My daughter is in Sechelt , BC and is driving a 94 Explorer. The tensioner pulley broke off from the bracket and was lying on the engine. As I can't physically look at it (she sent me pictures), it ha

question 3 , and double posted....
and still no hint as the the JOB.
what are you doing and why, so we are on same page?

wow,,, you do make this so hard.
if the questions is new belt time"only"?(yes? do i guess good?)
then i posted last post all 11 steps from the real fsm ON REMOVAL. so, now I add page 2.
So now you want ,INSTALL too?
the below only works if you did page 1 correctly

ok here. 11 more steps, totaling 22



Install the drive belt to the crankshaft pulley, the tensioner and the generator.

Rotate the drive belt tensioner clockwise.

Install the drive belt to the idler pulley (1).

NOTE

Important: Ensure the drive belt is properly aligned and seated into the grooves of the accessory drive pulleys.

Slowly release the drive belt tensioner.

Raise the vehicle.

Install the right side engine mount bracket. Refer to Engine Mount Bracket Replacement - Right Side .

Install the engine splash shield. Refer to Engine Splash Shield Replacement - Right Side .

Lower the vehicle.

Install the engine mount strut bracket. Refer to Engine Mount Strut Bracket Replacement - Right Side .

Remove the engine support fixture. Refer to Engine Support Fixture .

Install the the air cleaner assembly. Refer to Air Cleaner Assembly Replacement .

which engine option, you do know belts are not same on all engines right? fact.
2.7L V6 or bigger? IDN.

same on all cars. (answering in generic form do to above)
loosen the tension-er.
take off old
put back new
and if not a spring tension-er,set proper tension
the fSM cover all this.
why not read the manual, RTM?

here is one example (get the book, RTM or see alldata.com)

2008 xl7 engine


Removal Procedure

Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement .

Install the engine support fixture. Refer to Engine Support Fixture .

Remove the engine mount strut bracket. Refer to Engine Mount Strut Bracket Replacement - Right Side .

Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .

Remove the engine splash shield. Refer to Engine Splash Shield Replacement - Right Side .

Remove the right side engine mount bracket. Refer to Engine Mount Bracket Replacement - Right Side .

Lower the vehicle


Rotate the drive belt tensioner clockwise to release the drive belt tension.

Slide the drive belt off of the belt idler pulley (1).

Slowly release the drive belt tensioner.

Remove the drive belt from the accessory drive pulleys.

end remove
beg, install



Install the drive belt to the crankshaft pulley, the tensioner and the generator.

Rotate the drive belt tensioner clockwise.

Install the drive belt to the idler pulley (1).

NOTE

Important: Ensure the drive belt is properly aligned and seated into the grooves of the accessory drive pulleys.

Slowly release the drive belt tensioner.

Raise the vehicle.

Install the right side engine mount bracket. Refer to Engine Mount Bracket Replacement - Right Side .

Install the engine splash shield. Refer to Engine Splash Shield Replacement - Right Side .

Lower the vehicle.

Install the engine mount strut bracket. Refer to Engine Mount Strut Bracket Replacement - Right Side .

Remove the engine support fixture. Refer to Engine Support Fixture .

Install the the air cleaner assembly. Refer to Air Cleaner Assembly Replacement .
end.

find the bolts attaching the bracket to the engine (possibley2 or 3) Buy a genuine replacement assy and fit get a new belt as the old one may have suffered damage. Replace where you removed the broken bit and adjust the belt to the correct tension

Belt Installation, Aerostar 4.0L Engine





Item Part Number Description 1 8620 Drive Belt 2 N606068 Bolt 3 10300 Generator 4 10153 Generator Mounting Bracket 5 8509 Water Pump Pulley 6 6B209 Drive Belt Tensioner 7 N800199 Screw 8 8678 Belt Idler Pulley 9 N802096 Screw 10 19703 A/C Compressor 11 2882 A/C Compressor Mounting Bracket 12 3C718 Brace 13 N806020 Bolt 14 3A674 Power Steering Pump 15 3A733 Power Steering Pump Pulley 16 N800199 Screw 17 N606572 Bolt 18 N620481 Nut 19 8501 Water Pump 20 6312 Crankshaft Pulley A - Belt Tension Check (See Specifications) B - Tighten to 40-55 Nm
(30-41 Lb-Ft) C - Tighten to 24-30 Nm
(18-23 Lb-Ft) D - Tighten to 21-29 Nm
(15-21 Lb-Ft) E - Tighten to 40-50 Nm
(30-37 Lb-Ft)

Belt Installation, Ranger and Explorer 4.0L Engine





Item Part Number Description 1 8620 Drive Belt 2 10300 Generator 3 8678 Belt Idler Pulley 4 19703 A/C Compressor 5 3A733 Power Steering Pump Pulley 6 8501 Water Pump 7 6312 Crankshaft Pulley 8 6B209 Drive Belt Tensioner 9 N806020 Bolt 10 2882 A/C Compressor Mounting Bracket 11 3A674 Power Steering Pump 12 N606572-S2 Bolt 13 N800199-S8M Bolt 14 N620481-S2 Nut 15 3C718 Brace 16 N606068 Bolt 17 10153 Generator Mounting Bracket 18 8509 Water Pump Pulley 19 N605805-S2 Bolt A - Belt Tension Check (See Specifications) B - Tighten to 21-29 Nm
(15-21 Lb-Ft) C - Tighten to 40-55 Nm
(30-41 Lb-Ft)

Belt Installation, Ranger 2.3L Engine





Item Part Number Description 1 8678 Belt Idler Pulley 2 10300 Generator 3 8509 Water Pump Pulley 4 3A733 Power Steering Pump Pulley 5 2E884 A/C Clutch Pulley 6 6312 Crankshaft Pulley

Belt Installation, Aerostar 3.0L Engine





Item Part Number Description 1 10300 Generator 2 3F671 Belt Idler Pulley 3 3A733 Power Steering Pump Pulley 4 6B209 Drive Belt Tensioner 5 6312 Crankshaft Pulley 6 8509 Water Pump Pulley 7 19703 A/C Compressor

Don't know what size of motor you have but this should help you:

Removal & Installation

1. Loosen the accessory-to-mounting bracket bolt(s) and adjusting bolt.
   
2. Rotate the accessory to relieve belt tension.
   
3. Slip the drive belt from the accessory pulley and remove it from the engine.
   

If the engine uses more than one belt, it may be necessary to remove belts that are in front of the belt being removed

To install:

If the engine uses more than one belt, it may be necessary to remove belts that are in front of the belt being removed

1. Place the new belt over the crankshaft or drive pulley and stretch over the driven (accessory) pulley.
   
2. If removed, install the other belts in the same way.
   
3. Adjust the belts to the proper tension.
   
4. Tighten the adjusting and mounting bolts.
   

Models equipped with the V6 engine and most 1987-94 engines use a single (serpentine belt) to drive all engine accessories. The serpentine belt driven accessories are rigidly mounted with belt tension maintained by a spring loaded tensioner assembly. The belt tensioner has the ability to control belt tension over a fairly broad range of belt lengths. However, there are limits to the tensioner's ability to compensate for varying lengths of belts. Poor tension control and/or damage to the tensioner could result with the tensioner operating outside of its range.

To replace the belt push (rotate) the the belt tensioner and remove the belt. Use a 15mm socket on the 4-cyl. engines and a 3/4 in. open end wrench on the V6 engines.
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Disconnect the battery

Remove the air snorkel and upper half of the air box. You may have to remove the engine cover to get at the clamp for the air snorkel at the throttle body.

You will see the serp belt tensioner on the drivers side of the engine. In the center of the pulley will be a bolt head. use the appropriate sized socket and ratchet to rotate the tensioner using the bolt head. Once the tension is off the belt it can be removed from the alternator pulley. You do not need to remove the entire belt.

Remove the three bolts holding the alternator to the bracket. A 15mm socket and possible a swivel should to the trick.

Remove the plug in connector from the alternator and remove the nut holding the battery cable to the backside of the alternator.

Make sure the new alternator is the same amperage, has the same mounting brackets and the same pulley size and the same number of groove. Essentially make sure it looks identical to the old one.

Then reinstall. It should take you about an hour tops. Good luck!

I’m happy to assist further over the phone at https://www.6ya.com/expert/jeremy_d728a59f986299fa

Section 11-02A: Steering Pump, Power, C-II 1996 Aerostar, Ranger and Explorer Vehicles Workshop Manual REMOVAL AND INSTALLATION Pump and Pulley SPECIAL SERVICE TOOL(S) REQUIRED Description Tool Number Steering Pump Pulley Remover T69L-10300-B Steering Pump Pulley Replacer T65P-3A733-C
Removal

1. Disconnect the power steering return hose (3A713) at the pump and drain fluid.
   

1. Remove the power steering pressure hose (3A719) by unscrewing connector from the pump.
   

1. On the Aerostar 3.0L V-6 engine (6007), loosen the drive belt tensioner (6B209) and adjustment bolts.
   
   
   
   
   
   Item Part Number Description 1 10346 Generator 2 8501 Water Pump 3 8678 Belt Idler Pulley 4 3A733 Power Steering Pump Pulley 5 6303 Crankshaft 6 2884 A/C Clutch 7 — Without A/C On the 2.3L I-4 and 4.0L V-6 engines, slacken belt tension by lifting drive belt tensioner in a counterclockwise direction. On Ranger 3.0L V-6 engines, slacken belt tension by lifting drive belt tensioner in a clockwise direction. Remove drive belt (8620) from under drive belt tensioner and slowly lower pulley to stop. Remove the drive belt from the power steering pump pulley (3A733).
   
   
   
   
   
   Item Part Number Description 1 10346 Generator 2 2884 A/C Clutch 3 3A733 Power Steering Pump Pulley 4 8501 Water Pump 5 6303 Crankshaft 6 8678 Belt Idler Pulley 7 6B209 Drive Belt Tensioner

1. NOTE: If the drive belt requires servicing, refer to Section 03-05 .
   
   Remove the drive belt from the power steering pump pulley.
   

1. Remove the oil dipstick tube.
   

1. Remove the power steering pump support (3C511).
   

1. Install Steering Pump Pulley Remover T69L-10300-B on the pulley.
   

1. NOTE: Do not apply pressure on the power steering pump rotor shaft (3B559). Pressure will damage internal thrust areas of the power steering pump (3A674).
   
   While holding the remover tool nut stationary with a wrench, rotate the inner spindle of the remover tool clockwise until the pulley is pulled off the power steering pump rotor shaft.
   

1. Remove the bolts attaching the power steering pump to the A/C compressor mounting bracket (2882).
   

Installation

1. Install the power steering pump on the A/C compressor mounting bracket. Install and tighten attaching bolts to 41-61 Nm (30-45 lb-ft). On 4.0L engine, tighten to 47-64 Nm (35-47 lb-ft).
   

1. Position the support on the A/C compressor mounting bracket. Install mounting bolts and tighten to 47-64 Nm (35-47 lb-ft).
   

1. NOTE: Fore/aft location of power steering pump pulley on power steering pump rotor shaft is critical. Incorrect belt alignment may cause drive belt squeal or chirp. Make sure pull-off groove on power steering pump pulley is facing front and flush with end of shaft ± 0.254mm (± 0.010 inch).
   
   Install the Steering Pump Pulley Replacer T65P-3A733-C and install the power steering pump pulley.
   

1. Install the drive belt on the power steering pump pulley.
   

1. On the 2.3L I-4, Ranger 3.0L V-6, and 4.0L V-6 engines, position and rotate drive belt on engine. While lifting drive belt tensioner in a counterclockwise direction (clockwise on Ranger 3.0L V-6), slide drive belt under drive belt tensioner and lower drive belt tensioner to drive belt.
   On Aerostar 3.0L V-6 engine, position the belt idler pulley (8678) assembly to give the drive belt the tension specified. Refer to belt tension check in Section 03-05 . Tighten the drive belt tensioner and adjustment bolts to 47-64 Nm (35-47 lb-ft).
   

1. Install the power steering pump support, if removed.
   

1. Install the oil dipstick tube.
   

1. Install the pressure hose tube nut and new Teflon® wagner into power steering pump valve outlet fitting (3D654) and tighten to 41-54 Nm (30-40 lb-ft).
   

1. Connect the power steering return hose to the power steering pump, and reposition the clamp.
   

1. Fill the power steering oil reservoir (3A697) with Premium Power Steering Fluid E6AZ-19582-AA or equivalent fluid meeting specification ESW-M2C33-F. Start the engine and turn the steering wheel (3600) from left to right without hitting stops to remove air from the system.
   

1. Check for leaks and recheck the fluid level. Add fluid if necessary to proper level as specified in Section 11-00 .
   
   
   Power Steering Pump and Power Steering Pulley, 2.3L TPH Engine, Ranger Only
   
   
   
   
   
   Item Part Number Description 1 2882 A/C Compressor Mounting Bracket 2 N606543-S2 Bolt (2 Req'd) 3 N606069-S2 Bolt (2 Req'd) 4 N605803-S2 Bolt 5 N800199-S8M Screw 6 3D673 Power Steering Pump Pulley 7 3F671 Power Steering Belt Idler Support 8 N806020-S2 Bolt 9 3A674 Power Steering Pump 10 19703 A/C Compressor A — Tighten to 21.2-29 Nm (16-21 Lb-Ft) B — Tighten to 40.3-55 Nm (30-41 Lb-Ft) C — Tighten to 44-51 Nm
   (32-38 Lb-Ft)
   
   Power Steering Pump and Power Steering Pulley, 3.0L Engine, Aerostar
   
   
   
   
   
   Item Part Number Description 1 3A674 Power Steering Pump 2 3C511 Power Steering Pump Support 3 6007 Engine 4 N803564 Stud 5 N802827-S2 Nut 6 N800199-S8M Screw (3 Req'd) 7 N8011179-S2 Screw (3 Req'd) 8

You should only remove the drive belt shield if you raise the car. Below are step-by-step instructions per the repair manual. Drive Belt Tensioner
Removal & Installation To Remove:

1. Disconnect the negative battery cable.
2. Raise and safely support the vehicle.
3. Remove the drive belt shield at the right wheel well.
4. Remove the drive belt.
5. Remove the drive belt tensioner mounting bolt.
6. Remove the drive belt tensioner.

To Install:

1. Install the belt tensioner. Torque the mounting bolt to 21 ft. lbs. (28 Nm).
2. Install the drive belt.
3. Install the drive belt shield.
4. Lower the vehicle.
5. Connect the negative battery cable.

You should have a serpentine belt. You will see a pulley that attaches to a bracket. This pulley is spring mounted so it keeps the proper tension on the belt at all times. You will need to use a 3/8 drive ratchet or breaker bar to insert in to the square slot to pull the tensioner pulley back to remove the belt.

YOU HAVE WHATS CALLED A TENSIONER PULLEY IN FRONT OF ENGINE , ONE OF TWO PULLEYS THAT ARE SLICK (NO GROOVES). THE TENSIONER PULLEY IS WHAT YOUR AFTER. IT WILL BE ATTACHED TO A SLOTTED BRACKET WITH A BOLT HEAD DIRECTLY BEHIND IT.(LOOKING AT ENGINE FROM FRONT OF VEHICLE ITS USUALLY ON YOUR FAR RIGHT!) FIRST UNLOOSEN BOLT ON FRONT OF PULLEY ABOUT FIVE TURNS , THEN MOVE TO BOLT ON TOP BEHIND PULLEY , AND START UNLOOSENING IT TILL PROPER TENSION IS RELEASED TO SLIDE BELT OVER ALL PULLEYS(USE BELT DIAGRAM UNDER HOOD FOR PROPER INSTALLATION. ONCE BELT IS ON REVERSE STEPS 1 AND 2. TIGHTEN TOP BOLT BEHIND TENSION PULLEY TILL BELT HAS ABOUT A QUARTER INCH PLAY IN IT UP AND DOWN (DON'T OVER TIGHTEN).THEN TIGHTEN FRONT PULLEY BOLT TILL VERY SNUG.YOUR DONE! BELT MAY NEED RE-TIGHTENED AFTER DRIVING A FEW DAYS , BUT YOUR AN EXPERT NOW AND THAT WON'T BE A PROBLEM. HOPE THIS HELPED!