Idler pulley is making very slight contact with the tensioner pulley arm. It’s making a very slight squeaking sound as it rubs. I just installed this tensioner; original Motorcraft unit. The idler pulley was transferred over from my 2.5 along with the rest of the timing cover.
I mean I guess it will clearance itself eventually, but that seems wrong.
They sell a serpentine pully tool that's basically a long, flat wrench that'll get in there. I have one that works, but you gotta loosen the power steering line to get some movement. Or get one that's offset.
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