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Tensioner Pulley Removal
#1
Hi
We have a 1.9 Diesel on an 02 plate. Having had the Serp belt snap Twice it appears that the Tensioner Pulley is at fault. We have now unscrewed it with a cut down 8 ml Allan Key to replace it with a new one but it seems too tight to come out of the engine. Is there something else I need to take out in order to free the tensioner pulley? Also Is there an easier way to do this?
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#2
(12-12-2011, 12:00 PM)Marjochan Wrote:  Hi
We have a 1.9 Diesel on an 02 plate. Having had the Serp belt snap Twice it appears that the Tensioner Pulley is at fault. We have now unscrewed it with a cut down 8 ml Allan Key to replace it with a new one but it seems too tight to come out of the engine. Is there something else I need to take out in order to free the tensioner pulley? Also Is there an easier way to do this?

Hi just done it on mine, tensioner gave up at 99,000 miles, thinking about it I placed a jack under the engine and backed off the 3 engine mount bolts and the big nut on the engine mount, then jacked engine up or down can't remember which till the mount came out. Must have been reasonably easy as can't remember fighting with it, but it wouldn't come out with out jacking engine. Any help?
[+] 2 users say Thank You to squaddie for this post
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#3
Thanks for that Squaddie. Not really what I wanted to hear though!! Can I ask how long this little Job took you?
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#4
By the time the cars on a stand on the o/f side, wheel off, pratting around hour and a bit I suppose, I do remember my belt was dam tight to fit.
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#5
Ok Thanks Squaddie, much appreciated. We also found that the belt was tight to put back on before we realised that the Tensioner was on the way out. Thanks again.
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#6
Just an update. We did have to drop the engine and the job took about 1 1/2 hours and so far the belt has stayed on with no problems!
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#7
i have just done this today on my 2001 2.0 hdi dw8,

i supported the engine using a plank of wood on the sump and a trolley jack, removed the engine mounting (offside mount), i then put steering on full lock right to give access to plastic covering, remove this to gain access to bottom engine pulley and drop the engine using trolley jack, this then gives you access to remove the bolt holding the tensioner on, replace and refit belt, job done in about 1 hour total, cost of parts (belt and tensioner £51).

simon
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