poolmike
08-12-2008, 03:31 AM
This repair is not too terrible. It can be done by anyone who is handy with the tools.
Tool list:
E10 inverted Torx socket
E12 inverted Torx socket
12 point 17mm socket
a small sacrificial allen key/nail/ anything that will hold the tensioner under load(see pics)
3/8" drive ratchet
1/4" drive ratchet
Various length extensions for above mentioned ratchets
7mm x 1.00 tap
7mm x 1.00 die
10 fingertip eyeballs
PoolMike's Guide to Proper Swears and Vulgar Language During Sprinter Repair(in stores soon)
Here is the first pic from the top of the engine. It is difficult to snap a good shot to demonstrate what a failed tensioner looks like in place.
http://img520.imageshack.us/img520/6121/dsc0010bn4 .jpg
A pic from the bottom side.
http://img300.imageshack.us/img300/557/dsc0011ub3. jpg
You can almost see how the tensioner pulley is almost 1/2" forward of the power steering pulley. The ratchet and 17mm 12 point socket are on the tensioner release head. Pull the ratchet to release belt tension and install small sacrificial allen key/nail/ whatever into the little holes to hold the tensioner sprung...this is done so you can access the bolts.
Take your E10 inverted Torx socket and try to remove the two bolts that hold your precious tensioner in place. Fight with them for 1.5 hours using only your fingertip eyeballs for vision. Right about now you will need to consult PoolMike's Swear Guide. Take a deep breath and realize...this would be so much easier if that #$%%$%^^$##$ air conditioning compressor wasn't in the #$%%^ way. Obtain your E12 inverted Torx socket and remove the three bolts that hold your compressor in place(EASY and WORTH IT!!!)
Remove the two bolts from your tensioner, then remove your tensioner.
Here is the damage. The busticated tensioner is on the left.
http://img165.imageshack.us/img165/3513/dsc0012eg4 .jpg
Here is the part number on my new tensioner
http://img162.imageshack.us/img162/6536/dsc0014np2 .jpg
Reassembly.
Take your 7mm x 1.00 tap and run it through the two bolt holes for the tensioner. Take your 7mm x 1.00 die and clean the threads of your two bolts. I tried installing the bolts without tapping the holes and for whatever reason they fought me. You are only dealing with aluminum and small bolts in a very awkward location, so BE CAREFUL!!! Breaking a bolt off here WILL BE A PROBLEM!!
After cleaning the threads, the bolts went in with no problems. Slide your air conditioning compressor back into place and bolt it up. Route your new serpentine belt. Take your 17mm 12 point socket and ratchet and move the tensioner to remove the factory installed hold pin. Release your tensioner and you should be done. Check to make sure your belt is seated properly and fire it up!!
Tool list:
E10 inverted Torx socket
E12 inverted Torx socket
12 point 17mm socket
a small sacrificial allen key/nail/ anything that will hold the tensioner under load(see pics)
3/8" drive ratchet
1/4" drive ratchet
Various length extensions for above mentioned ratchets
7mm x 1.00 tap
7mm x 1.00 die
10 fingertip eyeballs
PoolMike's Guide to Proper Swears and Vulgar Language During Sprinter Repair(in stores soon)
Here is the first pic from the top of the engine. It is difficult to snap a good shot to demonstrate what a failed tensioner looks like in place.
http://img520.imageshack.us/img520/6121/dsc0010bn4 .jpg
A pic from the bottom side.
http://img300.imageshack.us/img300/557/dsc0011ub3. jpg
You can almost see how the tensioner pulley is almost 1/2" forward of the power steering pulley. The ratchet and 17mm 12 point socket are on the tensioner release head. Pull the ratchet to release belt tension and install small sacrificial allen key/nail/ whatever into the little holes to hold the tensioner sprung...this is done so you can access the bolts.
Take your E10 inverted Torx socket and try to remove the two bolts that hold your precious tensioner in place. Fight with them for 1.5 hours using only your fingertip eyeballs for vision. Right about now you will need to consult PoolMike's Swear Guide. Take a deep breath and realize...this would be so much easier if that #$%%$%^^$##$ air conditioning compressor wasn't in the #$%%^ way. Obtain your E12 inverted Torx socket and remove the three bolts that hold your compressor in place(EASY and WORTH IT!!!)
Remove the two bolts from your tensioner, then remove your tensioner.
Here is the damage. The busticated tensioner is on the left.
http://img165.imageshack.us/img165/3513/dsc0012eg4 .jpg
Here is the part number on my new tensioner
http://img162.imageshack.us/img162/6536/dsc0014np2 .jpg
Reassembly.
Take your 7mm x 1.00 tap and run it through the two bolt holes for the tensioner. Take your 7mm x 1.00 die and clean the threads of your two bolts. I tried installing the bolts without tapping the holes and for whatever reason they fought me. You are only dealing with aluminum and small bolts in a very awkward location, so BE CAREFUL!!! Breaking a bolt off here WILL BE A PROBLEM!!
After cleaning the threads, the bolts went in with no problems. Slide your air conditioning compressor back into place and bolt it up. Route your new serpentine belt. Take your 17mm 12 point socket and ratchet and move the tensioner to remove the factory installed hold pin. Release your tensioner and you should be done. Check to make sure your belt is seated properly and fire it up!!