There does look like theres a place to add a tensioner, but when we went to the Ford dealer they said that it's not meant for a 2004.
Here are the directions for how to remove and install the new water pump belt, just in case anyone else runs into this situation with a 2004-6 Duratec.
First you'll need to copy your VIN number, as the Ford dealer will need it to order the correct replacement belt. Depending on the date of manufacture, you may need a different belt number. It should be either JK3-262 or JK3-274. The Motorcraft web site says that all of these cars use the JK3274, but that is incorrect. Ours did need the JK3-262. You'll also need to save the old belt after you remove it, so that the Ford parts guy can double check it before you buy the replacement belt.
Unless you want to disassemble the entire engine to replace this belt, there is only one of two ways to remove the old belt. You can either cut the old belt off with a pair of tinsnips or a knife, or you can try to pry the old belt off, but if you try to pry the old belt off you may do some damage to the large (
upper) pulley, so be careful! We simply used a pair of tin snips and the belt was off in 5 seconds
Once the old belt is off you'll need to bring it to the Ford dealer so they can match it up with either JK3-262 or JK3-274. Don't forget to bring your VIN number.
There currently is NO aftermarket replacement belt. A lot of stores list the Gatorback, but (
sadly) it is 1 3/4 inches too big. We contacted Goodyear and they do NOT make a 25.5 inch Gatotback belt. It jumps from 25 inches to 26 inches, but nothing inbetween. This is why you'll need to buy the Motorcraft replacement belt. If Goodyear ever decides to carry the correct size belt for this it will be part number 4030255.
Getting the new belt on is a little trickier. Once the old belt has been removed you'll need to wrap the new belt around the
bottom pulley, and then
start to wrap it around the upper pulley on the side of the pulley that is closest to the windshield. Obviously it won't wrap completely around but as you'll see that's not a big problem. The problem is that once you let go of the new belt it might try to slip off. We used a small piece of tape to hold it in place. Then simply
tap the ignition switch (
do NOT start the car, just tap the ignition for a second). All you want to do is to get the pulleys to turn a half of a turn. Then the new belt will automatically slip into place by itself. Do
NOT be tempted to try to hold the belt in place while someone else taps the ignition. If you try to hold it in place you WILL be injured, so please use some common sense
If the belt slips off just reposition it again, and tap the ignition again for a second. Once the new belt is on simply replace the Duratec belt cover (
two screws). It takes around 5 seconds to remove the old belt, and around a minute or two to install the new one using the method above. The hardest part (
or should I say most frustrating part) is to get the new belt to hold in place on the upper pulley just before you tap the ignition. If anyone needs a diagram for how the belt should look just before you tap the ignition just let me know and I'll draw and post one for you
