Lincoln Corsair Manuals

Lincoln Corsair: Accessory Drive - 2.0L EcoBoost (177kW/240PS) – MI4 / Diagnosis and Testing - Accessory Drive

Inspection and Verification

  1. Verify the customer concern.
  1. Visually inspect for obvious signs of mechanical damage.

  Visual Inspection Chart


Mechanical
  • Damaged or contaminated accessory drive belt
  • Damaged or contaminated pulley(s)
  • Incorrect accessory drive belt
  • Incorrect fitment of the accessory drive belt
  • Generator
  • Air conditioning (A/C) compressor
  • Pulley(s)
  • Loose hardware
  1. 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

NOTICE: Do not lubricate the accessory drive belt as potential damage to the accessory drive belt material construction 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. 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 EcoBoost (177kW/240PS) – MI4, 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.

  1. 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 EcoBoost (177kW/240PS) – MI4, 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.

  1. 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.
    1. Small scattered pills. Not considered a concern. No action required.
    1. 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 EcoBoost (177kW/240PS) – MI4, Removal and Installation).
    1. 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 EcoBoost (177kW/240PS) – MI4, Removal and Installation).
    1. 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 EcoBoost (177kW/240PS) – MI4, Removal and Installation).
    1. 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 EcoBoost (177kW/240PS) – MI4, 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.

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

Global Customer Symptom Code (GCSC) Chart

Diagnostics in this manual assume a certain skill level and knowledge of Ford-specific diagnostic practices.
REFER to: Diagnostic Methods (100-00 General Information, Description and Operation).


Symptom Action
Start/Run/Move > Noise > Running/Standing > Always GO to Pinpoint Test A
Start/Run/Move > Noise > Running/Standing > Always GO to Pinpoint Test B
Start/Run/Move > Noise > Running/Standing > Always GO to Pinpoint Test C

Symptom Chart(s)

Symptom Chart: Accessory Drive

Diagnostics in this manual assume a certain skill level and knowledge of Ford-specific diagnostic practices.
REFER to: Diagnostic Methods (100-00 General Information, Description and Operation).


  Symptom Chart


Condition Actions
Accessory drive belt noise   GO to Pinpoint Test A
Accessory drive belt chirp   GO to Pinpoint Test B
Accessory drive rattle   GO to Pinpoint Test C

Pinpoint Tests

NOTICE: Do not lubricate the accessory drive belt as potential damage to the accessory drive belt material construction may occur.


PINPOINT TEST A: ACCESSORY DRIVE BELT NOISE

Normal Operation and Fault Conditions

REFER to: Accessory Drive - Component Location (303-05A Accessory Drive - 2.0L EcoBoost (177kW/240PS) – MI4, Description and Operation).

Possible Sources

  • Damaged or contaminated accessory drive belt
  • Damaged or contaminated pulley(s)
  • Incorrect accessory drive belt
  • Incorrect fitment of the accessory drive belt

Visual Inspection and Pre-checks

  • Inspect for loose, damaged, contaminated or incorrect components.
A1 CHECK FOR THE SOURCE OF THE NOISE.
  • Use a stethoscope or other listening device to determine the source of the noise.

Can the source of the noise be identified?
Yes INSTALL a new component as necessary.
No GO to A2

A2 CHECK FOR ACCESSORY DRIVE BELT AND A/C COMPRESSOR BELT FOR CRACKING

NOTE: 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 and a/c compressor belts for cracking.

Do the drive belts show signs of cracking?
Yes INSTALL a new accessory drive belt.
REFER to: Accessory Drive Belt (303-05A Accessory Drive - 2.0L EcoBoost (177kW/240PS) – MI4, Removal and Installation).
or a/c compressor belt. REFER to: Air Conditioning (A/C) Compressor Belt (303-05A Accessory Drive - 2.0L EcoBoost (177kW/240PS) – MI4, Removal and Installation).
No GO to A3

A3 CHECK FOR ACCESSORY DRIVE BELT AND A/C COMPRESSOR BELT FOR CHUNKING

NOTE: 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.

  • Check the accessory drive and a/c compressor belts for chunking.

Does the drive belts show signs of chunking?
Yes INSTALL a new accessory drive belt.
REFER to: Accessory Drive Belt (303-05A Accessory Drive - 2.0L EcoBoost (177kW/240PS) – MI4, Removal and Installation).
or a/c compressor belt. REFER to: Air Conditioning (A/C) Compressor Belt (303-05A Accessory Drive - 2.0L EcoBoost (177kW/240PS) – MI4, Removal and Installation).
No GO to A6

A4 CHECK FOR ACCESSORY DRIVE BELT AND A/C COMPRESSOR BELT FOR PILLING

NOTE: 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.

  • Check the accessory drive and a/c compressor belts for pilling.

Does the drive belts show signs of pilling?
Yes INSTALL a new accessory drive belt.
REFER to: Accessory Drive Belt (303-05A Accessory Drive - 2.0L EcoBoost (177kW/240PS) – MI4, Removal and Installation).
or a/c compressor belt. REFER to: Air Conditioning (A/C) Compressor Belt (303-05A Accessory Drive - 2.0L EcoBoost (177kW/240PS) – MI4, Removal and Installation).
No GO to A6

A5 CHECK FOR INCORRECT, DAMAGED OR CONTAMINATED ACCESSORY DRIVE BELT
  • Check the accessory drive belt for incorrect belt, damage or contamination.

Does the accessory drive belt show signs of incorrectness, damage or contamination?
Yes RECTIFY the source of the leak if necessary and INSTALL a new accessory drive belt.
REFER to: Air Conditioning (A/C) Compressor Belt (303-05A Accessory Drive - 2.0L EcoBoost (177kW/240PS) – MI4, Removal and Installation).
No GO to A6

A6 CHECK FOR INCORRECT, DAMAGED OR CONTAMINATED A/C COMPRESSOR DRIVE BELT
  • Check the a/c compressor drive belt for incorrect belt, damage or contamination.

Does the a/c compressor drive belt show signs of incorrectness, damage or contamination?
Yes RECTIFY the source of the leak if necessary and INSTALL a new a/c compressor drive belt.
REFER to: Air Conditioning (A/C) Compressor Belt (303-05A Accessory Drive - 2.0L EcoBoost (177kW/240PS) – MI4, Removal and Installation).
No GO to A7

A7 CHECK THE ACCESSORY DRIVE BELT FOR INCORRECT FITMENT

NOTE: Accessory drive belt noise can be generated by the accessory drive belt being incorrectly fitted on the pulley. Make sure that all the V grooves on the accessory drive belt contact correctly with the pulley.

  • Check the accessory drive belt for incorrect fitment.

Does the accessory drive belt show signs of incorrect fitment?
Yes INSTALL the accessory drive belt correctly and retest.
REFER to: Air Conditioning (A/C) Compressor Belt (303-05A Accessory Drive - 2.0L EcoBoost (177kW/240PS) – MI4, Removal and Installation).
No GO to A8

A8 CHECK THE A/C COMPRESSOR DRIVE BELT FOR INCORRECT FITMENT

NOTE: A/C compressor drive belt noise can be generated by the accessory drive belt being incorrectly fitted on the pulley. Make sure that all the V grooves on the accessory drive belt contact correctly with the pulley.

  • Check the a/c compressor drive belt for incorrect fitment.

Does the a/c compressor drive belt show signs of incorrect fitment?
Yes INSTALL a new a/c compressor drive belt correctly and retest.
REFER to: Air Conditioning (A/C) Compressor Belt (303-05A Accessory Drive - 2.0L EcoBoost (177kW/240PS) – MI4, Removal and Installation).
No The system is operating correctly at this time. The concern may have been caused by an intermittent component concern.

PINPOINT TEST B: ACCESSORY DRIVE BELT CHIRP

NOTE: Chirp is defined as a twittering noise, often intermittent

Normal Operation and Fault Conditions

REFER to: Accessory Drive - Component Location (303-05A Accessory Drive - 2.0L EcoBoost (177kW/240PS) – MI4, Description and Operation).

Possible Sources

  • Damaged or contaminated accessory drive belt
  • Damaged or contaminated pulley(s)
  • Incorrect fitment of the accessory drive belt
  • Pulley misalignment

Visual Inspection and Pre-checks

  • Inspect for loose, damaged, contaminated or incorrect components.
B1 CHECK FOR THE SOURCE OF THE NOISE.
  • Use a stethoscope or other listening device to determine the source of the noise.

Can the source of the noise be identified?
Yes INSTALL a new component as necessary.
No GO to B2

B2 CHECK FOR INCORRECT, DAMAGED OR CONTAMINATED ACCESSORY OR A/C COMPRESSOR DRIVE BELT
  • Check the accessory or a/c compressor drive belt for incorrect belt, damage or contamination.

Does the accessory or a/c compressordrive belt show signs of incorrectness, damage or contamination?
Yes GO to Pinpoint Test A
No GO to B3

B3 CHECK FOR PULLEY MISALIGNMENT
  • Engine RUNNING.

Are the accessory drive belts running centrally on the flat pulleys?
Yes With the engine running at idle, use a stethoscope to identify the source of the noise. INSTALL new components as necessary.
No CHECK the pulleys for excessive end float and bent flanges and replace as necessary

PINPOINT TEST C: ACCESSORY DRIVE BELT RATTLE

NOTE: Rattle is defined as a metallic knocking noise

Normal Operation and Fault Conditions

REFER to: Accessory Drive - Component Location (303-05A Accessory Drive - 2.0L EcoBoost (177kW/240PS) – MI4, Description and Operation).

Possible Sources

  • Generator
  • Air conditioning (A/C) compressor
  • Pulley(s)
  • Loose hardware
  • Loose components
Diagnostic steps are not provided for this symptom or DTC.  REFER to: Diagnostic Methods (100-00 General Information, Description and Operation).

Component Tests

Accessory Drive Belt Tensioner - Static Check

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

  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.
    REFER to: Accessory Drive Belt Tensioner (303-05B Accessory Drive - 2.3L EcoBoost (199kW/270PS), Removal and Installation).
  1. Detach the accessory drive belt in the area of the accessory drive belt tensioner.
  1. NOTE: The accessory drive belt tensioner has a damping feature, which is usually a friction device, therefore some friction within the system is normal.

    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.
  1. 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.
    REFER to: Accessory Drive Belt Tensioner (303-05B Accessory Drive - 2.3L EcoBoost (199kW/270PS), Removal and Installation).
  1. 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.
    REFER to: Accessory Drive Belt Tensioner (303-05B Accessory Drive - 2.3L EcoBoost (199kW/270PS), Removal and Installation).

Accessory Drive Belt Tensioner - Dynamic Check

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

  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.
    REFER to: Accessory Drive Belt Tensioner (303-05B Accessory Drive - 2.3L EcoBoost (199kW/270PS), Removal and Installation).
  1. 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 EcoBoost (177kW/240PS) – MI4, Removal and Installation).

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