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Old 08-12-2008, 02:31 AM   #1
poolmike
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Default '05 Serpentine belt tensioner replacement

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
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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.





A pic from the bottom side.




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.




Here is the part number on my new tensioner




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!!
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Old 08-12-2008, 05:43 AM   #2
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Default Re: '05 Serpentine belt tensioner replacement

Thanks Mike for the write-up.

How many miles are on the tensioner?
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Old 08-12-2008, 01:59 PM   #3
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Default Re: '05 Serpentine belt tensioner replacement

85,000ish
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Old 08-12-2008, 02:24 PM   #4
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Default Re: '05 Serpentine belt tensioner replacement

Hi Mike,


Did you put a factory Serpentine back, or install a Gatorback?
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Old 08-12-2008, 07:37 PM   #5
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Default Re: '05 Serpentine belt tensioner replacement

Factory, right from the dealer. Tensioner and belt set me back $230ish. I don't have the receipt in front of me for the exact number.
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Old 04-27-2009, 11:16 PM   #6
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Default Re: '05 Serpentine belt tensioner replacement

would you recommend an anti-seize or locktite?
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Old 04-28-2009, 01:39 AM   #7
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Default Re: '05 Serpentine belt tensioner replacement

Edit:
In case you don't read further I want to highlight this caution from Doktor A below.

DO NOT chase the timing cover's belt tensioner mounting threads with a tap. Also, DO NOT chase the bolt threads with a die.
The bolt has a thread forming design for strength. Tapping the hole will diminish the effectiveness.
***********
poolmike,
Thanks for the writeup. Nice job. I'm sure tensioner replacement isn't a case of if, but when.

If you need help with words for your book I think I can help. I should be embarrassed to tell this, but what the heck. Back when my kids were not too young I was working on my truck with the kids playing in the yard. They came in and my wife asked how I was doing. My daughter piped up with, "I think it's going pretty good. The whores and bastards haven't shown up yet."

Here's my Grease Pencil 2004 belt routing. HB = Harmonic Balancer F = Fan

WasherBottle.jpg

A 17mm or 18mm (poor memory) 12 pt box wrench can be used to release tension, or a rachet square drive.

0000tensionerB.jpg
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Last edited by Aqua Puttana; 01-04-2013 at 09:05 PM.
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Old 04-28-2009, 03:55 AM   #8
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Default Re: '05 Serpentine belt tensioner replacement

Heheheheh ......

.... out of the mouth of babes .....

I can only imagine the look on her face.
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Old 04-28-2009, 10:01 PM   #9
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Default Re: '05 Serpentine belt tensioner replacement

Quote:
Originally Posted by poolmike View Post
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.
DO NOT chase the timing cover's belt tensioner mounting threads with a tap. Also, DO NOT chase the bolt threads with a die.

I will post a tech alert on this subject- but for now let me stress that it is important to use the original (new or used), unmolested, 10.9 grade, THREAD FORMING bolts for this highly stressed component. These will NOT install with finger pressure-that's normal. Doktor A
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Old 08-01-2009, 05:42 PM   #10
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Default Re: '05 Serpentine belt tensioner replacement

Pool Mike's pictures seem to have disappeared.

These are the two idlers - both grooved for the 612:


P8010137.JPG

This is the tensioner:

P8010136.JPG

All the pulleys are made of plastic. I found that the flanges tend to randomly chip away for unknown reasons, but the pulleys seem to be OK notwithstanding the chipped flanges.

Last edited by hkpierce; 08-01-2009 at 05:47 PM.
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