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Re: 94 Mercury Cougar xr7 3.8l Belt Tensioner Re Install
The tensioner is not adjustable, the spring in it provides a preset tension, I don't understand what you did, but if it came apart then most likely you damaged it, buy a new one, if you get it wrong and it falls apart on the road you are stuck.
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BELT ROUTING DIAGRAM
1997 Mercury Sable 3.0L SFI 6cyl
The Belt Routing Diagram
Fig. Fig. 16: Rotate the belt tensioner and...
Fig. Fig. 17: ... remove the belt from around one of the pulleys to remove the belt
Use caution when removing or installing the belt and make sure the tool does not slip from the drive belt tensioner or personal injury or damage to the belt tensioner and the belt may occur.
Attach a 15mm socket or wrench to the bolt attaching the tensioner pulley.
On all 3.0L (OHV) engines, rotate the drive belt tensioner clockwise to relieve belt tension and slide the belt off the pulleys.
On 3.0L (DOHC) engines, rotate the tensioner counterclockwise to relieve belt tension and slide the belt off the pulleys.
Install the drive belt on all the pulleys except the tensioner pulley.
Rotate the belt tensioner as outlined in the removal procedure to relieve belt tension and install the belt onto the tensioner pulley. Make sure the V-grooves make proper contact with the pulleys. Make sure the spring keeper releases or improper belt tension will occur.
First remove the black engine cover that says 2.5 V6 Duratec 24 Valve etc, by removing 3 bolts. Then you can see the water pum, pulley and tensioner at the rear side of the engine (opposite to the battery). Just push the tensioner with hand or flathead screwdriver and take the belt off and put the new belt the same way.
There is no adjustment on the serpentine belt. I'm assuming that you have a 4.6 since it's an XR7. There is a spring loaded tensioner that keeps the belt in proper adjustment. The tensioner may be bad, or just corroded in one position. If there's no diagram for the belt routing under the hood...draw one. Then remove the belt and carefully persuade the tensioner to move. Careful not to break it or it's mount. If it doesn't move, it's going to need replacing. It's the one on the little arm, the arm should move.
"HOW TO": Standard Rules to Removal the Serpentine Belt with an Automatic Tensioner: 1. Find the Tensioner. 2. Using a Serpentine Belt Tensioner Tool, Or Wrench OR Ratchet, Rotate/Move the Tensioner USING THE AVAILABLE NUT (on the Pulley or Arm Base) OR the OPENING (3/8ths or 1/2 inch square opening) rotating the Tensioner Pulley/Arm - moving it away from contact with the belt and towards the area where the belt is not in contact with the Tensioner Pulley. The Tensioner is spring loaded, and is hard to rotate/move. 3. Remove the loosened belt off one of the other more easily accessed Pulleys. 4. DO NOT quickly release the Tensioner, but gently allow the Tensioner to rest in its closed position.
Standard Rules for Installing the Serpentine Belt with an Automatic Tensioner: a. Pick a Pulley that is most easily accessed. This will usually be on top. This will be the last Pulley that the belt will go on. b. Using the Diagram: Install the new Serpentine Belt on the remainder of the Pulleys....over, under, left right. c. Using a Serpentine Belt Tensioner Tool or Wrench or Ratchet Tool: Rotate/Move the Tensioner Pulley/Arm "away" from Belt contact area on the Tensioner. This spring is pretty hard and with a new belt, it will be even harder to install. Rotate/Move this to as-close to the maximum allowed inorder to have enough slack in the belt to get it up and over the last pulley. d. Using your other hand - Pull the Belt up and over the Last remaining Pulley. e. Before releasing the pressure on the Tensioner, visually inspect the remainder Pulleys and the Belts' Positioning on them. Let me know if this helped, or if you have additional information questions. Feel Free to contact me at FixYa.com!
To remove the alternator, you have to remove the serpentine belt. They have a tensioner in which you place a socket wrench and pull on it and it loosens the belt. Before removing the belt notice how it is routed. Some vehicles have a diagram on the hood or on the front near the grill.You take the belt off. Then you remove the alternator by removing the bolts attaching the alternator to the engine. There are two or three bolts you have to remove. Two of them are fairly big bolts. About a size 14 metric or so. Disconnect the negative battery cable battery so you won't hit any grounds.Then take off the plugs from the alternator and the small nuts that hold the wires. Notice how they are placed before removing so you can know where each plug goes.Then replace the new alternator. Plug it back up and install the same way you took it out.Replace the belt starting from the left to right and pull on the tensioner and reinstall.
this is hard to exsplain without showing you a photo ,but i will try. first get the belt around the engine crankshaft which is the pully closest to the bottom and center of the engine. when standing in front of engine start to lead the belt to the right and connect to power steering pump then up to generator, next thare is going to be a smooth pully not groved like the others to the left,put the smooth side of the belt on bottom of this pully and continue left to the ac/compressor go around ac/compressor andstraight down to the belt tensioner , and then right over to the water pump which has a smooth pully not grooved. remember the smooth pullys will always carry the smooth side of the belt and the grooved pullys the grooved side of belt. the belt tensioner will half to be released by a serpantine belt tensioner tool sold at your local auto parts store. these instructions is for 3.8 liter engine, if you have a 4.6 liter engine it will be different, so repost stating that you have a 4.6 if this dont help