Ford Galaxy / Ford S-MAX. Manual — part 413

Accessory Drive - 1.8L Duratorq-TDCi
(74kW/100PS) - Lynx/1.8L Duratorq-
TDCi (92kW/125PS) - Lynx - Accessory
Drive

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

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Diagnosis and Testing

Inspection and Verification

1. 1. Verify the customer concern.

2. 2. Visually inspect for obvious signs of mechanical damage.

Visual Inspection Chart

3. 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

CAUTION: Do not lubricate the accessory drive belt, accessory drive belt tensioner or

idler pulley(s) as potential damage to the accessory drive belt material construction,
accessory drive belt tensioner damping mechanism, accessory drive belt tensioner pulley
bearing and idler pulley(s) bearing may occur.

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.

1. 1. Check the accessory drive belt for cracks. If the damage exceeds the acceptable

limit, install 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)

Mechanical

Damaged or contaminated accessory drive belt
Damaged or contaminated pulley(s)
Incorrect accessory drive belt
Incorrect fitment of the accessory drive belt
Accessory drive belt tensioner
Accessory drive belt idler pulley
Generator
Power steering pump
Power steering pump leakage
Air conditioning (A/C) compressor
Pulley(s)
Loose hardware

- 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).

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.

2. 2. Check the accessory drive belt for damage. If any chunks are found to be missing,

install 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).

Pilling

Pilling is dust that forms in between the ribs of the accessory drive belt from rubber that is
worn off the accessory drive belt when it is new. There may also be loose particles left on
the accessory drive belt during the manufacturing process. These are worn off and form
into small balls of rubber that then get trapped in the grooves of the accessory drive belt.
This condition will usually clear itself within 4800 km - 8000 km (3000 miles - 5000 miles)
of normal driving.

3. 3. Check the accessory drive belt for pilling. 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. Small scattered pills. Not considered a concern. No action required.
3. Longer pills up to 50% of the rib height. Possible noise concern. INSTALL a new

accessory drive belt if noise is apparent. 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).

4. Longer pills up to 50% of the rib height. Possible noise concern. INSTALL a new

accessory drive belt if noise is apparent. 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).

5. Heavy deposits in the grooves. Possible noise and stability concern. INSTALL 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).

6. Heavy deposits in the grooves. Possible noise and stability concern. INSTALL 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).

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.

4. 4. If the cause is not visually evident, verify the symptom and refer to the Symptom

Chart.

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.

*