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post #6 of (permalink) Old 06-20-2012
Beernuts82
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Take it to the dealer

TSB
12-1-10 5.0L WITH MANUAL TRANSMISSION AND A/C COMPRESSOR STRETCHY BELT CONFIGURATION - LIGHT LOWER-END ENGINE KNOCK

Publication Date: January 18, 2012

FORD: 2011-2012 Mustang


ISSUE:
Some 2011-2012 Mustang vehicles equipped with a 5.0L engine, manual transmission and air conditioning (A/C) compressor stretchy belt configuration may exhibit a light lower end engine knock most noticeable when engine temperature is warm and the vehicle is at idle.

ACTION:
Refer to the Service Procedure to correct the condition.

SERVICE PROCEDURE

Remove the front end accessory drive (FEAD) and A/C compressor stretchy belt. Refer to Workshop Manual (WSM), Section 303-05. Start engine and re-evaluate concern. Is light, lower-end engine knock still present?
Yes - Do not continue with this article. Perform normal diagnostics. Refer to WSM, Section 303-00.
No - Obtain Service Kit and proceed to Step 2.
Remove the FEAD belt tensioner and bolt from the engine front cover. Refer to WSM, Section 303-05 - Exploded view.
Determine the engine built date. Refer to WSM, Section 303-01.
If the engine build date is on or before 4/15/2011, replace the engine front cover. Refer to WSM, Section 303-01.
If the engine build date is after 4/15/2011, do not replace the engine front cover. Use an 8 X 1.25 mm tap to clean the mounting locations noted on the engine front cover. Use compressed air to clean any remaining debris. (Figure 1)


Figure 1 - Article 12-1-10


Install A/C compressor drive belt idler pulley and A/C compressor drive belt idler pulley bolt supplied in the service kit. Tighten to 25 N-m (18 lb-ft).
Install A/C drive compressor belt tensioner supplied in the service kit. Tighten to 25 N-m (18 lb-ft).
Install new A/C compressor belt supplied in the service kit. Refer to WSM, Section 303-05, 5.0L (4V) late build vehicles, for proper belt routing. (Figure 2)


Figure 2 - Article 12-1-10


Install the FEAD belt tensioner and bolt. Tighten to 25 N-m (18 lb-ft). Refer to WSM, Section 303-05, FEAD - Exploded view, 5.0L (4V) late build vehicles.
Install FEAD belt. Refer to WSM, Section 303-05, FEAD - Exploded view 5.0L (4V) late build vehicles.
Install Integrated Diagnostic System (IDS) and identify the vehicle. Answer the IDS screen prompts according to the current vehicle A/C belt configuration.
Reprogram the Powertrain Control Module (PCM) using IDS release 76.03 or later. This new calibration is not included in the VCM 2011.11 DVD. Calibration files may also be obtained at Buy Motorcraft Parts Online | Official Motorcraft Auto Parts Site | FordParts.com.
Perform Misfire Monitor Neutral Profile Correction. Select IDS Toolbox Icon, Powertrain, Service Functions, then Misfire Monitor Neutral Profile Correction.



PART NUMBER PART NAME
CR3Z-8620-AA Kit-Drive Belt - Boss
BR3Z-8620-DA Kit-Drive Belt - GT
BR3Z-6019-G Front Cover
XW4Z-6700-A Crankshaft Seal - Front


WARRANTY STATUS:
Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
IMPORTANT: Warranty/ESP coverage limits/policies/prior approvals are not altered by a TSB. Warranty/ESP coverage limits are determined by the identified causal part and verified using the OASIS part coverage tool.

OPERATION DESCRIPTION TIME
120110A 2011-2012 Mustang 5.0L Manual Transmission: Diagnose, Install New A/C Compressor Drive Belt Idler Pulley, Tensioner, And Belt Includes Time To Reprogram The PCM And Perform Misfire Monitor Neutral Profile Correction (Do Not Use With Any Other Labor Operations) 1.0 Hr.
120110B 2011-2012 Mustang 5.0L Manual Transmission: Diagnose, Install New Engine Front Cover, A/C Compressor Drive Belt Idler Pulley, Tensioner, And Belt Includes Time To Reprogram The PCM And Perform Misfire Monitor Neutral Profile Correction (Do Not Use With Any Other Labor Operations) 5.4 Hrs.

DEALER CODING
BASIC PART NO. CONDITION CODE
6006 42
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