Ford Galaxy / Ford S-MAX. Manual — part 407
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).
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.
*
TEST the system for normal operation.
Accessory drive
belt incorrectly
installed.
*
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
(303-05A 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.
*
Pulley(s).
*
CHECK the pulley(s) for damage, freedom of
rotation, stone entrapment and alignment.
INSTALL new components as necessary. TEST the
system for normal operation.
*
Lubricant or
other
contamination.
*
CHECK the accessory drive belt for contamination
or damage. RECTIFY the source of the leak and
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).
TEST the system for normal operation.
*
NOTE: Squeal is
defined as a
continuous shriek,
Accessory drive
belt tensioner
worn, damaged
*
CHECK the accessory drive belt tensioner for
correct operation, damage or contamination.
REFER to the Accessory Drive Belt Tensioner
*
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