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I am looking for a simple, preferably manual way of being able to tension small toothed drive belts.

We work on fairly small machines which have a few toothed drive belts. I am looking for a very simple way of tensioning these belts preferably without the use of expensive complicated tools. any ideas? Thank you

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Move one pulley away from the other ( moving the drive motor on its mounts )
not really enough information to be more specific

Posted on Jan 03, 2017


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How do you remove tension from power steering belt

Hi Jeremy, Over here in Australia the Montero is badged as a 'Pajero'. I have a 2003 model but I presume the serpentine belt or accesory drive belt would be similar in both models and drives the power steering.

The belt most likely has an automatic tensioner as mine does. The tensioner looks like two small pulleys about 21/2" in diameter. The top one should have a square hole cutout for inserting a square peg handle to rotate the tensioner clockwise to release tension on belt.

If you can't find it - start your engine and with the hood popped rev the engine a few times. You should see the belt flexing and the tensioner will be the unit which flexes up and down to maintain the tension - all other pulleys should be rotating in a fixed position only.

Just to the right of the afore mentioned square hole is a small 1/4" hole which lines up with another hole when you rotate the tensioner clockwise to release the tension. Line up the holes and put an allen key or small screw driver through the holes to keep the tension released.

Naturally, I didn't have a square pegged hadle to lever the tensioner so I used a small gemmy or crow bar (whatever you call them in the USA) and levered between the crank pulley and the tensioner to rotate the tensioner clockwise. Be gentle and remember to remove the allen key/screw driver when you have finished.

Good Luck.

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How hard or easy is it replace the water pump in a 2001 VW beetle ?

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I need to change the timing belt and a few more...

moz-screenshot.pngmoz-screenshot-1.pngmoz-screenshot-2.png Removal & Installation
  1. Disconnect the negative battery cable.
  2. Rotate the auto tensioner clockwise to release tension, then remove the drive belt.
To install:
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  3. After putting belt on auto tensioner pulley, release the auto tensioner pulley slowly.
    93581gy2.gif Accessory serpentine belt routing—3.5L engine
    42050_sedo_g0020.gif Accessory serpentine belt (A) routing—3.8L engine

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– Mark direction of rotation of toothed belt with coloured felt tip marker pen. – Turn crankshaft to TDC. Mark on toothed belt guard -A- must align with mark on V-belt pulley -B-. – Check position of camshaft pulleys. The larger hole in the locking plates -arrows- must face inwards. hinweis.gif Note If the larger hole in the locking plate is positioned to the outside on the toothed belt pulley, the crankshaft must be turned one revolution in direction of engine rotation. – Remove sealing plug -arrow- from left side of cylinder block. The TDC drilling in the crankshaft must be visible (or able to be felt) in the sealing plug hole. – Screw clamping bolt -3242- carefully into hole onto limit stop so that the crankshaft is secured against turning. – Remove central toothed belt guard. – Unscrew vibration damper. hinweis.gif Note The vibration damper is secured to the crankshaft with 8 bolts. – First remove bolt -1- from oil filter housing, then remove bolts -2- for toothed belt tensioning element cover. – Remove cover. hinweis.gif Note t The toothed belt tensioning element is oil dampened. It can therefore only be pushed back slowly. t Use locking pin -T40011- to lock tensioning element. – If necessary, align holes in housing and on tensioning element piston, before tensioning using long nose pliers or a thin wire. – Turn tensioning lever of toothed belt tensioning roller -1- in -direction of arrow- using hexagon key. – Secure tensioning element with locking pin -T40011- when the tensioning lever of the toothed belt tensioning element -2- has been pushed back so that the holes in the housing and the pistons align. – Seat the camshaft clamp -T40005- into the camshaft locking plates and loosen the securing bolts approx. 5 turns. – Remove camshaft clamp -T40005- again. – Now pull the camshaft pulleys off the tapers using two-arm puller -T40001- and legs -T40001/2-. – Loosen tensioning roller -arrow- and remove toothed belt.

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Serpentine belt replacement

2.0L Engines
See Figures 11, 12 and 13
The accessory drive belt for 2.0L engines has no provision for manual belt adjustment, since these engines use an automatic belt tensioner. Drive belt slack is taken up by the automatic tensioner.
Movement of the automatic tensioner assembly during engine operation is not a sign of a malfunctioning tensioner. This movement is the tensioner self-adjusting and is required to maintain constant belt tension.
The belt tensioner has a belt length indicator. If the indicator marks are not between the MIN and MAX marks, the belt must be replaced.
0900c1528008d836.jpgFig. 11: Drive belt routing-2.0L SOHC engine with A/C 0900c1528008d837.jpgFig. 12: Drive belt routing-2.0L SOHC engine without A/C 0900c1528008d838.jpgFig. 13: Drive belt routing-2.0L DOHC engine

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