Installation
1. Install the belt guide (8680) as follows (Refer to Figure 1):
a. Remove the vacuum pump pulley using Steering Pump Pulley Remover T69L-10300-B or equivalent.
b. Remove two vacuum pump retainer bolts: the center one and the one towards the right side of the vehicle.
c. Position and secure the guide to the front of the pump using the removed bolts. Tighten bolts to 27 N-m (20 ft-lb). Refer to Figure 1.
d. Press on vacuum pump pulley using Power Steering Pulley Replacer T65P-3A733-C or equivalent, so the end of the pump shaft is flush with the pulley hub (+/- 0.010 inch).
CAUTION
Be sure to properly position the tensioner lug into the locating hole of the bracket. Failure to secure the tensioner as outlined may result in damage to front end accessory drive components.
2. Install the tensioner (6B209) as follows:
a. Position the tensioner assembly to the A/C-P/S bracket.
b. Tighten the hex-head bolt to 62.5 +/- 9.4 N-m (46 +/- 7 ft-lb). See Figure 1.
3. Position the flanged idler pulley (19A216) to A/C-P/C bracket. Be sure the cutout in the rear flange is positioned around the body of the tensioner assembly. Tighten idler pulley bolt to 55 N-m (40 ft-lb). See Figure 2.
CAUTION
Be sure to use the proper belt for the application being worked on. Use only F4TZ-8620-T for vehicles covered by this instruction sheet. Refer to Affected Vehicles at the beginning of this instruction sheet.
CAUTION
Do not apply more force than what is required to swing the tensioner to the INSTALL position. Damage to the tensioner may result.
NOTE:
If additional clearance is needed to install the belt, loosen the vacuum pump bolts and push the vacuum pump up as high as possible. Hold the pump in that position and retighten bolts to 27 N-m (20 ft-lb).
4. Install the rubber-backed serpentine drive belt (8620) as follows:
a. Loosely route the belt behind the tensioner pulley and over all other pulleys except the power steering pump pulley.
b. Make sure the belt fits correctly in all grooved pulleys.
c. Using a 15 mm box end wrench, swing the tensioner to the INSTALL position without the belt on the tensioner pulley, then slip the belt onto the power steering pulley.
d. Next, swing the tensioner to the INSTALL position again, and slip the belt over the tensioner pulley from the rear of the tensioner forward onto the pulley.
e. Verify proper belt seating before proceeding.
5. Install fan and shroud assembly. Only hand-tighten fan at this time.
6. Install shroud retaining screws. Tighten screws to 6.5 +/- 1.5 N-m (58 +/- 13 in-lb).
7. Tighten the fan clutch to133 +/- 20 N-m (98 +/- 15 ft-lb), using the Fan Clutch Holder T83T-6312-A and the Fan Clutch Nut Wrench T38T-6312-B.
8. Connect and secure upper radiator hose to radiator.
9. Install air cleaner assembly (E-Series) or air intake tube assembly (F-Series).
10. Connect both battery negative cables. Remove Memory Saver.
11. Fill radiator with removed coolant and install radiator cap.
12. Locate the existing belt routing decal on the radiator support. Clean the decal then install new decal (8B656) over it. See Figure 3
13. Start the engine. Check belt for proper tracking by closely inspecting the belt at the flanged idler pulley. You must be able to see some portion of the idler pulley on both sides of the belt. Refer to Figure 4. If adjustment is required, you will need to procure Shim Kit F2TZ-6B306-E. It is not included in the parts kit for this program.
a. If the belt is tracking rearward and beyond the pulley width, add shims behind the crankshaft pulley as needed to bring the belt back into alignment.
b. If the belt is tracking forward and beyond the pulley width, replace the spacer behind the crankshaft pulley with shims as needed to bring the belt back into proper alignment.
14. Remove fender and seat covers, then close the hood and door.