Guide: Changing Auxiliary Belt tensioner
 

Here is a guide to removing the auxiliary/alternator/serpentine belt tensioner. This guide is applicable to 1.6/1.8/2.0 non-turbo petrol engines from 96-00 (PH1).

Mine seized on 120k miles,I think this is around the life expectancy of them. Of course they shouldn't reach this stage as they are meant to be replaced according to the correct service intervals. But for those of us that don't follow service intervals here is a guide how to remove.

TIME REQUIRED: 15 Mins
TOOLS REQUIRED: 14MM Spanner

Here is the offending item:
http://i102.photobucket.com/albums/m...Si-Muove/1.jpg


Check to see it is actually the tensioner that is seized before you remove it:
http://i102.photobucket.com/albums/m...Si-Muove/2.jpg


There is a 14mm bolt deep undneath and behind the alternator. You need a good 14MM spanner to remove as there is no space for a socket/wrench. Give an almighty push down to crack off then you can undo it by hand:
http://i102.photobucket.com/albums/m...Si-Muove/3.jpg


Put your otherhand down and support the tensioner, give it a wriggle to aid removing of bolt with fingers:
http://i102.photobucket.com/albums/m...Si-Muove/4.jpg


Once bolt is undone removed tensioner downwards, there is 1mm of space but it does fit!:
http://i102.photobucket.com/albums/m...Si-Muove/5.jpg


Remove downwards and bring forwards under alternator:
http://i102.photobucket.com/albums/m...Si-Muove/6.jpg


Manky:
http://i102.photobucket.com/albums/m...Si-Muove/7.jpg


One old auxiliary belt and seized tensioner:
http://i102.photobucket.com/albums/m...Si-Muove/8.jpg

Put kettle on :)


Edit: Original thread