303-05E

Accessory Drive 303-05E-1

SECTION 303-05E: Accessory Drive

VEHICLE APPLICATION: 2014 Falcon EcoBoost

CONTENTS
SPECIFICATIONS
Torque Specifications............................................................................................................................303-05-01
General Specifications...........................................................................................................................303-05-01
DESCRIPTION AND OPERATION
Accessory Drive..................................................................................................................................... 303-05-02
DIAGNOSIS AND TESTING
Accessory Drive..................................................................................................................................... 303-05-04
REMOVAL AND INSTALLATION
Accessory Drive Belt..............................................................................................................................303-05-13
Idler Pulley (Centre)................................................................................................................................303-05-13
Idler Pulley (Lower).................................................................................................................................303-05-14

Version: 2014 Falcon

303-05E Accessory Drive 303-05E-1

SPECIFICATIONS

Torque Specifications

Description Nm
Accessory drive belt 25 Nm
tensioner bolts, 2.0L
GTDi
Drive belt idler pulley 25 Nm
assembly bolt lower,
2.0L GTDi
Drive belt idler pulley 25 Nm
assembly bolt upper and
Lower, 2.0L GTDi
Crankshaft damper bolt, Refer to crank shaft
2.0L GTDi damper
Coolant pump pulley Refer to coolant pump
bolts, 2.0L GTDi

General Specifications

Item Specification
Accessory drive belt, 6 ribs
2.0L GTDi

Version: 2014 Falcon

303-05E Accessory Drive 303-05E-2

DESCRIPTION AND OPERATION

Accessory Drive
Component Location

2 4

3
1

9
8

7 5
AUS09072

Item Description
1 Accessory drive belt
2 Alternator pulley
3 Idler pulley 2 (upper)
4 Power steering pump-pulley
5 A/C compressor-Pulley
6 Coolant pump -pulley
7 Crankshaft belt pulley
8 Idler pulley 1 (lower)
9 Accessory drive belt tensioner

Overview
The accessory drive system provides power to
operate components which power other systems.
These could include components such as the
generator, power steering pump, water 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.

Version: 2014 Falcon

303-05E Accessory Drive 303-05E-3

DESCRIPTION AND OPERATION (Continued)

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.
Automatic belt tensioners are calibrated to provide
the correct amount of tension to the belt for a given
accessory drive system. Unless a spring or damping
band within the tensioner assembly breaks or some
other mechanical part of the tensioner fails, there is
no need to check the tensioner for correct tension.
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.
Accessory Drive Belt Routing

AUS09071

Version: 2014 Falcon

303-05E Accessory Drive 303-05E-4

DIAGNOSIS AND TESTING

Accessory Drive
Inspection and Verification
1. Verify the customer’s concern by operating the
engine to duplicate the condition.
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.
2. Visually inspect for obvious signs of mechanical
damage.
Visual Inspection Chart

Mechanical
• Inspect for obvious signs of mechanical damage.
• Inspect for signs of drive belt cracking/chunking/wear.
• Inspect for signs of belt/pulley contamination.
• Inspect for signs of a incorrect accessory drive belt.
• Inspect for signs of pulley misalignment or excessive pulley runout.
• Inspect for signs of loose or mislocated hardware.
• Inspect for signs of loose accessory drive belt.
• Inspect for signs of damaged pulleys.
• Inspect for signs of tensioner arm misalignment.
• Inspect for signs of belt stretch.
3. If an obvious cause for an observed or reported
concern is found, correct the cause (if possible)
before proceeding to the next step.
Note: Minor cracks in the V-grooved portion of the
drive belt are considered normal and acceptable. If
the drive belt has chunks missing from the ribs, a new
drive belt should be installed.
4. If the cause is not visually evident, verify the
symptom and refer to the Symptom Chart.

Version: 2014 Falcon

303-05E Accessory Drive 303-05E-5

DIAGNOSIS AND TESTING (Continued)

Accessory Drive Belt Concerns Pilling

CAUTION Pilling is dust that forms in between the ribs of the

accessory drive belt from rubber that is worn off the
Do not lubricate the accessory drive belt, accessory drive belt when it is new. There may also
accessory drive belt tensioner or idler pulley(s) be loose particles left on the accessory drive belt
as potential damage to the accessory drive belt during the manufacturing process. These are worn
material construction, accessory drive belt tensioner off and form into small balls of rubber that then get
damping mechanism, accessory drive belt tensioner trapped in the grooves of the accessory drive belt.
pulley bearing and idler pulley(s) bearing may occur. This condition will usually clear itself within 4800 km -
8000 km of normal driving.
Cracking
Accessory drive belts are made from rubber which
hardens with time and can develop cracks. As the
accessory drive belt runs on the back of some of
the pulleys, the cracks are opened up. Small cracks
are not considered to be a failure of the accessory
drive belt. Only if the crack is deep enough to reach
the bottom of the groove to expose the cord or any
chunks are found to be missing from the accessory
drive belt, is the accessory drive belt condition
considered to be unacceptable.
Check the accessory drive belt for cracks. If the
damage exceeds the acceptable limit, install a new
accessory drive belt. For additional information, refer
to Accessory Drive Belt procedure in this section.
Chunking
Chunking describes the condition where long lengths
of rubber become detached from the ribs of the
accessory drive belt. This is considered to be a failure
of the accessory drive belt. AUS06575

Check the accessory drive belt for +. The condition of

the accessory drive belt should be compared against
the illustration.
1. Small scattered pills. Not considered a concern.
No action required.
2. Longer pills up to 50% of the rib height. Possible
noise concern. Install a new accessory drive belt
if noise is apparent. For additional information,
refer to Accessory Drive Belt procedures in this
section.
3. Heavy deposits in the grooves. Possible noise
AUS06574
and stability concern. Install a new accessory
drive belt. For additional information, refer to
Check the accessory drive belt for damage. If
Accessory Drive Belt procedures in this section.
any chunks are found to be missing, install a new
accessory drive belt. For additional information, refer
to Accessory Drive Belt procedure in this section.

Version: 2014 Falcon

303-05E Accessory Drive 303-05E-6

DIAGNOSIS AND TESTING (Continued)

Incorrect fitment
Accessory drive belt noise can be generated by the
accessory drive belt being incorrectly fitted on the
pulley as shown in the following illustration. Make sure
that all the V grooves on the accessory drive belt
contact correctly with the pulley.

AUS06576

Belt Tensioner
Note: The only mechanical check that needs to be
made is a check for tensioner stick, grab or bind.
1. Remove the belt in the area of the tensioner.
2. Rotate 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 there is tension on the belt
tensioner spring.
3. If the tensioner does not meet the above criteria,
install a new tensioner. See ’Accessory Drive Belt
Tensioner’ in this section.

Version: 2014 Falcon

303-05E Accessory Drive 303-05E-7
DIAGNOSIS AND TESTING (Continued)
Symptom Chart
Symptom
Accessory drive belt noise
Version: 2014 Falcon
Possible Sources
• Accessory drive system
• Accessory drive belt
incorrectly installed
• Pulley(s)
• Lubricant or other
contamination
Action
• 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.
• CHECK the accessory drive
belt is correctly installed in the
pulley grooves.
• INSTALL a new accessory
drive belt as necessary.
• REFER to Accessory Drive Belt
(303-05 - Accessory Drive -
Removal and Installation)
• TEST the system for normal
operation
• CHECK the pulley(s) for
damage, freedom of rotation,
stone entrapment and
alignment.
• INSTALL new components as
necessary.
• TEST the system for normal
operation
• CHECK the accessory drive
belt for contamination or
damage.
• RECTIFY the source of the
leak
• INSTALL a new accessory
drive belt.
• REFER to Accessory Drive Belt
(303-05 - Accessory Drive -
Removal and Installation)
• TEST the system for normal
operation
303-05E Accessory Drive 303-05E-8
DIAGNOSIS AND TESTING (Continued)
Symptom
Accessory drive belt squeal
Note: Squeal is defined as
a continuous shriek, most
noticeable when the engine is
being accelerated or with electrical
load
Version: 2014 Falcon
Possible Sources Action
• Accessory drive belt • CHECK the accessory drive
tensioner worn, damaged or belt tensioners for correct
contaminated with oil operation, damage or
contamination.
• REFER to the Accessory Drive
Belt Tensioner Component
Test in this section
• INSTALL a new accessory
drive belt tensioner as
necessary.
• TEST the system for normal
operation
• Accessory drive belt worn, • INSPECT the accessory drive
damaged or contaminated belt tensioner is within the
with oil wear indicator marks.
• CHECK the accessory
drive belt for damage or
contamination.
• INSTALL a new accessory
drive belt as required
• TEST the system for normal
operation
303-05E Accessory Drive 303-05E-9
DIAGNOSIS AND TESTING (Continued)
Symptom
Accessory drive belt whine
Note: Whine is defined as a
continuous noise at the same
frequency, generally associated
with plastic pulleys.
Accessory drive belt chirp
Note: Chirp is defined as a
twittering noise, often intermittent
Version: 2014 Falcon
Possible Sources
• Poor surface finish on
accessory drive belt idler
pulley flat surface(s).
• Accessory drive belt idler
pulley bearing failure.
• Accessory drive belt worn,
damaged or contaminated
with oil
• Pulley misalignment (usually
evident at idle).
Action
• REMOVE the accessory drive
belt.
• REFER to the Accessory Drive
Belt procedure in this section
• INSPECT the idler pulley(s) for
surface finish.
• INSTALL a new idler pulley(s)
as necessary.
• TEST the system for normal
operation
• REMOVE the accessory drive
belt.
• REFER to the Accessory Drive
Belt procedure in this section.
• INSPECT the idler pulley(s) for
smooth rotation.
• INSTALL a new idler pulley(s)
as necessary.
• TEST the system for normal
operation
• INSPECT the accessory drive
belt tensioner is within the
wear indicator marks.
• CHECK the accessory
drive belt for damage or
contamination.
• INSTALL a new accessory
drive belt as required
• TEST the system for normal
operation
• CHECK that the accessory
drive belt is running 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
303-05E Accessory Drive 303-05E-10
DIAGNOSIS AND TESTING (Continued)
Symptom
Accessory drive belt rattle
Note: Rattle is defined as a
metallic knocking noise
Accessory drive belt fraying
Knocking or rattle noise when
vehicle decelerates or on gear up
shifts.
Version: 2014 Falcon
Possible Sources
• Accessory drive belt tensioner
hitting the end stops.
• Loose components or
hardware.
• Accessory drive belt Pulley(s).
• Belt stretch
Action
• INSPECT the accessory drive
belt tensioner is within the
wear indicator marks.
• CHECK the accessory drive
belt tensioner for correct
operation or damage.
• REFER to the Accessory Drive
Belt Tensioner Component
Test in this section.
• INSTALL a new accessory
drive belt tensioner as
necessary.
• TEST the system for normal
operation.
• CHECK the components
or hardware for correct
installation and tighten as
necessary.
• TEST the system for normal
operation.
• 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
• CHECK the belt stretch.
• REFER to Instructions for
checking for accessory drive
belt stretch.
• If belt is stretched, replace the
belt.
303-05E Accessory Drive 303-05E-11

DIAGNOSIS AND TESTING (Continued)

Component Tests Accessory Drive Belt Tensioner - Dynamic

Check
Accessory Drive Belt Tensioner - Static
Check The accessory drive belt tensioner may be checked
dynamically as follows:
The accessory drive belt tensioner may be checked
statically as follows: 1. With the engine running, observe the accessory
drive belt tensioner movement. The accessory
1. Inspect the area surrounding the accessory drive belt tensioner should move (respond) when
drive belt tensioner for lubricant or other the engine is accelerated rapidly or when the
contamination. Rectify any leaks before installing A/C clutch cycles ON and OFF (the degree of
a new accessory drive belt tensioner. If the movement can be up to 4 mm). If the accessory
accessory drive belt tensioner is contaminated, drive belt tensioner movement is not constant
do not attempt to clean it as the damping without engine acceleration or A/C clutch cycling,
mechanism inside may be damaged. Install a a pulley or shaft is possibly bent, out of round, or
new accessory drive belt tensioner as necessary. the damping mechanism inside the accessory
Test the system for normal operation. drive belt tensioner may be damaged. Install a
2. Release the tension from the accessory drive new accessory drive belt tensioner as necessary.
belt and detach the accessory drive belt from the Test the system for normal operation.
accessory drive belt tensioner. 2. Excessive accessory drive belt rideout (uneven
Note: The accessory drive belt tensioner has a depth of grooves in the accessory drive belt) may
damping feature, which is usually a friction device, cause excessive accessory drive belt tensioner
therefore some friction within the system is normal. movement. Check the condition by installing a
new accessory drive belt. Test the system for
3. Using the correct tool, move the accessory drive normal operation.
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. 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.

Version: 2014 Falcon

303-05E Accessory Drive 303-05E-12

DIAGNOSIS AND TESTING (Continued)

Instructions for checking for accessory drive Condition -2

belt stretch
Identification

3 4 AUS09520
2
1
In the above image the arrow shows the direction of
AUS09518
the rotation.

Item Description Item Description

1 1st mark on tensioner arm 1 Reference line lies between 2nd and
2 2nd mark on tensioner arm 3rd markings on tensioner arm

3 3rd mark on tensioner arm 2 Feature on stationary side of

tensioner housing
4 Feature on stationary side of
tensioner housing • Feature on stationary side is to the left of a
point between the 2nd and 3rd markings on
the spring loaded side
To check the belt stretch • Belt has stretched.
Condition -1 • Replace the belt.

2
1
AUS09519

In the above image the arrow shows the direction of

the rotation.

Item Description
1 Reference line lies between 2nd and
3rd markings on tensioner arm
2 Feature on stationary side of
tensioner housing
• Feature on stationary side is to the right of a
point between the 2nd and 3rd markings on
the spring loaded side.
• Belt stretch is OK.
• Belt replacement is not required.

Version: 2014 Falcon

303-05E Accessory Drive 303-05E-13

REMOVAL AND INSTALLATION

Accessory Drive belt Removal

Removal
1. Remove the air intake tube to the turbocharger.
For additional information refer to the section
303-12B of the 2014 Falcon Workshop Manual.
2. Release the belt tension from the tensioner.
4. Remove accessory drive belt. For additional
information refer to the accessory drive belt
procedure in this section.
5. Remove the idler pulley retaining bolt.

AUS09482

AUS09480 6. Remove the idler pulley.

3. Carefully remove the belt. Installation
Installation 1. Install the idler pulley.
1. Route the belt in its original position. 2. Install the idler pulley retaining bolt and tighten the
bolt to the specification.
2. Release the tensioner and refit the accessory
drive belt. 3. Install the accessory drive belt.
3. Install the air intake tube to the turbocharger. For
additional information refer to the section 303-
12B of the 2014 Falcon Workshop Manual.
Idler pulley (centre)

Version: 2014 Falcon

303-05E Accessory Drive 303-05E-14

REMOVAL AND INSTALLATION (Continued)

Idler pulley (lower)

Removal
1. Remove accessory drive belt. For additional
information refer to the accessory drive belt
procedure in this section.
2. Remove the idler pulley retaining bolt.

AUS09481

3. Remove the idler pulley.

Installation
1. Install the idler pulley.
2. Install the idler pulley retaining bolt and tighten the
bolt to the specification.
3. Install the accessory drive belt.

Version: 2014 Falcon