2003 FORD MUSTANG air condition

GENERAL PROCEDURES
Purging —CIII Power Steering Pump
CAUTION: If the air is not purged from the power steering system correctly, premature
power steering pump failure can result. This condition can occur on pre- delivery vehicles with
evidence of aerated fluid or on vehicles that have had steering component repairs.
1. NOTE: A whine heard from the power steering pump may be caused by air in the system. The
power steering purge procedure must be performed prior to any component repair for which
power steering noise complaints are accompanied by evidence of aerated fluid.
Remove the reservoir cap. Check the fluid level. If necessary, fill the reservoir to the correct
level.
zUse Motorcraft MERCON® Multi-Purpose ATF XT -2-QDX or MERCON® equivalent.
2. Tightly insert the Vacuum Pump stopper into the reservoir.
3. Start the vehicle.
4. Using the special tool, apply maximum vacuum and maintain it for a minimum of three minutes with the engine speed set at idle. SECTION 211-
00: Steering System — General Information 2003 Mustang Workshop Manual Special Tool(s)
Vacuum Pump
416-
D002 (D95L-7559- A) or
Equivalent Klj . 1 ba
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Inspection and Verification
1. Verify the customer concern by operating the engine to duplicate the condition.
2. Visually inspect for obvious signs of mechanical damage. Refer to the following chart.
3. If the inspection reveals obvious concerns that can be readily identified, repair as necessary.
4. If the concerns remain after the inspection, determine the symptoms. GO to Symptom Chart .
Symptom Chart Material
Item Specification
Gasoline Engine Oil
Dye
164-
R3705 or
equivalent ESE-
M99C103- B1 Engine Oil Refer to owner
literature
Visual Inspection Chart Mechanical
z
Engine coolant leaks
z Engine oil leaks
z Fuel leaks
z Damaged or severely worn parts
z Loose mounting bolts, studs and nuts
Symptom Chart Condition
Possible Sources Action
z Difficult
starting z
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 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 Damaged starting
system. z
Refer to the appropriate section
in Group 303 for the procedure. Klj . 2 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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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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16.
CAUTION: The cap screw is hidden; make sure to remove it or the engine front
cover will be damaged.
NOTE: Record the location, type and size of the fasteners.
Remove the engine front cover. zSlide the engine front cover off the two dowels.
z Remove and discard the engine front cover gasket.
Installation 1. CAUTION: In order to prevent foreign material from contaminating the engine block
or the engine front cover it is necessary to seal the coolant and oil passages of both
components. Failure to follow these directions will result in engine damage.
CAUTION: Do not use a surface conditioning pad or any other type of fibrous
abrasive disc to clean the gasket surfaces. Failure to follow these directions will result in
engine damage.
Clean and inspect the engine block and front cover as follows:
zPack the exposed portion of the oil pan with clean shop towels.
z Plug the oil and coolant passages.
z Clean the gasket surfaces.
z Clean all surfaces requiring gasket sealant with metal surface cleaner.
z Using compressed air, remove any remaining foreign material from the engine block and
engine front cover.
z Remove the shop towels from the oil pan.
z Remove the plugs or seals from the engine block and engine front cover. Klj . 4 ba
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3. If the inspection reveals an obvious concern that can be readily identified, repair as necessary.
4.
CAUTION: Some vehicle cooling systems are filled with Motorcraft Premium Gold
Engine Coolant VC -7-A (in Oregon VC -7-B) or equivalent meeting Ford specification
WSS- M97B51- A1 (yellow color). Always fill the cooling system with the same coolant that
is present in the system. Do not mix coolant types.
NOTE: The addition of Motorcraft Cooling System Stop Leak Pellets, VC-6, darkens Motorcraft
Premium Gold Engine Coolant from yellow to golden tan.
Inspect the coolant condition. 1. Inspect the coolant color.
„If Motorcraft Premium Gold Engine Coolant (yellow color) VC-7- A (in Oregon VC-
7- B) or equivalent meeting Ford specification WSS-M97B51- A1 has a clear or
pale yellow color, this indicates higher water content than required.
„ Dark brown can indicate unauthorized stop leak may have been used. Use
Motorcraft Cooling System Stop Leak Pellets VC- 6 or equivalent meeting Ford
specification ESE-M99B37- 5 except as noted in ES-F6SE-19A511- AA only.
„ A light or reddish brown color indicates that rust may be present in the cooling
system. Flush the system and refill with the correct mixture of water and engine
coolant.
„ An iridescent sheen on top of the coolant can indicate a trace of oil is entering the
system. For additional information on engine diagnosis, refer to Section 303 - 00 .
„ A milky brown color may indicate that either engine oil or transmission fluid is
entering the cooling system. If transmission fluid is suspected, the cause may be a
leaky radiator. Pressure test the cooling system. For additional information, refer
to component tests in this section. If engine oil is suspected the cause of the leak
may be internal to the engine. For additional information, refer to Section 303 - 00 .
2. If the engine coolant appearance is acceptable, test the engine coolant freezing point
range with the battery and anti- freeze tester. The freezing point should be in the range -
40°C to - 20°C (-50°F to - 10°F). If the vehicle is driven in cold climates less than - 32°C (-
34°F), it may be necessary to increase the coolant concentration to get adequate freeze
protection.
„Maximum coolant concentration is 60% coolant/40% water.
„ Minimum coolant concentration is 40% coolant/60% water. 3. Adjust coolant range and level, if necessary: Visual Inspection Chart
Mechanical
z
Leaks
z Hoses
z Hose clamps
z Water gasket
z Head gaskets
z Intake manifold gasket
z Coolant pump
z Radiator
z Degas bottle/coolant expansion tank
z Heater core
z Fan/fan clutch
z Engine coolant temperature sensor (4.6L)
z Cylinder head temperature sensor (3.8L)
z Circuitry Klj . 2 ba
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PINPOINT TEST B: THE ENGINE OVERHEATS
Test Step Result / Action to
Take B1 CHECK THE ENGINE COOLANT LEVEL
WARNING: Never remove the pressure relief cap while
the engine is operating or when the cooling system is hot.
Failure to follow these instructions can result in damage to
the cooling system or engine or personal injury. To avoid
having scalding hot coolant or steam blow out of the degas
bottle when removing the pressure relief cap, wait until the
engine is cooled, then wrap a thick cloth around the
pressure relief cap and turn it slowly. Step back while the
pressure is released from the cooling system. When you are
sure all the pressure has been released, turn and remove
the pressure relief cap (still with a cloth). NOTE: If the engine
is hot, allow the engine to cool before proceeding.
z Key in OFF position.
z Check the engine coolant level at the degas bottle/coolant
expansion tank.
z Is the engine coolant OK? Yes
GO to
B2 .
No
REFILL the engine
coolant at the degas
bottle/coolant
expansion tank. Go To Pinpoint Test A .
B2 CHECK THE COOLANT CONDITION
z
Check the coolant for dirt, rust or contamination.
z Is the coolant condition OK? Yes
GO to
B3 .
No
FLUSH the engine
cooling system.
REFER to Engine and Radiator Flushing in
this section. TEST the
system for normal
operation. B3 CHECK FOR AN AIRFLOW OBSTRUCTION
z
Inspect the A/C condenser core and radiator for obstructions
such as leaves or dirt.
z Is there an obstruction? Yes
REMOVE the
obstruction. CLEAN the
A/C condenser core
and radiator. TEST the
system for normal
operation.
No
GO to
B4 .
B4 CHECK THE WATER THERMOSTAT OPERATION
z
Start the engine and allow the engine to run for ten minutes.
z Feel the inlet and outlet heater water hoses and the underside of
the upper radiator hose.
z Are the upper radiator hose and the heater water hoses
cold? Yes
INSTALL a new water
thermostat. REFER to
Thermostat
— 3.8L ,
Thermostat — 4.6L(2V)
or
Thermostat — 4.6L
(4V) in this section.
TEST the system for
normal operation.
No
GO to B5 . Klj . 5 ba
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