🔧 Fusion - Serpentine Belt Replacement

The serpentine belt drives important front-engine accessories such as the alternator, A/C compressor, and water pump-related accessory drive components on your Fusion. Replacing it means relieving belt tension, removing the old belt, routing the new belt correctly, and checking that it sits fully in every pulley groove.

Difficulty Level: Beginner | Estimated Time: 0.5-1.0 hours

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⚠️ Safety & Precautions

• ⚠️ Work only with the engine completely off and cool. The belt and pulleys can move suddenly if the engine is started.
• ⚠️ Keep fingers, clothing, hair, and tools away from the belt path and pulleys.
• ⚠️ Disconnect the negative battery cable before working near the accessory drive area to prevent accidental starting.
• ⚠️ Support your Fusion securely if you raise the right-front corner. Never rely on a floor jack alone.
• ⚠️ The belt tensioner is spring-loaded. A tensioner is the arm that keeps the belt tight; move it slowly and keep a firm grip on the tool.

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🔧 Required Tools

You'll need the following tools for this repair:

• Serpentine belt tool with 3/8-inch square drive (specialty)
• 3/8-inch drive ratchet
• 8mm socket
• 10mm socket
• 7mm socket
• Flat-blade screwdriver
• Trim clip removal tool
• Floor jack (rated 2-ton minimum)
• Jack stands (rated 2-ton minimum)
• Wheel chocks
• Work gloves
• Safety glasses
• Flashlight

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🔩 Required Parts

HowToo sells all the parts you need for this repair:

• Serpentine drive belt - Qty: 1

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📋 Before You Begin

• Park your Fusion on level ground, shift to Park, and apply the parking brake.
• Place wheel chocks behind the rear wheels.
• Open the hood and let the engine cool completely.
• Use a 10mm socket to disconnect the negative battery cable, then position the cable so it cannot spring back to the battery post.
• Take a clear photo of the old belt routing before removal. This is your backup map.
• Tip: Draw the pulley path before removing the belt.

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🔨 Step-by-Step Instructions

Follow these steps in order:

Step 1: Raise and Secure the Right-Front Side

• Use the floor jack rated 2-ton minimum at the proper front jacking point to lift the right-front side of your Fusion.
• Place a jack stand rated 2-ton minimum under the approved support point.
• Lower the vehicle gently onto the jack stand and lightly shake the vehicle to confirm it is stable.
• Keep the wheel chocks behind the rear wheels.

Step 2: Remove the Lower Splash Shield Access

• Put on safety glasses and work gloves.
• Use a 7mm socket to remove the lower splash shield screws near the right-front underside area.
• Use a trim clip removal tool to remove any plastic push clips. A trim clip tool is a small fork-shaped tool that lifts plastic clips without breaking them.
• Use a flat-blade screwdriver only if needed to gently help release stubborn clips.
• Move the shield aside enough to access the crankshaft pulley and belt path.
• Tip: Keep screws and clips in a cup.

Step 3: Locate the Belt Tensioner

• Use a flashlight to follow the serpentine belt around the pulleys.
• Find the spring-loaded belt tensioner. It has a smooth pulley and a square tool opening or hex area for moving the arm.
• Compare the pulley layout to your belt-routing photo before removing anything.

Step 4: Release Belt Tension

• Install the serpentine belt tool with 3/8-inch square drive into the tensioner tool opening.
• If the specialty tool does not fit due to space, use a 3/8-inch drive ratchet in the tensioner opening.
• Slowly rotate the tensioner away from the belt to remove tension.
• Hold the tensioner steady. Do not let it snap back.
• Slide the belt off the easiest smooth pulley first, usually the idler or tensioner pulley.
• Slowly release the tensioner back to its resting position.

Step 5: Remove the Old Belt

• Use your hands to pull the old belt out through the access area.
• Work it around the crankshaft pulley and accessories carefully.
• Use the flashlight to check that no pieces of belt remain trapped in the pulley grooves.
• Inspect the old belt for cracks, missing ribs, glazing, frayed edges, or oil contamination.

Step 6: Inspect the Pulleys Before Installing the New Belt

• Spin the accessible smooth pulleys by hand while wearing work gloves.
• They should spin smoothly without grinding, wobbling, or rough noise.
• Use the flashlight to check pulley grooves for dirt, rubber pieces, or damage.
• If a pulley wobbles or grinds, replace that pulley before installing the new belt.
• Tip: A noisy pulley can ruin a new belt.

Step 7: Route the New Serpentine Belt

• Route the serpentine drive belt around the crankshaft pulley first.
• Follow your belt-routing photo and the under-hood routing decal if present.
• Use your hands to seat the ribbed side of the belt into grooved pulleys.
• Keep the smooth side of the belt against smooth pulleys.
• Leave the easiest smooth pulley for last so the belt can slip on after the tensioner is moved.
• Use the flashlight to verify the belt is not twisted.

Step 8: Reapply Tension and Seat the Belt

• Use the serpentine belt tool with 3/8-inch square drive or 3/8-inch drive ratchet to rotate the tensioner again.
• Slip the belt over the final pulley.
• Slowly release the tensioner until it tightens the belt.
• Do not pry the belt on with a screwdriver. That can damage the belt ribs.
• Use the flashlight to inspect every pulley and confirm the belt ribs sit fully inside the grooves.

Step 9: Reinstall the Splash Shield

• Reposition the lower splash shield by hand.
• Install the plastic clips using your fingers, then seat them with the trim clip removal tool handle if needed.
• Use a 7mm socket to reinstall the splash shield screws until snug.
• If any 8mm fasteners were removed from your splash shield, reinstall them with the 8mm socket until snug.

Step 10: Lower the Vehicle and Reconnect the Battery

• Use the floor jack rated 2-ton minimum to lift slightly off the jack stand.
• Remove the jack stand rated 2-ton minimum.
• Lower your Fusion slowly to the ground.
• Use a 10mm socket to reconnect the negative battery cable.
• Tighten the battery terminal securely, but do not overtighten.

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✅ After Repair

• Start the engine and let it idle while standing clear of the belt area.
• Watch the belt for 30-60 seconds. It should run smoothly without wobbling, walking off a pulley, or squealing.
• Turn the A/C on and confirm the belt still tracks correctly.
• Shut the engine off and recheck belt seating with a flashlight.
• If you hear squealing, shut the engine off immediately and recheck routing and pulley alignment.
• After a short drive, recheck the belt visually once the engine is off and cool.

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💰 DIY vs Shop Cost

Shop Cost: $130-$260 (parts + labor)

DIY Cost: $25-$70 (parts only)

You Save: $105-$190 by doing it yourself!

Shop labor rates vary but typically run $100-$150/hour. This repair takes a shop approximately 0.5-1.0 hours.

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🎯 Ready to get started?

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