How to replace an idler pulley on a 1994 Lincoln continental

this is a fairly straight forward repair. diagram the routing of the belt, remove the belt, i believe the tensioner has a square 3/8 drive hole you can put a ratchet in to unload it. then unbolt the tensioner. i wound also recommend replacing the idler pulley at this time. you will need to know if the pulleys on your engine are smooth or grooved when buying the parts

The belt is automatically tensioned by a spring loaded idler pulley. It is the part the moves when the engine is running, it is a pulley wheel on a spring loaded arm. Picture below.

I'm wondering if perhaps your belt is slipping. That would cause both the over heating and dead battery issues. Look for shiny spots on the belt and sections of missing "teeth" in the serpentine belt. Also be sure the belt tensioner is keeping the belt tight. You may also have failed bearings in a idler pulley. Be sure to spend the extra couple of dollars for a good replacement belt. Cheap belts tend to fail leading to problems just like this. Please let me know how you make out and if you have any more questions. Of course there are a lot of other potentials but this one gets both at once. Thanks and good luck!

3.8L Engine

1. Insert a 1/2 inch flex handle in the square hole in the tensioner. The tensioner has a square hole cast into the rear of the tensioner body directly behind the pulley. Rotate the tensioner clockwise and remove the belt from the pulleys.
   

NOTE As an alternate method, a 16mm socket can be placed on the tensioner pulley bolt and rotated clockwise to remove the belt.

To install:

1. Following the schematic on the decal under the hood, loop the drive belt over all the pulleys except the alternator pulley.
   
2. With the belt installed properly on all except the alternator pulley, rotate the tensioner as described above and install the belt on the alternator pulley. Ensure that all the V-grooves make proper contact with the pulleys.
   

4.6L Engine
WARNING Do not allow the drive belt tensioner to snap back as damage to the drive belt tensioner or personal injury could result.

1. Rotate the drive belt tensioner clockwise with a breaker bar installed in the 3/8 inch square hole in the drive belt tensioner.
   
2. Lift the drive belt over the idler pulley flange and remove the drive belt.
   

To install:

1. Following the schematic on the decal under the hood, position the belt over the pulleys, except the idler pulley.
   
2. Rotate the tensioner as described above and install the belt on the idler. Ensure that all the V-grooves make proper contact with the pulleys.
   

You should have a serpetine belt on your car for all pulleys.
There should be a diagram of the belt either on top of the front cowling apron(In front of the radiator) or under the hood in front by the upper locking hook.
You should not need to remove the radiator.

You will need a 3/8 or 1/2 inch rachet or breaker bar to move the idler pulley to slip on the belt. The idler pulley is spring loaded and keeps tension on the belt.

Step 1 Inspect the belt already in your Lincoln for cracks or wear. It is best to replace serpentine belts early, before any major damage occurs, as a break in the belt will cause a critical failure in a motor vehicle while under power.

Step 2 Find the belt routing diagram under the hood, this can usually be found on the top of the radiator mount. Lincolns, even those of the same year model, may have different accessories run by the serpentine belt. So the exact routing of the belt will vary from vehicle to vehicle.

Step 3 Loosen the tensioner pulley until you can push it relatively easily. The belt should still be too tight remove, if it is not the idler pulley is malfunctioning.

Step 4 Unscrew the idler pulley belt until the idler pulley loosens enough to allow the belt to be removed.

Step 5 Make note of the direction of rotation of the serpentine belt as it is important to install the new belt in a way that it is intended to rotate.

Step 6 Insert the new belt in accordance with your Lincoln's belt installation chart.

Step 7 Tighten the idler and tensioner pulleys an assistant with a pry bar may be needed to properly tighten your Lincoln's serpentine belt.

It may be a idler pulley bearing starting to freeze up remove the belt and turn all pulleys,power steering pump, alternator, idler pulley , etc. to find out if there is excessive resistance offered if so this is the culprit, on the idler pulley check the raidial play in the bearing by trying to move it by holding it with your hand and try to wiggle it gently back and forth same with the other (pulleys) check for loosness or play in pulleys bearings if everything checks out ok the battery may be running low and upon startup the alternator is under alot of strain to compensate for the recent drain on the battery while it is stressed to turn the starter to start car, your car may be drawing power from the battery as the car sits causing this condition disconect the pos. terminal of the battery and run a positive voltmeter wire to battery terminal then run negative volt meter wire to the now removed positive battery terminal cable set the voltmeter to dc there should not be 12 volts present if so there is and open circuit present drawing down the battery as the car sits while off.

Good luck

A common problem in the continental (my 95 had the same problem). You can TRY to reset the error. The link below lists step by step instructions for the error reset. Best of luck.
Greg

http://www.synthetic-direct.ca/technical/reset_oil_service_light_lincoln.htm

fuses are located left side of instrument panel and under hood next to left fender.

Item Part Number Description 1 10300 Generator 2 8509 Water Pump Pulley 3 8678 Belt Idler Pulley 4 6B209 Drive Belt Tensioner 5 3A674 Power Steering Pump 6 8620 Drive Belt 7 19703 A/C Compressor 8 6312 Crankshaft Pulley