FORD MUSTANG 2003 Workshop Manual

Item Part Number Description
1 8678 Belt idler pulley
2 8678 Belt idler pulley
3 8678 Belt idler pulley
4 3A733 Power steering pulley
5 10344 Coolant pump pulley
6 6C254 Crankshaft pulley
7 6B209 Belt tensioner
8 19D784 A/C clutch pulley
9 8620 Drive belt Klj . 2 ba
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DIAGNOSIS AND TESTING
Accessory Drive
Inspection and Verification
1. Verify customer concern by running the engine.
2. Inspect the drive belt for chunking, fraying and wear.
3. Check the drive belt for correct routing.
Drive Belt Cracking/Chunking/Wear
V Ribbed Serpentine Drive Belt With Cracks Across Ribs
The accessory drive:
zhas a single serpentine drive belt.
z has an automatic drive belt tensioner.
z does not require adjustment.
V Ribbed Belt With Chunks of Rib Missing
Symptom Chart SECTION 303-
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Component Tests
Drive Belt Noise/Flutter
Drive belt chirp occurs due to pulley misalignment or excessive pulley runout. It can be the result of a
damaged pulley or an incorrectly aligned pulley.
To correct, determine the area where the noise comes from. Check each of the pulleys in that area
with a straightedge to the crankshaft pulley, looking for accessory pulleys out of position in the fore/aft
direction or at an angle to the straightedge.
Drive belt squeal is an intermittent noise that occurs when the drive belt slips on a pulley during certain
conditions, such as: engine start up, rapid engine acceleration, or A/C clutch engagement.
Drive belt squeal can occur:
zif any of the accessories are damaged, have a worn or damaged bearing, internal torsional
resistance above normal. All accessories should be rotatable by hand in the unloaded condition.
If not, inspect the accessory.
z if fluid gets on the drive belt. This includes power steering fluid, engine coolant, engine oil or air
conditioning system lubricant. If fluid does get on the drive belt during service, clean the drive
belt with soap and water and thoroughly rinse with clean water.
z NOTE: The drive belt tensioner arm should rotate freely without binding.
if the drive belt is too long. A drive belt that is too long will allow the drive belt tensioner arm to
go all the way to the arm travel stop under certain load conditions, which will release tension to
the drive belt. If the drive belt tensioner indicator is outside the installation wear range window,
install a new drive belt.
z if the drive belt tensioner is worn or damaged.
Belt Tension
NOTE: Drive belt tension is not adjustable.
The drive belt tensioner automatically adjusts drive belt tension. Symptom Chart Condition
Possible Sources Action
z Drive belt
noise, chirping,
flutter z
Defective/worn drive
belt.
z Misaligned pulley.
z Pulley runout.
z Damaged
accessories.
z Fluid contamination
of drive belt. z
GO to Component Tests, Drive
Belt, Noise/Flutter.
z Damaged or worn
drive belt tensioner. z
GO to Component Tests, Belt
Tensioner, Automatic.
z Premature
drive belt wear z
Defective drive belt.
z Misaligned pulley.
z Pulley runout.
z Damaged
accessories.
z Incorrectly installed
drive belt. z
GO to Component Tests, Drive
Belt Noise/Flutter and Drive
Belt Misalignment diagnosis. Klj . 2 ba
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Belt Tensioner, Automatic
Check the automatic drive belt tensioner:
1. With the engine off, check for correct drive belt routing; refer to Accessory Drive . Repair as
necessary.
2. Rotate the drive belt tensioner and check for a binding or frozen condition. Install new components as necessary.
Drive Belt Misalignment
CAUTION: Incorrect drive belt installation will cause excessive drive belt wear and may
cause the drive belt to come off the drive pulleys.
Non- standard drive belts may track differently or incorrectly. If a drive belt tracks incorrectly, install it
with an original equipment drive belt to avoid performance failure or loss of drive belt.
With the engine running, check drive belt tracking. If the (A) edge of the drive belt rides beyond the
edge of the pulleys, noise and premature wear may occur. Make sure the (B) drive belt rides correctly
on the pulley. If a drive belt tracking condition exists, proceed with the following:
zVisually check the drive belt tensioner for damage, especially the mounting pad surface. If the
drive belt tensioner is not installed correctly, the mounting surface pad will be out of position.
This will result in chirp and squeal noises.
z With the engine running, visually observe the grooves in the pulleys (not the pulley flanges or
the pulley forward faces) for excessive wobble. Install new components as necessary.
z Check all accessories, mounting brackets and the drive belt tensioner for any interference that
would prevent the component from mounting correctly. Correct any interference condition and
recheck the drive belt tracking.
z Tighten all accessories, mounting brackets, and drive belt tensioner retaining hardware to
specification. Recheck the drive belt tracking. Klj . 3 ba
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REMOVAL AND INSTALLATION
Accessory Drive Belt —
3.8L
Removal and Installation 1. Rotate the drive belt tensioner counterclockwise and remove the drive belt.
2. NOTE: Make sure the drive belt is correctly installed on each pulley.
To install, reverse the removal procedure. zRefer to Accessory Drive for drive belt routing.
SECTION 303-
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REMOVAL AND INSTALLATION
Accessory Drive Belt —
4.6L (2V) and (4V)
Removal and Installation
Mach I 1. Remove the air intake scoop. For additional information, refer to Section 303 - 12 .
Cobra 2. Remove the supercharger drive belt cover.
3. Rotate the supercharger belt tensioner clockwise and remove the supercharger belt.
4. Remove the coolant hose mounting bolt.
5. Remove the belt idler support bracket assembly.
SECTION 303-
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6. Remove auxiliary crankshaft pulley. For additional information, refer to
Section 303 - 01C .
All engines 7. Rotate the belt tensioner and remove the accessory drive belt.
8. NOTE: Make sure the accessory drive belt is correctly installed on each pulley.
To install, reverse the removal procedure. zRefer to Accessory Drive and
Accessory Drive — Cobra for accessory drive belt routing. Klj . 2 ba
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REMOVAL AND INSTALLATION
Supercharger Belt
Removal and Installation
1. Remove the supercharger drive belt cover.
2. Rotate the supercharger belt tensioner clockwise and remove the supercharger belt.
3. To install, reverse the removal procedure.
SECTION 303-
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