Accessory Drive System -- E-Series Ford Cutaway E350 Super Duty

GENERAL SPECIFICATIONS

GENERAL SPECIFICATIONS

Note. All belts new and used must meet the same specifications for the specific application.

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

The gasoline engine accessory drive system

1. has a single serpentine drive belt (6 ribs).
2. has one idler pulley.
3. has an automatic belt tensioner.
4. is not adjustable.

The diesel engine accessory drive system

1. has a single serpentine drive belt (with single generator) (8 ribs).
2. has 2 serpentine drive belts (with dual generators) (8 ribs).
3. has 3 idler pulleys (with single generator).
4. has 6 idler pulleys (with dual generator).
5. has an automatic belt tensioner.
6. is not adjustable.

The accessory drive system provides power to operate components which power other systems. These could include components such as the generator, power steering pump and A/C compressor. Each of these components is equipped with a pulley which is driven by the accessory drive belt. The accessory drive belt is driven by the engine crankshaft pulley. One or more idler pulleys may be provided to facilitate belt routing and alignment. The automatic belt tensioner maintains correct belt tension and compensates for component wear and changes in system load. System load changes can be caused by the A/C compressor clutch engaging or disengaging, or demand changes on other systems powered by the accessory drive belt. To maintain correct operation of this system, it is critical that the correct length drive belt be installed. The pulleys must also be correctly aligned and kept clean.

Scheme 1

TORQUE SPECIFICATIONS

Scheme 2

PARTS DESCRIPTION CHART

Scheme 3

PARTS DESCRIPTION CHART

Scheme 4

PARTS DESCRIPTION CHART

Inspection and Verification

Note. Under no circumstances should the accessory drive belt, tensioner or pulleys have any fluids or belt dressing applied to them as damage to the belt material and tensioner damping mechanism may occur.

1. Verify the customer concern by operating the system.
2. Visually inspect for obvious signs of mechanical damage. VISUAL INSPECTION CHART Mechanical Drive belt cracking/chunking/wear Belt/pulley contamination Incorrect accessory drive belt Incorrectly routed accessory drive belt Pulley misalignment or excessive pulley runout Loose or mislocated hardware Incorrectly routed power steering tubes (rubbing) Loose accessory drive belt Damaged pulleys Tensioner arm misalignment

Belt Tensioner With Belt Length Indicator

Note. Modular engine (without A/C) belt tensioner shown in illustration, others similar.

Note. Belt tensioner is shown in the free-state position against the arm travel stops.

Scheme 5

ITEM DESCRIPTION CHART

1. Check that the belt length indicator, if equipped, on the belt tensioner is in the acceptable belt installation and wear range. If the indicator is in the belt replacement range, either an incorrect belt is installed or the belt is worn beyond the service limit. Install a new belt as necessary.
2. Eliminate all other non-belt related noises that could cause belt misdiagnosis, such as A/C compressor engagement chirp, A/C slugging noise, power steering cavitations at low temperatures, Variable Camshaft Timing (VCT) tick or generator whine.
3. If a concern is found, correct the condition before proceeding to the next step.

Scheme 6

1. Check the belt for cracks. Up to 15 cracks in a rib over a distance of 100 mm (4.0 in) can be considered acceptable. If cracks exceed this standard, install a new belt.

V-Ribbed Serpentine Belt With Piling

Note. Piling is an excessive buildup in the V-grooves of the belt.

Scheme 7

1. The condition of the V-ribbed drive belt should be compared against the illustration and appropriate action taken. Small scattered deposits of rubber material. This is not a concern, therefore, installation of a new belt is not required. Longer deposit areas building up to 50% of the rib height. This is not considered a durability concern, but it can result in excessive noise. If noise is apparent, install a new belt. Heavy deposits building up along the grooves resulting in a possible noise and belt stability concern. If heavy deposits are apparent, install a new belt.

Scheme 8

1. There should be no chunks missing from the belt ribs. If the belt shows any evidence of this, install a new accessory drive belt.
2. If the concern is not visually evident, verify the symptom and GO to «SYMPTOM CHART»(/ford/cutaway-e350-super-duty/2008-2012/remont/accessory-drive-belts/#accessory-drive-system-e-series__symptom-chart) .

Symptom Chart

SYMPTOM CHART

Drive Belt - Noise/Flutter

Note. Under no circumstances should the accessory drive belt, tensioner or pulleys have any fluids or belt dressing applied to them as damage to the belt material and tensioner damping mechanism may occur.

Drive belt chirp occurs due to pulley misalignment or excessive pulley runout. It can be the result of a damaged or incorrectly aligned grooved 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. Look for accessory pulleys out of position in the fore/aft direction or at an angle to the straightedge.

Drive belt squeal may be an intermittent or constant noise that occurs when the drive belt slips on an accessory pulley under certain conditions.

A short intermittent squeal may occur during engine start up and shut down or during very rapid engine acceleration and decelerations, such as

1. Wide Open Throttle (WOT) 1-2 and 2-3 shifts or 2-3 and 3-4 back-out shifts on automatic transmissions.
2. WOT 1-2 and 2-3 shifts and any combination of rapid downshifting on manual transmissions.

These special short-term transient events are expected, and are due to the higher system inertias required to meet the electrical and cooling demands on today's vehicle systems. Constant or reoccurring drive belt squeal can occur

1. if the A/C discharge pressure goes above specifications: the A/C system is overcharged. the A/C condenser core airflow is blocked. the A/C anti-slugging strategy executes after a long hot heat soak.
2. if the A/C off equalized pressure (the common discharged and suction pressure that occurs after several minutes) exceeds specifications.
3. if any of the accessories or idler pulley(s) are damaged or have a worn or damaged bearing. All accessories should be rotatable by hand in the unloaded condition. If not, inspect the accessory.
4. if there is evidence of fluid contamination on the accessory drive belt. When the drive belt has been exposed to fluid contamination during vehicle operation, such as leaks from the power steering system, A/C system or cooling system, clean all pulleys with soap and water, rinse with clean water and install a new accessory drive belt. If the drive belt has been exposed to fluids in a localized area during routine vehicle service, such as replacement of hoses or fluids, the drive belt and pulleys should be washed with soap and water immediately (prior to starting the engine), and rinsed with clean water.
5. if the accessory drive belt is too long. A drive belt that is too long will allow the accessory 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 accessory drive belt tensioner indicator is outside the normal installation wear range window, install a new accessory drive belt.
6. Install a new accessory drive belt tensioner if the drive belt tensioner is worn or damaged.

Drive Belt - Incorrect Installation

Note. Incorrect accessory drive belt installation will cause excessive drive belt wear and may cause the drive belt to come off the pulleys.

Non-standard accessory drive belts can track differently or incorrectly. If an accessory drive belt tracks incorrectly, install a new accessory drive belt to avoid performance failure or loss of the drive belt.

Scheme 9

Correct Installation

Scheme 10

With the engine running, check accessory drive belt tracking on all pulleys. If the edge of the accessory drive belt rides beyond the edge of the pulleys, noise and premature wear will occur. Make sure the accessory drive belt rides correctly on the pulley. If an accessory drive belt tracking condition exists, proceed with the following

1. Visually check the accessory drive belt tensioner for damage and wear, especially the mounting pad surface and arm alignment. If the accessory drive belt tensioner is not installed correctly, the mounting surface pad will be out of position. If the tensioner arm is worn, the arm will be out of alignment. Either of these conditions will result in chirp and squeal noises.
2. 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.
3. Check all accessories, mounting brackets and the accessory drive belt tensioner for any interference that would prevent the component from mounting correctly. Correct any interference condition and recheck the accessory drive belt tracking.
4. Tighten all accessories, mounting brackets and accessory drive belt tensioner retaining hardware to specification. Recheck the accessory drive belt tracking.

Belt Tensioner - Mechanical

The only mechanical check that needs to be made is a check for tensioner stick, grab or bind.

1. With the engine off, check routing of the accessory drive belt. Refer to the illustrations under «ACCESSORY DRIVE»(/ford/cutaway-e350-super-duty/2008-2012/remont/accessory-drive-belts/#accessory-drive-system-e-series) .
2. Release the tension on the belt and detach the accessory drive belt from the tensioner. Carry out the following tests: Move the tensioner from its relaxed position, through its full stroke and back to the relaxed position to make sure there is no stick, grab or bind, and to make sure that there is tension on the tensioner spring. Rotate the tensioner pulley by hand and check for a binding, contaminated or seized condition. Inspect the area surrounding the accessory drive belt tensioner for oil leaks or contamination and repair any leaks.
3. If the accessory drive belt tensioner does not meet the criteria in the previous step, install a new tensioner. If the accessory drive belt tensioner meets the criteria in the previous step, proceed to testing the tensioner dynamically.
4. If the tensioner is saturated with oil and grease internally, install a new tensioner.

Belt Tensioner - Dynamics

The accessory drive belt tensioner can be checked dynamically as follows

1. With the engine running, observe the accessory drive belt tensioner movement. The accessory drive tensioner should move (respond) when the A/C clutch cycles (if equipped), or when the engine is accelerated rapidly. If the accessory drive belt tensioner movement is excessive without A/C clutch cycling or engine acceleration, check belt rideout. Excessive belt rideout (uneven depth of grooves in the belt) can cause excessive accessory drive belt tensioner movement. Check rideout condition by installing a new belt. If excessive accessory drive belt tensioner movement still exists, install a new accessory drive belt tensioner.

Front End Accessory Drive (FEAD) - Exploded View, 4.6L, 5.4L and 6.8L

Note. 4.6L with A/C shown in illustration, 5.4L and 6.8L similar.

Scheme 11

PARTS DESCRIPTION CHART

Note. 4.6L without A/C shown in illustration, 5.4L and 6.8L similar.

Scheme 12

PARTS DESCRIPTION CHART

1. For additional information, refer to the appropriate procedure(s).

Removal and Installation

1. Remove the Air Cleaner (ACL) assembly. For additional information, refer to «INTAKE AIR DISTRIBUTION & FILTERING»(/ford/cutaway-e350-super-duty/2008-2012/remont/removal-installation/#intake-air-distribution-system-intake-air-filtering-system-e-series) .
2. Rotate the tensioner clockwise and remove the drive belt.
3. To install, reverse the removal procedure. For additional information, refer to «ACCESSORY DRIVE»(/ford/cutaway-e350-super-duty/2008-2012/remont/accessory-drive-belts/#accessory-drive-system-e-series) (Drive Belt Routing - 4.6L, 5.4L, 6.8L With A/C illustration).

1. Remove the Air Cleaner (ACL) assembly. For additional information, refer to «INTAKE AIR DISTRIBUTION & FILTERING»(/ford/cutaway-e350-super-duty/2008-2012/remont/removal-installation/#intake-air-distribution-system-intake-air-filtering-system-e-series) .
2. Rotate the tensioner counterclockwise and remove the drive belt.
3. To install, reverse the removal procedure. For additional information, refer to «ACCESSORY DRIVE»(/ford/cutaway-e350-super-duty/2008-2012/remont/accessory-drive-belts/#accessory-drive-system-e-series) (Drive Belt Routing - 4.6L, 5.4L, 6.8L Without A/C illustration).

1. Remove the accessory drive belt. For additional information, refer to «ACCESSORY DRIVE BELT - 4.6L, 5.4L AND 6.8L WITH A/C»(/ford/cutaway-e350-super-duty/2008-2012/remont/accessory-drive-belts/#accessory-drive-system-e-series) or «ACCESSORY DRIVE BELT - 4.6L, 5.4L AND 6.8L WITHOUT A/C»(/ford/cutaway-e350-super-duty/2008-2012/remont/accessory-drive-belts/#accessory-drive-system-e-series) .
2. Remove the 3 accessory drive belt tensioner bolts and the tensioner. To install, tighten to 25 Nm (18 lb-ft).
3. To install, reverse the removal procedure.

1. Remove the accessory drive belt. For additional information, refer to «ACCESSORY DRIVE BELT - 4.6L, 5.4L AND 6.8L WITH A/C»(/ford/cutaway-e350-super-duty/2008-2012/remont/accessory-drive-belts/#accessory-drive-system-e-series) or «ACCESSORY DRIVE BELT - 4.6L, 5.4L AND 6.8L WITHOUT A/C»(/ford/cutaway-e350-super-duty/2008-2012/remont/accessory-drive-belts/#accessory-drive-system-e-series) .
2. Remove the accessory drive belt idler pulley bolt and pulley. To install, tighten to 25 Nm (18 lb-ft).
3. To install, reverse the removal procedure.

Scheme 13

PARTS DESCRIPTION CHART

Scheme 14

PARTS DESCRIPTION CHART

1. For additional information, refer to the appropriate procedure(s).

1. Remove the cooling fan stator. For additional information, refer to «ENGINE COOLING»(/ford/cutaway-e350-super-duty/2008-2012/remont/cooling-system-mechanical/#engine-cooling-system-e-series) .
2. Rotate the tensioner clockwise and remove the accessory drive belt.
3. To install, reverse the removal procedure.

1. Remove the accessory drive belt. For additional information, refer to «ACCESSORY DRIVE BELT - 6.0L DIESEL»(/ford/cutaway-e350-super-duty/2008-2012/remont/accessory-drive-belts/#accessory-drive-system-e-series) .
2. Remove the 2 accessory drive belt tensioner bolts and the tensioner. To install, tighten to 25 Nm (18 lb-ft).
3. To install, reverse the removal procedure.

1. Remove the accessory drive belt. For additional information, refer to «ACCESSORY DRIVE BELT - 6.0L DIESEL»(/ford/cutaway-e350-super-duty/2008-2012/remont/accessory-drive-belts/#accessory-drive-system-e-series) .
2. Remove the accessory drive belt idler pulley bolt and the pulley. To install, tighten to 47 Nm (35 lb-ft).
3. To install, reverse the removal procedure.

See also:
• INTAKE AIR DISTRIBUTION & FILTERING
• ENGINE COOLING
• SYMPTOM CHART
• INSPECTION AND VERIFICATION
• COMPONENT TESTS, DRIVE BELT - NOISE/FLUTTER
• COMPONENT TESTS, BELT TENSIONER - MECHANICAL
• BELT TENSIONER - DYNAMICS
• DRIVE BELT - INCORRECT INSTALLATION
• ACCESSORY DRIVE