Engine stalls when alternator belt tightens or car

A serpentine belt almost never breaks unless one thing happens---one of the accessories seizes and won't turn.Remove the belt and see which pulley won't turn.The serpentine belt is strong enough to keep the engine from cranking up(better grip on the pulleys compared to the old V-belts).I actually remember a tech 3 stalls down from me sell a customer an engine,only to find the alternator was just seized.(embarassing!)Any one accessory bearing will keep it from cranking up,and I'm sure you'll find it quickly after removing the belt.

YOUR V BELT HAS A ADJUSTER BOLT LOOSEN ADJUSTER BOLT TURN THE TURN TENSION BOLT UNTIL DRIVE BELT START TIGHTEN YOU SHOULD HAVE ABOUT 1/2 INCH DEFLECTION WHEN YOU PRESS DOWN ON BELT WITH THUMB. DONT TIGHTEN V BELT TOO TIGHT WILL CAUSE WATER PUMP AND ALTERNATOR SHAFT BEARING FAILURE.

Has it just started with cold weather? Does it squeal at first then as the engine is revved, stop squealing.

If so its probably your alternator belt has worked loose and needs tightening. I'd check this out first, if you've not done it before ask a friend with some know how for guidance. But as a guide, there should be about an inch of give when flexed on the longest run between 2 pulleys, if more then probably needs tightening. If more than a couple of years old, replace with a new one.

If it still squeals after tightening/replacing, you could have a faulty water pump bearing or pulley bearing. Either would require replacement to pre-empt catastrophic failure and resultant engine damage.

check for spark and fuel after it dies.

If there is spark but no fuel, then the fuel pump may be bad or a clogged fuel filter.

If there is fuel but not spark, then the ignition control module or the ignition coil could be bad.

Also, check that the timing belt is timing the engine correctly.
Timing Belt & Balancer Belt

Removal & Installation

2.3L Engine

To Remove:

1. Record anti-theft code for radio.
   
2. Disconnect battery negative cable then positive cable.
   
   
   
   
   
   
   
   
   
   
   
3. Turn crankshaft pulley until TDC is achieved.
   
4. Raise and safely support vehicle.
   
5. Remove front tire assembly.
   
6. Remove splash shield.
   
7. Remove power steering belt.
   
8. Remove alternator and alternator bracket.
   
9. Safely support engine under oil pan.
   
   
   
   
   
   Upper bracket removal
   
   
   
   
   
10. Remove stop, detach ground cable and remove upper bracket.
    
11. Remove cylinder head cover.
    
12. Remove upper cover.
    
13. Remove dipstick and tube assembly.
    
14. Remove crankshaft pulley.
    
15. Remove adjusting nut rubber seal and remove lower cover.
    
    
    
    
    
    Timing belt/balancer belt removal
    
    
    
    
    
16. Loosen adjusting nut 1 turn.
    
17. Push up on balancer belt tensioner to relieve belt tension.
18. Push down on timing belt tensioner to relieve belt tension.
    
19. Tighten adjusting nut 1 turn.
    
20. Remove balancer belt and timing belt.

To Install:


NOTE: Clean balancer belt drive pulley, timing belt pulleys and
upper/lower timing cover prior to belt installation.

1. Set timing belt drive pulley to TDC by aligning dimple on pulley with dimple
   on oil pump.
   
   
   
   
   
   
   
   
   
   
   
2. Set camshaft pulley to TDC so that "UP" mark is at top and grooves align
   with top of cylinder head.
   
   
   
   
   
   Timing belt installation
   
   
   
   
   
3. Starting with driver pulley, install timing belt in a counterclockwise
   sequence.
   
4. Loosen and ten retighten adjusting nut.
   
5. Install balancer belt drive pulley.
   NOTE: Inspect rubber seal on lower cover and replace as necessary.
   
   
6. Install lower cover.
   
7. Install crankshaft pulley and bolt.
   
8. Rotate crankshaft pulley counterclockwise several times to seat belt.
   
9. Loosen adjusting nut 1 turn.
   
10. Rotate crankshaft counterclockwise 3 teeth on camshaft pulley.
    
11. Tighten adjusting nut to 33 ft lb (44 Nm).
    
    
    
    
    
    
    
    
    
    
    
12. Turn crankshaft pulley until TDC is achieved.
    
    
    
    
    
    
    
    
    
    
    
13. Ensure that camshaft pulley "UP" mark is at top and grooves align with top
    of cylinder head.
    
14. Remove crankshaft pulley and lower cover.
    
15. Rotate crankshaft to TDC again and lock timing belt adjuster arm with a 6 mm
    timing cover bolt.
    
16. Loosen adjuster nut 1 turn and ensure that belt tensioner freely moves.
    
17. Push tensioner up and tighten adjusting nut.
    
    
    
    
    
    Balancer shaft alignment
    
    
    
    
    
18. Remove bolt and washer from maintenance hole.
    
19. Using a 6 X 100 mm bolt, scribe a mark 2.9 in (74 mm) from end.
    
20. Insert bolt into maintenance hole and hole in balancer shaft.
    
21. Install bolt up to scribed line.
    
    
    
    
    
    Balancer shaft alignment
    
    
    
    
    
22. Align groove on balancer shaft with pointer on oil pump housing.
    
23. Install balancer belt and loosen adjusting nut 1 turn to tension.
    
24. Retighten bolt.
    
    
    
    
    
    Balancer shaft alignment
    
    
    
    
    
25. Remove bolt from maintenance hole and install bolt and washer. Tighten to
    22 ft lb (29 Nm).
    
26. Reinstall crankshaft pulley.
    
27. Loosen adjusting nut 1 turn.
    
28. Rotate crankshaft pulley counterclockwise 1 turn and tighten adjusting nut.
    
29. Remove bolt from timing belt adjuster arm.
    NOTE: Inspect rubber seal on lower cover and replace as necessary.
    
    
30. Remove crankshaft pulley.
    
31. Install lower cover.
    
32. Install seal at adjusting nut.
    NOTE: Crankshaft pulley, bolt and washer must be cleaned prior to
    installation.
    
    
33. Lubricate crankshaft pulley bolt between head and washer and bolt threads
    with clean engine oil.
    
    
    
    
    
    
    
    
    
    
    CAUTION
    Do not use impact wrench to perform
    following step.
    
    
34. Install crankshaft pulley and tighten bolt using special tools to 181 ft
    lb (245 Nm).
    
35. Install dipstick/tube assembly.
    
36. Install upper cover. Tighten bolts to 9 ft lb (12 Nm).
    
37. Install cylinder head cover.
    
38. Install alternator bracket and alternator.
    
39. Install power steering pump belt and alternator belt.
    
    
    
    
    
    Upper bracket installation
    
    
    
    
    
40. Install upper bracket and tighten fasteners in proper numbered sequence.
    
41. Install stop.
    
42. Install battery and enter radio anti-theft code.

The crank shaft is not froze up if the engine is running. Without knowing how severe the situation is, it is probably best to remove the belt and feel each pulley or drive wheel to detect the condition of the bearings. It should be very clear which pulley bearing is loose by "wiggling" the pulleys. One of the pulleys will have a lot of play in the bearing. Also the pulley with the bad bearing will be hard to turn by hand with the belt off. Be sure to check every pulley on that belt circuit, except the crank shaft, you can't turn it by hand.

Daewoo has interference engines in them, so if the timing belt broke while the engine was running, you will need to replace half of the valves which were bent when the pistons crashed into them when the cams stopped turning and the crank shaft continued to turn. Minimum of $700-1000.00 (usually more). If you do it all yourself and the valve guides are not damaged, still at least $400.00 worth of parts to fix. Pull plastic air dams around bottom of engine on front and right side . Support engine with jack. Drain antifreeze from engine and radiator. remove air filter housing and serpentine belt. remove front engine mount. remove cam belt cover. remove broken cam belt and check cam tensioner bearings and idler bearing as well. They are usually bad. Then remove spark plug cover. Remove valve cover. Remove intake from head. remove coil from head. remove heat shield from exhaust manifold then remove manifold from exhaust and from head. remove water hoses and connecting assemblies from side of head and rear of head. remove Cam shaft bearing caps loosening them all evenly so as not to bend cams. remove cams. remove head bolts. remove head. remove valve hydraulic lifters, compress valve springs and remove valve retainers and dissassemble valves. Clean everything very well. Make sure head is not damaged. Remove valve guide seals. install new valve guide seals, new valves. Seat valves with valve grinding compound. clean well. instal valves in reverse order of dissasembly. Before putting head on, make sure number 1 cylinder is at top dead center position. install head using proper torque of 18 ft # in a spiral application rotation from the center outward in a clockwise direction. Then do spiral rotation again tightening bolts each one-quarter turn. Repeat the tightening process two more times only turning the bolts one-quarter turn each time. Use new head bolts. They are designed to stretch in the process of installation and are not to be re-used. Align cams to proper orientation then bolt into place. do not overtorque cam bearing cap bolts. Less than 5 ft # of torque can stretch these bolts. Snug them then tighten them 90 degrees. Then tighten them another 90 degrees (quarter turn). Snug them all then go back and tighten all of them a quater turn, then go back and tighten all of them another quarter turn. Install the cam idler and tensioner and install the cam belt. then install the intake, exhaust and all other items in reverse order of assembly. Do not turn engine over unless you are sure you have the cam belt on with the crank shaft pulley aligned at top dead center and the intake and exhauste pulley marks aligned to their proper marks with the cam belt properly tensioned. You can't be even one tooth off. This must be right before you turn the engine over! Remove spark plugs and turn engine over by hand two rotation clockwise using a wrench on the center bolt of the crank shaft pulley. Check that the timing of cams is still perfect. If not, correct, retension cam belt, double check timing positions again then rotate engine two revolutions. Check cam timing positions again. The timing should not change! The engine should turn over relatively easily. If it feels like it doesn't want to turn, don't force it. You may have the timing off and be pressing a piston against a valve. If you are at this point, then you need to remove cam belt and unbolt cam shafts to release all tension on any of the valves. return the number one cylinder to top dead center position and then reinstall the cams and cam belt. Once it is assembled and in time, then reattatch the rest of the components that were removed in dissassembly. Do this in reverse order of dissassembly. then connect battery and fill radiator fluid. Start car.

2005 Ford Mustang 4.0L SFI SOHC 6cyl
Ford Mustang 1999-2005
Alternator - Removal & Installation

3.8L And 4.0L Engines

1. Before servicing the vehicle, refer to the precautions at the beginning of this section.
2. Disconnect the negative battery cable.
3. Remove the accessory drive belt.
4. Disconnect the alternator electrical connectors.
5. Remove the alternator shield (4.0L engine).
6. Remove the alternator mounting bolts.
7. Remove the alternator from the vehicle.
8. Installation is the reverse of the removal procedure.

To install:

1. Position the alternator onto engine. Tighten the lower bolt to 35 ft. lbs. (47 Nm) and the upper bolt to 18 ft. lbs. (25 Nm).
2. Install the alternator shield (4.0L engine).
3. Connect the alternator electrical connectors.
4. Install the accessory drive belt.
5. Connect the negative battery cable.

4.6L Engines (Non-Supercharged)

1. Before servicing the vehicle, refer to the precautions at the beginning of this section.
2. Disconnect the negative battery cable.
3. Remove the air intake scoop bracket, if equipped.
4. Remove the accessory drive belt.
5. Remove the upper alternator bracket.
6. Disconnect the alternator electrical connectors.
7. Remove the alternator bolts.
8. Remove the alternator from the vehicle.
9. Installation is the reverse of the removal procedure.

To install:

1. Position the alternator onto engine. Tighten the mounting bolts to 18 ft. lbs. (25 Nm).
2. Connect the alternator electrical connectors.
3. Install the upper alternator bracket. Tighten the bolts to 89 inch lbs. (10 Nm).
4. Install the accessory drive belt.
5. Install the air intake scoop bracket, if equipped.
6. Connect the negative battery cable.

4.6L Engines (Supercharged)

1. Before servicing the vehicle, refer to the precautions at the beginning of this section.
2. Disconnect the negative battery cable.
3. Remove the accessory drive belt.
4. Raise the vehicle.
5. Disconnect the alternator electrical connectors.
6. Remove the alternator bolts.
7. Remove the alternator from the vehicle.
8. Installation is the reverse of the removal procedure.

To install:

1. Position the alternator onto engine. Tighten the lower bolt to 18 ft. lbs. (25 Nm) and the upper bolt to 37 ft. lbs. (50 Nm).
2. Connect the alternator electrical connectors.
3. Lower the vehicle.
4. Install the accessory drive belt.
5. Connect the negative battery cable.
6. Installation is the reverse of the removal procedure.

More details about this model in Autozone.com (free register).

I hope help you with this (remember rated this help). Good luck.

Disconnect the negative clamp on the battery. Remove the bolt on the adjustment arm (the one with the slot) of the alternator. Loosen the pivot bolt at the bottom of the Alt. Swing the alt inward to loosen the belt. Take the belt of the pulley. Take off the wires noting where they attach. Remove the pivot bolt. You should be able to take the alt off now. Reverse the sequence but when adjusting the belt tension pry the side of the alternator with a bar so the belt can only be deflected about three quarters of an inch. Tighten the adjustment bolt. Don't over tighten the belt. It'll prematurely wear your bearings. Don't under tighten. It'll squeal.

Tune-up Specifications
Air/Fuel Ratio 0.7% Air/Fuel Ratio-Limits[1] 0.3 - 1.1% Timing[2] 6°+/- 1°BTDC Timing Advance[3] 30°+/- 3°BTDC Idle RPM[4] 800 +/- 50 [1] Check CO with the oxygen sensor connected. [2] AT 2300 RPM, and coolant temperature sensor disconnected. [3] Normal operating temperature, with coolant temp. sensor connected, at 2300 RPM. Add initial timing. [4] A/C off.
Timing mark is on flywheel, access hole is on top of bellhousing. Remove access plug with 27mm wrench if necessary
Firing Order is > 1342 Clockwise Rotation & #1 Plug Wire is at 2 Oclock on Distribitor Cap


Align the mark (can be a dot or notch) on the intermediate shaft sprocket with the notch in the crank pulley. Align the mark (can be a dot or notch) on the "Back" of camshaft sprocket with the top edge of the valve cover gasket. Be sure all the timing marks are properly aligned.

For further information refer to Timing Belt : Service and Repair
NOTE : The 8 valve engine requires a special wrench, Volkswagen No. US4493 or equivalent, to adjust the camshaft drive belt tensioner. Whenever the drive belt is removed and refitted, the camshaft and intermediate shaft timing MUST be adjusted. The drive belt can be replaced without removing the belt sprockets.

1. Loosen alternator adjusting bolts and remove the fan belt.
2. Remove the water pump pulley bolts and remove the pulley.
3. Remove the upper timing cover bolts and remove the cover.
4. Remove the timing belt guide, if equipped.
5. Turn the engine by hand to set the No. 1 piston at Top Dead Center (TDC) and remove the crankshaft pulley.
6. Remove bolt and nuts securing the lower timing cover and remove the cover. CAUTION: Turning the camshaft or crankshaft with the timing belt removed may cause damage to pistons and/or valves.
7. Loosen timing belt tensioner locknut, release belt tension and remove belt from sprockets.
8. Inspect belt for visible damage such as missing teeth or exposed threads. Inspect tensioner bearing for smooth running. Any damaged components should be replaced.

NOTE : On high mileage engines, failure of the tensioner bearing is a possibility. Consider replacing the bearing when replacing the timing belt.

1. Align the mark (can be a dot or notch) on the intermediate shaft sprocket with the notch in the crank pulley. Align the mark (can be a dot or notch) on the "Back" of camshaft sprocket with the top edge of the valve cover gasket. Be sure all the timing marks are properly aligned.
2. Temporarily install the crankshaft pulley to the crankshaft. Fit the timing belt starting with the crankshaft and intermediate shaft sprockets. Fit the belt so that it is as tight as possible between the crankshaft and the intermediate shaft sprockets and between the intermediate shaft and camshaft sprockets.
   1. Turn the belt tensioner clockwise to adjust the tension. The direction is important to avoid contact with the timing cover. Check the tension by twisting the belt as shown. You should be able to twist it no more than 90 degrees.
   2. Tighten the tensioner locknut to: 33 ft lbs (45 Nm)
   3. Rotate the crankshaft two revolutions and recheck the belt tension and the timing marks for proper alignment.
   NOTE: Very slight movement of sprockets and marks can be expected as belt tension is adjusted. Slight movement is OK. The smallest possible increment of adjustment is one whole tooth of the belt or sprocket.
   1. Remove the crankshaft pulley and refit the lower timing cover. Tighten the bolts to: 87 in lbs (10 Nm)
   2. Refit crankshaft pulley and tighten the bolts to: 15 ft lbs (20 Nm)
   3. Refit timing belt guide, if equipped.
   4. Refit upper timing cover and tighten bolt and nuts to: 87 in lbs (10 Nm)
   5. Refit water pump pulley and tighten the bolts to: 15 ft lbs (20 Nm)
   6. Refit fan belt and adjust tension. Tighten alternator adjusting bolts.
   
   Please Dont Forget To RATE ME !
   

I am not sure where the crank position sensor is on your car but when the alternator belt broke on my Buick it trashed the crank sensor that is located next to the crank shaft pulley. The computer needs the crank senor to know the position of the crank shaft. If the sensor is bad the car will not start.