SECTION 303-05 Accessory Drive - 2.0L Duratec-HE (MI4) /2.3L Duratec-HE (MI4)

Accessory Drive — 2.0L Duratec-HE (MI4)/2.
3L
303-05-1 Duratec-HE (MI4) 303-05-1
.
SECTION 303-05 Accessory Drive — 2.0L Duratec-HE

(MI4)/2.3L Duratec-HE (MI4)
VEHICLE APPLICATION:2008.50 Mondeo
CONTENTS PAGE
DESCRIPTION AND OPERATION

Accessory Drive.................................................................................................................. 303-05-2
DIAGNOSIS AND TESTING

Accessory Drive.................................................................................................................. 303-05-3
Inspection and Verification.................................................................................................. 303-05-3
Accessory Drive Belt Concerns.......................................................................................... 303-05-3
Symptom Chart................................................................................................................... 303-05-5
Component Tests................................................................................................................ 303-05-8
REMOVAL AND INSTALLATION

Accessory Drive Belt...................................................................................... (21 567 0) 303-05-10
Accessory Drive — 2.0L Duratec-HE (MI4)/2.3L
303-05-2 Duratec-HE (MI4) 303-05-2
DESCRIPTION AND OPERATION
Accessory Drive
3
2
8
7
6 5
E64007
Item Description Item Description

1 Generator 7 Crankshaft pulley
2 Accessory drive belt idler pulley 8 Accessory drive belt tensioner pulley
3 Power steering pump pulley
4 Coolant pump pulley
5 Air conditioning (A/C) compressor
6 Accessory drive belt
2008.50 Mondeo 1/2009 G510165en

303-05-3 Duratec-HE (MI4) 303-05-3
Accessory Drive
Inspection and Verification 1. Check the accessory drive belt for cracks. If the
damage exceeds the acceptable limit, install a
1. Verify the customer concern. new accessory drive belt. REFER to:
2. Visually inspect for obvious signs of mechanical Accessory Drive Belt (303-05 Accessory Drive
damage. - 2.0L Duratec-HE (MI4)/2.3L Duratec-HE
(MI4), Removal and Installation),
Visual Inspection Chart
Accessory Drive Belt (303-05 Accessory Drive
Mechanical - 1.8L Duratorq-TDCi (Lynx) Diesel, Removal
– Damaged or contaminated accessory drive and Installation),
belt Accessory Drive Belt (303-05 Accessory Drive
- 2.2L Duratorq-TDCi (DW) Diesel, Removal
– Damaged or contaminated pulley(s)
and Installation).
– Incorrect accessory drive belt
– Incorrect fitment of the accessory drive belt Chunking
– Accessory drive belt tensioner Chunking describes the condition where long
– Accessory drive belt idler pulley lengths of rubber become detached from the ribs
– Generator of the accessory drive belt. This is considered to
be a failure of the accessory drive belt.
– Power steering pump
– Power steering pump leakage
– Air conditioning (A/C) compressor
– Pulley(s)
– Loose hardware
3. If an obvious cause for an observed or reported

concern is found, correct the cause (if possible)
before proceeding to the next step.
Accessory Drive Belt Concerns MPZ9632071
CAUTION: Do not lubricate the accessory 2. Check the accessory drive belt for damage. If
drive belt, accessory drive belt tensioner any chunks are found to be missing, install a
or idler pulley(s) as potential damage to new accessory drive belt. REFER to:
the accessory drive belt material Accessory Drive Belt (303-05 Accessory Drive
construction, accessory drive belt - 2.0L Duratec-HE (MI4)/2.3L Duratec-HE
tensioner damping mechanism, accessory (MI4), Removal and Installation),
drive belt tensioner pulley bearing and idler Accessory Drive Belt (303-05 Accessory Drive
pulley(s) bearing may occur. - 1.8L Duratorq-TDCi (Lynx) Diesel, Removal
and Installation),
Cracking
Accessory drive belts are made from rubber which - 2.2L Duratorq-TDCi (DW) Diesel, Removal
hardens with time and can develop cracks. As the and Installation).
accessory drive belt runs on the back of some of
the pulleys, the cracks are opened up. Small cracks Pilling
are not considered to be a failure of the accessory Pilling is dust that forms in between the ribs of the
drive belt. Only if the crack is deep enough to reach accessory drive belt from rubber that is worn off
the bottom of the groove to expose the cord or any the accessory drive belt when it is new. There may
chunks are found to be missing from the accessory also be loose particles left on the accessory drive
drive belt, is the accessory drive belt condition belt during the manufacturing process. These are
considered to be unacceptable. worn off and form into small balls of rubber that
2008.50 Mondeo 1/2009 G165389en

303-05-4 Duratec-HE (MI4) 303-05-4
then get trapped in the grooves of the accessory accessory drive belt if noise is apparent.
drive belt. This condition will usually clear itself REFER to:
within 4800 km - 8000 km (3000 miles - 5000 miles) Accessory Drive Belt (303-05 Accessory Drive
of normal driving. - 2.0L Duratec-HE (MI4)/2.3L Duratec-HE
- 1.8L Duratorq-TDCi (Lynx) Diesel, Removal
and Installation),
and Installation).
5. Heavy deposits in the grooves. Possible
noise and stability concern. INSTALL a new
accessory drive belt. REFER to:
- 2.0L Duratec-HE (MI4)/2.3L Duratec-HE
and Installation),
and Installation).
6. Heavy deposits in the grooves. Possible
noise and stability concern. INSTALL a new
accessory drive belt. REFER to:
VUE0037805 (MI4), Removal and Installation),
3. Check the accessory drive belt for pilling. The - 1.8L Duratorq-TDCi (Lynx) Diesel, Removal
condition of the accessory drive belt should be and Installation),
compared against the illustration. Accessory Drive Belt (303-05 Accessory Drive
1. Small scattered pills. Not considered a - 2.2L Duratorq-TDCi (DW) Diesel, Removal
concern. No action required. and Installation).
2. Small scattered pills. Not considered a
concern. No action required. Incorrect fitment
3. Longer pills up to 50% of the rib height. Accessory drive belt noise can be generated by
Possible noise concern. INSTALL a new the accessory drive belt being incorrectly fitted on
accessory drive belt if noise is apparent. the pulley as shown in the following illustration.
REFER to: Make sure that all the V grooves on the accessory
drive belt contact correctly with the pulley.
and Installation),
and Installation).
4. Longer pills up to 50% of the rib height.
Possible noise concern. INSTALL a new
2008.50 Mondeo 1/2009 G165389en

303-05-5 Duratec-HE (MI4) 303-05-5
4. If the cause is not visually evident, verify the
symptom and refer to the Symptom Chart.
VUE0037806
Symptom Chart
Symptom Possible Sources Action

• Accessory drive belt noise • Accessory drive system • CHECK the system with the
engine running and the
accessory drive belt removed
(only run the engine for a very
short period). If a noise is
apparent, the cause is not the
accessory drive system. If a
noise is not apparent, the
cause is the accessory drive
system. CHECK where the
noise is coming from. Use a
stethoscope or other listening
device to determine the source
of the noise. INSTALL new
components as necessary.
TEST the system for normal
operation.
• Accessory drive belt incorrectly • CHECK the accessory drive
installed. belt is correctly installed in the
pulley grooves. INSTALL a new
accessory drive belt as neces-
sary. REFER to:
Accessory Drive Belt (303-05
Accessory Drive - 2.0L
Duratec-HE (MI4)/2.3L
Duratec-HE (MI4), Removal
and Installation),
Duratorq-TDCi (Lynx) Diesel,
Removal and Installation),
Duratorq-TDCi (DW) Diesel,
Removal and Installation).
operation.
2008.50 Mondeo 1/2009 G165389en

303-05-6 Duratec-HE (MI4) 303-05-6
• Pulley(s). • CHECK the pulley(s) for
damage, freedom of rotation,
stone entrapment and align-
ment. INSTALL new compon-
ents as necessary. TEST the
system for normal operation.
• Lubricant or other contamina- • CHECK the accessory drive
tion. belt for contamination or
damage. RECTIFY the source
of the leak and INSTALL a new
accessory drive belt. REFER
to:
and Installation),
operation.
NOTE: Squeal is defined as a • Accessory drive belt tensioner • CHECK the accessory drive
continuous shriek, most noticeable worn, damaged or contamin- belt tensioner for correct opera-
when the engine is being accelerated with oil. tion, damage or contamination.
ated or with electrical load. REFER to the Accessory Drive
Belt Tensioner Component Test
• Accessory drive belt squeal
in this procedure. INSTALL a
new accessory drive belt
tensioner as necessary. TEST
the system for normal opera-
tion.
2008.50 Mondeo 1/2009 G165389en

303-05-7 Duratec-HE (MI4) 303-05-7
NOTE: Whine is defined as a • Poor surface finish on • REMOVE the accessory drive
continuous noise at the same accessory drive belt idler pulley belt. REFER to:
frequency, generally associated flat surface(s). Accessory Drive Belt (303-05
with plastic pulleys. Accessory Drive - 2.0L
• Accessory drive belt whine Duratec-HE (MI4)/2.3L
and Installation),
INSPECT the idler pulley(s) for
surface finish. INSTALL a new
idler pulley(s) as necessary.
operation.
• Accessory drive belt idler pulley • REMOVE the accessory drive
bearing failure. belt. REFER to:
and Installation),
INSPECT the idler pulley(s) for
smooth rotation. INSTALL a
new idler pulley(s) as neces-
sary. TEST the system for
normal operation.
2008.50 Mondeo 1/2009 G165389en

303-05-8 Duratec-HE (MI4) 303-05-8
NOTE: Chirp is defined as a twit- • Pulley misalignment (usually • CHECK that the accessory
tering noise, often intermittent evident at idle). drive belt is running centrally
on the flat pulleys. TEST the
• Accessory drive belt chirp
• CHECK the pulleys for
excessive end float and bent
flanges.
• With the engine running at idle,
use a stethoscope to identify
the source of the noise.
INSTALL new components as
necessary. TEST the system
for normal operation.
NOTE: Rattle is defined as a • Accessory drive belt tensioner • CHECK the accessory drive
metallic knocking noise hitting the end stops. belt tensioner for correct opera-
tion or damage. REFER to the
• Accessory drive belt rattle
Accessory Drive Belt Tensioner
Component Test in this
procedure. INSTALL a new
accessory drive belt tensioner
as necessary. TEST the system
for normal operation.
• Loose components or hard- • CHECK the components or
ware. hardware for correct installation
and tighten as necessary.
operation.
• Accessory drive belt fraying • Accessory drive belt. • CHECK the extent of the
• Pulley(s). fraying by referring to the illus-
trations shown in the Visual
Inspection section. Only
INSTALL a new accessory
drive belt if the fraying is within
the criteria quoted in the Visual
Inspection section. TEST the
• CHECK the pulley(s) for
damage, freedom of rotation
and alignment. INSTALL new
components as necessary.
operation.
Component Tests 1. Inspect the area surrounding the accessory

drive belt tensioner for lubricant or other
contamination. Rectify any leaks before
Accessory Drive Belt Tensioner - Static installing a new accessory drive belt tensioner.
Check If the accessory drive belt tensioner is
contaminated, do not attempt to clean it as the
The accessory drive belt tensioner may be checked damping mechanism inside may be damaged.
statically as follows: INSTALL a new accessory drive belt tensioner
2008.50 Mondeo 1/2009 G165389en

303-05-9 Duratec-HE (MI4) 303-05-9
as necessary. TEST the system for normal installing a new accessory drive belt. REFER
operation. to:
2. Detach the accessory drive belt in the area of Accessory Drive Belt (303-05 Accessory Drive
the accessory drive belt tensioner. - 2.0L Duratec-HE (MI4)/2.3L Duratec-HE
3. NOTE: The accessory drive belt tensioner (MI4), Removal and Installation),
has a damping feature, which is usually a Accessory Drive Belt (303-05 Accessory Drive
friction device, therefore some friction within - 1.8L Duratorq-TDCi (Lynx) Diesel, Removal
the system is normal. and Installation),
Using the correct tool, move the accessory drive - 2.2L Duratorq-TDCi (DW) Diesel, Removal
belt tensioner from its relaxed position through and Installation).
its full stroke and back to the relaxed position TEST the system for normal operation.
to make sure there is no excessive stick, grab
or bind, and to make sure there is tension on
the accessory drive belt tensioner spring.
4. Rotate the accessory drive belt tensioner pulley
and check for damage, freedom of rotation and
alignment. INSTALL a new accessory drive belt
tensioner as necessary. TEST the system for
normal operation.
5. If the accessory drive belt tensioner meets the
above criteria, proceed to test the accessory
drive belt tensioner dynamically. If the accessory
drive belt tensioner does not meet the above
criteria, INSTALL a new accessory drive belt
tensioner. TEST the system for normal
operation.
Accessory Drive Belt Tensioner - Dynamic

Check
The accessory drive belt tensioner may be checked

dynamically as follows:
1. With the engine running, observe the accessory
drive belt tensioner movement. The accessory
drive belt tensioner should move (respond)
when the engine is accelerated rapidly or when
the A/C clutch cycles ON and OFF (the degree
of movement can be up to 4 mm). If the
accessory drive belt tensioner movement is not
constant without engine acceleration or A/C
clutch cycling, a pulley or shaft is possibly bent,
out of round, or the damping mechanism inside
the accessory drive belt tensioner may be
damaged. INSTALL a new accessory drive belt
tensioner as necessary. TEST the system for
normal operation.
2. Excessive accessory drive belt rideout (uneven
depth of grooves in the accessory drive belt)
may cause excessive accessory drive belt
tensioner movement. Check the condition by
2008.50 Mondeo 1/2009 G165389en

303-05-10 Duratec-HE (MI4) 303-05-10
REMOVAL AND INSTALLATION
Accessory Drive Belt(21 567 0)

Installation
Removal
1. To install, reverse the removal procedure.
NOTE: Removal steps in this procedure may
contain installation details. 2. Refer to: Accessory Drive (303-05 Accessory
Drive - 2.0L Duratec-HE (MI4)/2.3L
1. Remove the right-hand front wheel and tire. Duratec-HE (MI4), Description and Operation).
Refer to: Wheel and Tire (204-04 Wheels and
Tires, Removal and Installation).
2.
E65299
3.
E66154
4.
E65300
2008.50 Mondeo 1/2009 G543727en

SECTION 303-05 Accessory Drive - 2.0L Duratec-HE (MI4) /2.3L Duratec-HE (MI4)

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SECTION 303-05 Accessory Drive - 2.0L Duratec-HE (MI4) /2.3L Duratec-HE (MI4)

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Accessory Drive — 2.0L Duratec-HE (MI4)/2.

SECTION 303-05 Accessory Drive — 2.0L Duratec-HE

DESCRIPTION AND OPERATION

DIAGNOSIS AND TESTING

REMOVAL AND INSTALLATION

Item Description Item Description

2008.50 Mondeo 1/2009 G510165en

3. If an obvious cause for an observed or reported

Accessory Drive Belt Concerns MPZ9632071

2008.50 Mondeo 1/2009 G165389en

2008.50 Mondeo 1/2009 G165389en

Symptom Possible Sources Action

2008.50 Mondeo 1/2009 G165389en

2008.50 Mondeo 1/2009 G165389en

2008.50 Mondeo 1/2009 G165389en

Component Tests 1. Inspect the area surrounding the accessory

2008.50 Mondeo 1/2009 G165389en

Accessory Drive Belt Tensioner - Dynamic

The accessory drive belt tensioner may be checked

2008.50 Mondeo 1/2009 G165389en

Accessory Drive Belt(21 567 0)

2008.50 Mondeo 1/2009 G543727en

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