Ford Galaxy / Ford S-MAX. Manual - part 408

most noticeable
when the engine is
being accelerated
or with electrical
load.

Accessory drive belt
squeal

or contaminated
with oil.

Component Test in this procedure. INSTALL a
new accessory drive belt tensioner as necessary.
TEST the system for normal operation.

NOTE: Whine is
defined as a
continuous noise at
the same
frequency,
generally
associated with
plastic pulleys.

Accessory drive belt
whine

Poor surface

finish on
accessory drive
belt idler pulley
flat surface(s).

REMOVE the accessory drive belt. REFER to:

Accessory Drive Belt

(303-05A Accessory

Drive - 2.0L Duratec-HE (107kW/145PS) -
MI4/2.0L Duratec-HE Flex Fuel
(107kW/145PS) - MI4/2.3L Duratec-HE
(118kW/160PS) - MI4, Removal and
Installation),

Accessory Drive Belt

(303-05A Accessory

Drive - 2.0L Duratec-HE (107kW/145PS) -
MI4/2.0L Duratec-HE Flex Fuel
(107kW/145PS) - MI4/2.3L Duratec-HE
(118kW/160PS) - MI4, Removal and
Installation),

Accessory Drive Belt

(303-05C Accessory

Drive - 2.5L Duratec (162kW/220PS) - VI5,
Removal and Installation),

Accessory Drive Belt

(303-05D Accessory

Drive - 1.8L Duratorq-TDCi (74kW/100PS) -
Lynx/1.8L Duratorq-TDCi (92kW/125PS) -
Lynx, Removal and Installation),

Accessory Drive Belt

(303-05F Accessory

Drive - 2.2L Duratorq-TDCi (129kW/175PS) -
DW, Removal and Installation).

INSPECT the idler pulley(s) for surface finish.
INSTALL a new idler pulley(s) as necessary. TEST
the system for normal operation.

Accessory drive

belt idler pulley
bearing failure.

REMOVE the accessory drive belt. REFER to:

Accessory Drive Belt

(303-05A Accessory

Drive - 2.0L Duratec-HE (107kW/145PS) -
MI4/2.0L Duratec-HE Flex Fuel
(107kW/145PS) - MI4/2.3L Duratec-HE
(118kW/160PS) - MI4, Removal and
Installation),

Accessory Drive Belt

(303-05A Accessory

Drive - 2.0L Duratec-HE (107kW/145PS) -
MI4/2.0L Duratec-HE Flex Fuel
(107kW/145PS) - MI4/2.3L Duratec-HE
(118kW/160PS) - MI4, Removal and
Installation),

Accessory Drive Belt

(303-05C Accessory

Drive - 2.5L Duratec (162kW/220PS) - VI5,
Removal and Installation),

Accessory Drive Belt

(303-05D Accessory

Drive - 1.8L Duratorq-TDCi (74kW/100PS) -
Lynx/1.8L Duratorq-TDCi (92kW/125PS) -
Lynx, Removal and Installation),

Accessory Drive Belt

(303-05F Accessory

Drive - 2.2L Duratorq-TDCi (129kW/175PS) -
DW, Removal and Installation).

INSPECT the idler pulley(s) for smooth rotation.
INSTALL a new idler pulley(s) as necessary. TEST
the system for normal operation.

NOTE: Chirp is

Pulley

CHECK that the accessory drive belt is running

Component Tests

Accessory Drive Belt Tensioner - Static Check

The accessory drive belt tensioner may be checked statically as follows:

1. 1. Inspect the area surrounding the accessory drive belt tensioner for lubricant or

other contamination. Rectify any leaks before installing a new accessory drive belt
tensioner. If the accessory drive belt tensioner is contaminated, do not attempt to
clean it as the damping mechanism inside may be damaged. INSTALL a new
accessory drive belt tensioner as necessary. TEST the system for normal operation.

2. 2. Detach the accessory drive belt in the area of the accessory drive belt tensioner.

NOTE: The accessory drive belt tensioner has a damping feature, which is usually a
friction device, therefore some friction within the system is normal.

3. Using the correct tool, move the accessory drive belt tensioner from its relaxed

position through its full stroke and back to the relaxed position 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. 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. 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

defined as a
twittering noise,
often intermittent

Accessory drive belt
chirp

misalignment
(usually evident
at idle).

centrally on the flat pulleys. TEST the system for
normal operation.

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
metallic knocking
noise

Accessory drive belt
rattle

Accessory drive

belt tensioner
hitting the end
stops.

CHECK the accessory drive belt tensioner for

correct operation or damage. REFER to the
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
hardware.

CHECK the components or hardware for correct

installation and tighten as necessary. TEST the
system for normal operation.

Accessory drive belt
fraying

Accessory drive

belt.

Pulley(s).

CHECK the extent of the fraying by referring to

the illustrations 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 system for
normal operation.

CHECK the pulley(s) for damage, freedom of

rotation and alignment. INSTALL new components
as necessary. TEST the system for normal
operation.

The accessory drive belt tensioner may be checked dynamically as follows:

1. 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. 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 installing a new accessory drive belt. REFER to:

Accessory Drive Belt

(303-05A Accessory Drive - 2.0L Duratec-HE (107kW/145PS) -

MI4/2.0L Duratec-HE Flex Fuel (107kW/145PS) - MI4/2.3L Duratec-HE
(118kW/160PS) - MI4, Removal and Installation),

Accessory Drive Belt

(303-05A Accessory Drive - 2.0L Duratec-HE (107kW/145PS) -

MI4/2.0L Duratec-HE Flex Fuel (107kW/145PS) - MI4/2.3L Duratec-HE
(118kW/160PS) - MI4, Removal and Installation),

Accessory Drive Belt

(303-05C Accessory Drive - 2.5L Duratec (162kW/220PS) -

VI5, Removal and Installation),

Accessory Drive Belt

(303-05D Accessory Drive - 1.8L Duratorq-TDCi (74kW/100PS)

- Lynx/1.8L Duratorq-TDCi (92kW/125PS) - Lynx, Removal and Installation),

Accessory Drive Belt

(303-05F Accessory Drive - 2.2L Duratorq-TDCi

(129kW/175PS) - DW, Removal and Installation).

TEST the system for normal operation.

Accessory Drive - 2.0L Duratec-HE
(107kW/145PS) - MI4/2.0L Duratec-HE
Flex Fuel (107kW/145PS) - MI4/2.3L
Duratec-HE (118kW/160PS) - MI4 -
Accessory Drive Belt

S-MAX/Galaxy 2006.5 (02/2006-)

Removal and Installation

Removal

NOTE: Removal steps in this procedure may contain installation details.

Installation

1. Remove the right-hand front wheel and tire.

Refer to:

Wheel and Tire

(204-04 Wheels and

Tires, Removal and Installation).

1. To install, reverse the removal procedure.

Refer to:

Accessory Drive

(303-05A Accessory

Drive - 2.0L Duratec-HE (107kW/145PS) -
MI4/2.0L Duratec-HE Flex Fuel (107kW/145PS) -
MI4/2.3L Duratec-HE (118kW/160PS) - MI4,
Description and Operation).

Content .. 406 407 408 409 ..