2003 FORD MUSTANG fuel pressure

7. Inspect for normal burning.
zThis can be identified by light tan or gray deposits on the firing tip.
8. Inspect for pre- ignition.
z This can be identified by melted electrodes and possibly a blistered insulator. Metallic
deposits on the insulator indicate engine damage.
z Install a new spark plug.
9. Inspect for overheating. zThis can be identified by a white or light gray insulator with small black or gray brown
spots and a bluish- burnt appearance of the electrodes.
z This may be caused by engine overheating, the wrong type of fuel, loose spark plugs, too
hot a plug, low fuel pump pressure or incorrect ignition timing.
z Install a new spark plug. Klj . 3 ba
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8. Inspect for overheating.
zThis can be identified by a white or light gray insulator with small black or gray brown
spots and with bluish- burnt appearance of the electrodes.
z This may be caused by engine overheating, wrong type of fuel, loose spark plugs, too hot
a plug, low fuel pump pressure or incorrect ignition timing.
z Install a new spark plug.
9. Inspect for fused spot deposits. zThis can be identified by melted or spotty deposits resembling bubbles or blisters.
z This may be caused by sudden acceleration.
z Clean the spark plug.
Installation 1. Adjust the spark plug gap as necessary. Klj . 3 ba
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REMOVAL AND INSTALLATION
Exhaust Gas Recirculation (EGR) Valve —
Cobra
Removal and Installation 1. Disconnect the accelerator cable and the speed control cable.
2. Remove the accelerator cable bracket bolts.
3. Release the clip and position the accelerator cable bracket and the cables aside.
4. 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-
08: Engine Emission Control 2003 Mustang Workshop Manual Klj . 1 ba
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5. Disconnect the vacuum hoses from the differential pressure feedback EGR system.
6. Disconnect the vacuum hoses from the supercharger bypass vacuum solenoid, and the
actuator.
7. Disconnect the vacuum hoses from the fuel pulse damper and the EGR vacuum regulator solenoid.
8. Disconnect the vacuum hose from the EGR valve. Klj . 2 ba
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DESCRIPTION AND OPERATION
Intake Air Distribution and Filtering —
Supercharger,
Charge Air Cooler
The supercharger (SC) is a positive displacement pump. Its purpose is to supply an excess volume of
intake air to the engine by increasing air pressure and density in the intake manifold. The supercharger
is matched to the engine by its displacement and belt ratio, and can provide excess airflow at any
engine speed.
NOTE: The supercharger is repaired only as an assembly. Disassembly of the supercharger unit may
void the warranty.
NOTE: The supercharger is not a bolt- on option. It is part of an integrated engine system. Many
components of the supercharged engine are not interchangeable with similar parts from a non-
supercharged engine.
The supercharger contains two three- lobed rotors. The helical shape and specialized porting provide a
smooth discharge flow and low level of noise during operation. The rotors are supported by ball
bearings in front and needle bearings at the rear. The drive gears are pressed into place, therefore the
supercharger is installed new as a unit, and is not repairable.
The supercharger system is a blow- through type with the fuel injected directly into the intake ports. The
supercharger is belt driven off the crankshaft through an idler pulley. The throttle body controls the
amount of intake air to the supercharger through the intake plenum. Air from the supercharger is
routed through the charge air cooler (CAC), then to the intake manifold. The resulting denser air
charge in the combustion chamber provides for a higher power output of the engine over a non-
supercharged engine of the same displacement.
NOTE: It is not possible to increase manifold pressure or engine power output by altering the bypass
valve or the actuator.
At partial- throttle opening or when vacuum is present in the intake system, a vacuum- controlled
bypass valve reroutes some discharged air from the supercharger back through the intake plenum.
This prevents the supercharger from cavitating, causing reduced performance, increased
temperatures, and poor fuel economy.
The supercharger has a self- contained oiling system that does not require a fluid change for the life of
the vehicle. However, at every 30,000 mile interval, the supercharger fluid level should be checked.
The vehicle should be parked on a level surface, the engine cool, and not running. To check the oil,
remove the Allen head plug located at the front of the supercharger. The oil level should be at the
bottom of the fill plug threads when cold. If the fluid level is low, add Synthetic Supercharger Fluid
E9SZ- 19577- A or equivalent meeting Ford specification ESE-M99C115–A
Supercharged vehicles are equipped with a charge air cooler (CAC). The CAC cools the pressurized
air from the supercharger, increasing the air density, which improves combustion efficiency, engine
horsepower and torque. SECTION 303-
12: Intake Air Distribution and Filtering 2003 Mustang Workshop Manual Klj . 1 ba
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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
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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
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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
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