A/C Compressor Drive Belt - Rumble Noise
86ford23 Article No. 86-3-7AIR CONDITIONING COMPRESSOR DRIVE BELT RUMBLE NOISE - VEHICLES WITH 2.3L STANDARD AND TURBO ENGINES
FORD 1983-84 MUSTANG, THUNDERBIRD, LTD
LINCOLN-MERCURY 1983-84 CAPRI, COUGAR, MARQUIS
During A/C operation at vehicle engine speeds between 1100 and 1500 rpm, an objectionable rumble noise may be heard from the engine compartment on the subject vehicles.
If a vehicle with this condition is encountered, replace the existing A/C compressor mounting braces with new design mounting braces and install a new water pump pulley and A/C compressor drive belt. This repair also requires rerouting the heater and oil cooler tubes and hoses.
Testing
1. Start the engine and accelerate the engine to speeds between 1100 and 1500 rpm. With the air conditioner operating, verify the rumble noise condition.
2. If the rumble noise occurs, switch the A/C to "off" and verify that the noise does or does not stop.
A. If the noise does not stop with the A/C off, refer to the Noise, Vibration and Harshness Diagnosis (NVH) located in Group 18 of the 1983 Shop Manual.
B. If the noise stops with the A/C off, continue to Step 3.
3. Replace the designated A/C compressor mounting braces with the new design braces. Install the new water pump pulley and A/C compressor drive configuration and reroute the heater tubes.
For additional information, refer to the following procedure.
Figure 5:
Compressor Brace Replacement
1. Loosen the pivot bolt (N606063-S100) from the bottom rear of the A/C compressor assembly (Figure 5).
2. Remove and discard front brace (19D894) and spacer (389780-S) by first removing bolts (2) (N605799-S100) (save), and attaching bolt (N606063-S100) (discard) and screw and washer assembly (N602742-S100) (save) (Figure 5).
3. Rotate the compressor assembly inboard and remove and discard the drive belt.
Figure 5:
Figure 6:
4. Remove the upper left bolt (N605800-S100) on bracket (19D624) (Figure 5) and install new rear studded brace (E4SZ-2889-C) with the removed bolt (Figure 6) and hand tighten.
5. Install new front brace (E4SZ-2888-A) by inserting the stud attached to new rear studded brace (E4SZ- 2889-C) through the hole provided for it in the new front brace. Install and hand tighten the two bolts (N605799-S100) removed in Step 2 to attach the new front brace to the engine cylinder head. Loosely install screw and washer assembly (N602742-S100) removed in Step 2 to attach existing bracket (19D625) to the new front brace (E4SZ-2888-A) (Figure 6).
6. Install new brace (E5SZ-2889-D) by first placing spacer (390337-S) behind the hole in the brace and inserting bolt (N605801-S100) through both parts, then fasten to existing hole in the cylinder head between the first and second spark plug. Place other end over stud which protrudes through front brace assembly (E4SZ-2888-A) and secure with nut (Figure 6) and hand tighten both ends.
NOTE: If contact is made between new rear brace (E4SH-19D897-BA) and a heater water tube, refer to the following "Heater Water Tubes Replacement" procedure.
7. Remove the upper left compressor bracket (19D625) attaching bolt (N606063-S100) (discard) (Figure 1) and install new attaching bolt (N606062- S36) (Figure 6).
8. Tighten all nuts and bolts, which are not required for belt tensioning, to 35 ft.lbs.
9. Replace the water pump pulley following the succeeding pulley replacement procedure.
10. Install new A/C compressor drive belt (E5PZ-8620- D) over the water pump and A/C compressor drive pulleys, and using Belt Tension Gauge T63L-8620- A, tension to 130 lbs. Tighten screw and washer assembly (N602742-S100) to 35 ft.lbs. to maintain tension.
11. Install bolt (N605800-S100) attaching bracket (19D625) to brace (E4SZ-2888-A). Tighten to 35 ft.lbs.
Figure 7:
Water Pump Pulley Replacement
1. Loosen alternator pivot bolt (389483-S36) on the inboard side of alternator (Figure 7).
2. Loosen alternator adjusting bolt (57103-S2) and push the alternator inboard (Figure 7).
3. Remove the two drive belts from the water pump pulley sheaves and push aside (save).
4. Remove and discard water pump pulley (8509) by removing bolts (4) (N602550-S2) (save) (Figure 7).
5. Install new three sheave water pump pulley (E5ZZ- 8509-C) and attach using (4) (N602550-S2) bolts removed in Step 4. Torque to 14-20 ft.lbs.
NOTE: Spacer - water pump pulley (E3ZE- 8456-BA) must be reinstalled.
6. Install the two drive belts removed in Step 3 over the pulleys and using Belt Tension Gauge T63L- 8620-A, tension to 130 lbs. Tighten alternator adjusting bolt (57103-S2) to 30 ft.lbs. to maintain tension. Tighten alternator pivot bolt (389483-S36) to 50 ft.lbs. (Figure 7).
Heater Water Tubes Replacement
Removal
1. Drain the engine coolant into a suitable container.
Figure 8:
2. Remove the four (4) hose clamps at the right front of the engine retaining the connecting heater hoses to the engine and to the two (2) water tubes (Figure 8). Then remove the hoses and discard.
3. Remove the heater core inlet hose from the heater core inlet tube (Figure 8).
4. Loosen the engine lifting bracket retaining nut at the right rear of the engine (Figure 4).
5. Cut as necessary and remove the heater water inlet tube and attached heater core inlet hose from the engine. Discard the removed tube and hose assembly.
6. Cut the oil cooler outlet tube at the right rear corner of the engine as shown in Figure 8. Then remove and discard the tube from the right side of the engine, cutting the tubes as required, for removal from under the exhaust manifold.
Figure 9:
7. Working from under the vehicle, disconnect the oil cooler outlet hose from the engine oil cooler on the lower left side of the engine (Figure 9).
Figure 10:
8. Cut the oil cooler outlet tube at the left rear corner of the engine (Figure 10) and discard the tube end and outlet hose. Do not remove the section of the oil cooler outlet tube that is clamped to the rear of the engine.
Figure 11:
Installation
1. Install the oil cooler hose bracket (E5RY-6K759-A) under the engine rocker cover left rear attaching screw (Figure 11).
2. Position clamp (378042-S) onto the oil cooler outlet hose (E5ZZ-18472-A) as shown in Figure 11. Then position the outlet hose over the engine rocker cover and down the left side of the engine to the oil cooler (Figure 11). Connect the hose to the oil cooler, but do not tighten the hose clamp.
3. Attach clamp (378042-S) to the bracket installed on the left rear corner of the rocker cover with screw (E-610888-S71). After the hose is secured with the clamp, route the temperature sending unit wire under the hose and connect it to the sending unit.
Figure 12:
4. Position the new oil outlet tube (E5RY-6B749-B) to the right side of the engine and connect the tube to the oil cooler outlet hose (E5ZZ-18472-A) routed over the rocker cover (Figure 12). Do not tighten the clamp.
5. Connect the other end of the oil cooler outlet tube (E5RY-6B749-B) to the water pump with formed hose (E5ZZ-18472-C). See Figure 12. Do not tighten the clamp.
6. Position the new heater water inlet tube (E5ZZ- 18B402-A) to the right side of the engine above the oil cooler outlet tube (E5RY-6B749-B) (Figure 12). Then connect the tube to the thermostat housing fitting with formed hose (E5ZZ-18472-B).
NOTE: On 1983 2.3L turbo and 1983-84 Canadian 2.3L engines, the thermostat housing (E37E-8594-AB) must be replaced with a new thermostat housing (D8FZ- 8592-A) with gasket (E4ZZ-8255-A).
7. Connect the heater water inlet tube to the heater core with hose (E5SZ-18472-A: standard heater or manual A/C-heater, or E5SZ-18D371-B: ATC) as shown in Figure 12.
8. Install clamp (E3ZZ-18481-B) with bolt (N605771- S47) to retain the two tubes to the right front side of the engine rocker cover (Figure 12).
9. Install the spring clip (N802623-S2) on the inlet and outlet tubes at the right rear side of the engine near the bend of the inlet tube (Figure 12).
10. Tighten all hose clamps to 22-30 in.lbs. torque.
11. Tighten the engine lifting bracket on the exhaust manifold stud.
12. Fill the cooling system following the procedure given in the Car Shop Manual.
13. Start the engine and with the air conditioner operating, accelerate the engine from 1100 to 14OO rpm to assure the noise condition has been corrected.
PARTS INFORMATION - COMPRESSOR BRACES
PART NAME PART NUMBER QTY.
Old Parts - Remove and Discard
Bolt N606063-S100 2
Brace - Front E3SH-19D894-AA 1
Spacer 389780-S 1
V-Belt - A/C Drive E3AE-8620-DA 1
Pulley - Water Pump E3ZE-8509-EA 1
Old Parts - Remove and Re-install
Bolt N605799-S100 2
Screw & Washer Ass'y N602742-S100 1
Bolt N605800-S100
PART NAME PART NUMBER QTY. CLASS
New Parts - Install
Brace - Rear (w/Stud) E4SZ-2889-C 1 C
Brace - Front E4SZ-2888-A 1 C
Brace - Rear E5SZ-2889-D 1 C
Bolt N606062-S36 1 S
Bolt N605801-S100 1 BR
V-Belt - A/C Drive E5PZ-8620-D 1 C
Pulley - Water Pump E5ZZ-8509-C 1 C
Spacer 390337-S 1 S
PART NAME PART NUMBER YEAR
Old Parts - Remove and Discard
(1) Oil Cooler Outlet Hose E3ZE-18472-BB 1983
(1) Oil Cooler Outlet Hose E4ZE-18472-AA 1984
(1) Oil Cooler Outlet Tube E3ZE-18674-AC 1983
(1) Heater Core Inlet Hose E3SH-18D334-BA 1983
(1) Heater Core Inlet Hose E4SH-18D334-AB 1984
(1) Heater Core Inlet Hose E4SH-18D376-AB 1984 (ATC)
(1) Heater Inlet Tube E3ZE-18698-AB 1983
(1) Heater Inlet Tube E4ZE-18698-AA, AC 1984
(1) Heater Inlet Tube-toThermostat Housing
(1) Oil Cooler Outlet Tubeto-Water Pump
(1) Thermostat Housing E37E-8594-AB 1983 Turbo & 1983-84 Canadian Built - 2.3L Engines
PART NAME PART NUMBER CLASS
New Parts - Install
(1) Oil Cooler Outlet Hose E5ZZ-18742-A R
(1) Oil Cooler Hose E5ZZ-l8B402-B C
(1) Oil Cooler Hose E5ZZ-18B402-C C
(1) Oil Cooler Outlet Tube E5RY-6B749-B C
(1) Oil Cooler Outlet TubeE5ZZ-18472-C C to-Water Pump Hose
(1) Oil Cooler Outlet Hose E5RY-6K759-A C Bracket
(1) Oil Cooler Outlet Hose 378042-A BR Clip
(1) Oil Cooler Outlet Hose E-610888-S71 S Clip Screw
(1) Water Tubes Clip N-802623-S2 S
(1) Water Tube Bracket-toE3ZZ-18481-B C Rocker Cover
(1) Bracket Bolt N605771-S47 BS
(1) Heater Core Inlet Hose E5SZ-18472-A C
(1) Heater Core Inlet Hose E5SZ-18D371-B CG (ATC)
(1) Heater Core Inlet Hose E4ZZ-18472-B C (Must. - Base Htr. Only)
(1) Heater Inlet Tube-toE5ZZ-18472-B C Thermostat Housing
(1) Heater Inlet Tube E5ZZ-18B402-A C
(1) Thermostat Housing D8FZ-8592-A AM
(1) Housing Gasket E4ZZ-8255-A A
OTHER APPLICABLE ARTICLES: None
WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual.
OPERATION: SP2889A85
TIME: 2.4 Hrs. DLR. CODING: Basic Part No. 2889 - Code: 56