2003 FORD MUSTANG jump cable

pressure reading. Release pressure and repeat the test. Install a new radiator cap if the
pressure is not 99.3-
121.4 kPa (14.4-17.6 psi).
Cap — 4.6L
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).
1. Remove the pressure relief cap from the degas bottle.
2. Follow the instructions from the pressure tester.
3. NOTE: If the plunger of the pump is depressed too quickly, an erroneous pressure reading will
result.
Slowly depress the plunger of the pressure test pump until the pressure gauge reading stops
increasing and note the highest pressure reading obtained.
4. If the pressure test gauge readings are not within specifications, install a new pressure relief cap. If the pressure test gauge readings are within specifications, carry out the cooling system
Pressure Test.
Thermostat — Water
A new water thermostat should be installed only after the following electrical and mechanical tests
have been carried out.
Thermostat — Electrical Test
CAUTION: Always vent the exhaust to the outside when carrying out this test.
NOTE: The electrical thermostat test is most accurate if carried out at less than 37.8°C (100°F)
ambient air. This test may be carried out with or without the hood open and with the engine warm or
cold.
1. Check the engine coolant level. Fill as needed.
2. With the ignition OFF, remove the engine coolant temperature (ECT) (4.6L) or cylinder head temperature (CHT) (3.8L) sensor harness connector and attach ECT (4.6L) or CHT (3.8L)
Sensor "T" Cable as a jumper between the powertrain control module (PCM) (12A650) and the
ECT (4.6L) or CHT (3.8L) sensor. Attach the 73III Automotive Meter to the ECT (4.6L) or CHT
(3.8L) Sensor "T" Cable. Voltage values (0- 5 V) may now be monitored while the sensor retains
its connection to the wiring harness.
An appropriate diagnostic tool may be used to monitor the ECT on vehicles equipped with data link connector (DLC). Klj . 8 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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Component Tests
Starter Motor —Voltage Drop Test
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 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.
Always make the Digital Multimeter connections at the component terminal rather than at the wiring
end connector. Making a connection at the wiring end connector could result in false readings because
the meter will not pick up a high resistance between the wiring connector and the component.
Starter Motor— Motor Feed Circuit
1. Make sure the battery is fully charged. Perform a battery load test. For additional information, refer to Section 414 - 00 .
2. Disconnect the inertia fuel shut off (IFS) switch.
3. Connect a remote starter switch between the starter solenoid S- terminal and the battery positive
(+) terminal.
4. Connect the Digital Multimeter positive lead to the battery positive (+) post. Connect negative lead to the starter solenoid M- terminal. brackets for cracks.
z Check the starter motor mounting
bolts for looseness.
z Is the starter motor mounted
correctly? GO to
D2 .
No
REINSTALL the starter motor correctly. REFER to
Starter Motor — 3.8L or
Starter Motor — 4.6L in this
section. D2 INSPECT THE STARTER MOTOR
z
Remove the starter motor; refer to
Starter Motor — 3.8L or
Starter Motor — 4.6L in this section.
z Inspect the starter motor for
damage.
z Is the starter motor damaged? Yes
INSTALL a new starter motor. REFER to
Starter Motor — 3.8L or
Starter Motor — 4.6L in this section.
TEST the system for normal operation.
No
CHECK the starter drive. REFER to Component
Tests, Starter Drive Test in this section. INSTALL a
new starter motor. TEST the system for normal
operation. Klj . 8 ba
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PINPOINT TEST F: NO OPERATION IN ALL TEMPERATURE
SETTINGS
PINPOINT TEST G: THE BLOWER MOTOR DOES NOT
OPERATE/DOES NOT OPERATE CORRECTLY INSTALL a new A/C
compressor due to low
performance. REFER to
Section 412
- 03 . TEST the
system for normal operation. Test Step Result / Action to Take
F1 CHECK THE TEMPERATURE CONTROL
z
Start the engine and run at idle. Allow the engine to reach
normal operating temperature.
z Place the function selector switch in the NORMAL A/C
position.
z Adjust the temperature control to full warm position, and
physically feel the discharge air temperature at the at the
center panel vents.
z Rotate the temperature control to full cold position, and
physically feel the discharge air temperature at the center
panel vents.
z Does the discharge air temperature vary? Yes
The temperature blend
door is functioning
correctly. RETURN to the
symptom chart.
No
GO to
F2 .
F2 CHECK FOR A BROKEN A/C TEMPERATURE CONTROL
CABLE z
Remove the climate control assembly to gain access to the
control cable head.
z Move the temperature control from full warm to full cold.
z Inspect the cable control head as you move the temperature
control.
z Does the alignment mark on the control head move? Yes
INSTALL a new
evaporator housing.
REFER to
Section 412 -
02 .
No
INSTALL a new
temperature control cable
assembly. REFER to
Section 412 - 04 .
Test Step Result / Action to Take
G1 CHECK FOR VOLTAGE AT C238
z
Disconnect: Blower Motor Jumper C238.
z Key in ON position.
z Turn the blower motor selector to LOW.
z Turn the function selector to FLOOR.
z Check for voltage between C238- 6, circuit 249 (DB/LG) and
C238- 3, circuit 261 (OG/BK). Yes
GO to
G2 .
No
GO to G4 . Klj . 30 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 TEST C: CONTINUOUS SEEK/SCAN IN AM/FM
PINPOINT TEST D: NO SOUND FROM ONE OR MORE OF THE
SPEAKERS —
NOT ALL SPEAKERS z
Is the noise eliminated? jumper cable. When noise is eliminated,
PROVIDE a permanent ground where
necessary. TEST the system for normal
operation.
Test Step Result / Action to Take
C1 CHECK OPERATION OF THE
SEEK/SCAN FUNCTIONS z
Key in ON position.
z Operate the SEEK/SCAN functions
with the audio unit in both AM and FM
tuner modes.
z Do the SEEK/SCAN functions
search continuously? Yes
GO to
C2 .
No
The system is OK. C2 CHECK ANTENNA FOR DAMAGE
z
Key in OFF position.
z Disconnect: Antenna Lead Terminal.
z Measure the resistance between the
antenna cable lead terminal and the
end of the antenna grid wire.
z Is the resistance less than 8 ohms? Yes
GO to
C3 .
No
REPAIR the antenna. REFER to Section 415 - 02
C3 SUBSTITUTE ANTENNA EXTENSION
CABLE z
Substitute a known good antenna
cable between the audio unit and the
antenna.
z Key in START position.
z Check the operation of the audio unit.
z Is the noise eliminated? Yes
INSTALL a new antenna extension cable. REFER
to
Section 415 - 02 . TEST the system for normal
operation.
No
REINSTALL the original cable. REMOVE the
audio unit and SEND it to an authorized Ford
audio system repair facility. TEST the system for
normal operation. Test Step Result / Action to
Take D1 CHECK FOR SOUND
z
Key in ON position.
z Turn on the audio unit.
z Are all speakers without sound? Yes
GO to
Pinpoint Test E .
No
For convertible,
GO to D2 .
For coupe, GO to
D4 . Klj . 7 ba
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