Ford Mustang (1999-2004) Service Manual: Inspection and Verification
WARNING: Batteries contain sulfuric acid. Avoid contact with skin, eyes, or clothing.
Also, shield your eyes when working near batteries to protect against possible splashing of the acid solution. In case of acid contact with skin or eyes, flush immediately with water for a minimum of 15 minutes and get prompt medical attention. If acid is swallowed, call a physician immediately.
WARNING: Batteries normally produce explosive gases which can cause personal injury.
Therefore, do not allow flames, sparks or lighted substances to come near the battery. When charging or working near a battery, always shield your face and protect your eyes. Always provide ventilation.
WARNING: When lifting a plastic-cased battery, excessive pressure on the end walls could cause acid to spew through the vent caps resulting in personal injury, damage to the vehicle or to the battery. Lift with a battery carrier or with your hands on opposite corners.
1. Verify the customer concern by operating the engine to duplicate the concern.
2. Inspect the charging system (battery, generator cable, harness connectors, connections) to determine if any obvious mechanical or electrical concerns exist. If found, repair as necessary and test the system for normal operation. Refer to the following tables:
Visual Inspection Chart
Mechanical | Electrical |
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3. Check the operation of the charging system warning indicator lamp (instrument cluster). Normal operation is as follows:
- With the ignition switch OFF, the charging system warning indicator should be OFF.
- With the ignition switch in RUN and the engine off, the charging system warning indicator light should be on.
- With the engine running, the charging system warning indicator light should be off.
4. Verify the battery is being charged. Carry out the Battery-Load Test. Refer to Component Tests in this section.
Normal Charging System Voltages
5. If the customer concern is verified after the initial inspection, refer to the Symptom Chart to determine which tests to carry out.
Symptom Chart
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Functionality
With the ignition switch in the RUN position, voltage is applied
through the warning indicator I circuit
904 (LG/RD) to the voltage regulator. This turns the regulator on,
allowing current to ...
Pinpoint Tests
CAUTION: Do not make jumper connections except as directed.
Incorrect connections
may damage the voltage regulator test terminals, fuses, or fuse links.
CAUTION: Do not allow any metal object ...
Other materials:
Supercharger Belt Idler Pulley
Removal and Installation
1. Remove the supercharger drive belt cover.
2. Rotate the supercharger belt tensioner clockwise and remove the
supercharger belt.
3. Remove the bolt and the supercharger belt idler pulley.
4. To install, reverse the removal pro ...
Cable - Antenna Lead In
Removal
1. Remove the audio unit. Refer to Section.
2. Lower the glove compartment by releasing the stops from the
instrument panel.
3. Disconnect the antenna in-line connector.
4. Remove the antenna lead in cable.
1. Disconnect the pin-type ...
Exhaust Manifold to Exhaust Gas Recirculation (EGR)
Valve Tube - Mach I
Removal
1. Remove the air intake scoop. For additional information, refer to
Section.
2. Disconnect the exhaust gas recirculation (EGR) tube from the EGR valve.
3. With the vehicle in NEUTRAL, position it on a hoist.
4. Disconnect the EGR tube from th ...