Running
z Start the engine and, while idling, check for correct operation of all parts. Check the following:
Valve Train Analysis— Engine Running, Valves and Cylinder Head
z Check for plugged oil drain back holes.
z Check for missing or damaged valve stem seals or guide mounted valve stem seals.
z Check for a plugged oil metering orifice in the cylinder head oil reservoir (4.6L engine only).
If insufficient oiling is suspected, check oil passages for blockage, then accelerate the engine to 1,200
rpm with the transmission in NEUTRAL and the engine at normal operating temperature. Oil should
spurt from the rocker arm oil holes such that valve tips and camshaft roller followers are well oiled.
With the valve covers (6582) off, some oil splash may overshoot camshaft roller followers.
Valve Train Analysis— Engine Running, Camshaft Lobe Lift— OHC Engines
Check the lift of each camshaft lobe in consecutive order and make a note of the readings. 1. Remove the valve covers.
2. Remove the spark plugs.
3. Install the Dial Indicator Gauge with Holding Fixture so the rounded tip of indicator is on top of the camshaft lobe and on the same plane as the valve tappet.
4. Rotate the crankshaft using a breaker bar and socket attached to the crankshaft pulley retainer bolt. Rotate the crankshaft until the base circle of the camshaft lobe is reached.
5. Zero the dial indicator. Continue to rotate the crankshaft until the (1) high- lift point of the
camshaft lobe is in the fully- raised position (highest indicator reading).
6. To check the accuracy of the original indicator reading, continue to rotate crankshaft until the (2) base circle is reached. The indicator reading should be zero. If zero reading is not obtained,
repeat Steps 1 through 6.
7. NOTE: If the lift on any lobe is below specified service limits, install a new camshaft, and new
camshaft roller followers.
Remove the Dial Indicator Gauge with Holding Fixture.
8. Install the spark plugs. Klj . 15 ba
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