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How to replace tensioner pulley - 2000 Dodge Neon

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I have to replace my pulley as well; all of the information I've found on the net say's you need to remove the whole engine mount plate assembly from the left side of the engine and that you can't replace just the pulley.

Well they're all full of ****; rockauto.com sells a replacement pulley, you'll find it in there online catalog. In order to replace the pulley, you will need to remove the power steering pump and support bracket, with the power steering pump removed, the tensioner arm will move to it's rest position with the pulley mounting bolt hidden behind the support bracket, you can push down on the tensioner arm against the spring pressure to expose the allen headed mounting bolt and get an allen wrench on it.

Rockauto offers three different pulleys from about 15 to 25 dollars.... not a terribly easy job, but very doable and about $300.00 cheaper (part only) than replacing the tensioner arm asm.

Good Luck!

Posted on Jan 03, 2010

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I'm having this same problem. However, when you take the power steering pump off, you still can't get to the bolt that is on the pulley itself. At rest, and when you move the pulley with the 17mm wrench. It makes no difference. I've been trying now for a couple of hours with no luck. You will have to remove the whole damn engine mount bracket,or atleast loosen all the bolt to get some play and raise or lower the engine.
If you have anymore tips it would be greatly appreciated.

Posted on Feb 01, 2010

  • modesto jrodriguez Oct 12, 2011

    im having the same problem with my neon . because this problem my power ssteering stop working.

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Posted on Jan 02, 2017

SOURCE: How to replace tensioner pulley on 2000 Dodge Neon

Make sure you locate the Serpentine Belt Routing Sticker before you proceed. If not make an excellent drawing and take a GOOD Picture. Do NOT try to just remember how it goes back on Should be a 15mm wrench to loosen tensioner to remove belt. Locate mounting bolts to tensioner and remove, replace with NEW tensioner tighten bolts then use wrench arc torque about 15 degrees should snug it down, reroute belt then using 15mm pull tensioner to either side of belt to install belt in correct route. Remove all tools and body parts from engine bay. Do not start engine if anyone is in the vicinity of engine bay. Belt may fly off if you did not do it right and cause all kinds of shrapnell, if it doesn't fly off, visually inspect belt before starting and after, I would suggest being very careful before during and after starting to insure safety.

Posted on Jan 05, 2010

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1 Answer

Need to know timing marks


REMOVAL
1. Disconnect negative battery cable.
2. Loosen power steering lock bolts and nuts accordingly and remove tension from power steering (P/S) and/or air conditioning (A/C) compressor drive belt.
3. Remove P/S and/or A/C drive belt.
4. Loosen generator mounting bolts and adjusting bolt.
5. Remove generator bolts.
6. Remove water pump pulley.
7. Remove crankshaft pulley.
8. Remove upper and lower timing belt covers.
9. Turn crankshaft so that timing mark on timing belt pulley is aligned with timing mark on engine.
10. Check that "I" mark on intake camshaft pulley is aligned with mark on seal plate and "E" mark on exhaust camshaft pulley is aligned with mark on seal plate.
Do not move camshaft or crankshaft once timing marks have been correctly positioned.
11. Loosen tensioner pulley lock bolt.
12. Protect timing belt with a rag.
13. Remove tensioner pulley.
14. Remove timing belt. Mark the direction of timing belt rotation (on the timing belt) for proper reinstallation.

INSTALLATION
1. Install tensioner pulley. Replace tensioner spring whenever timing belt is replaced.
2. Pull tensioner pulley to its furthest point and tighten lock bolt.
3. Check that timing mark on timing belt pulley is aligned with timing mark on engine.
4. Check that "I" mark on intake camshaft pulley is aligned with mark on seal plate and "E" mark on exhaust camshaft pulley is aligned with mark on seal plate.
If existing timing belt is being reused, install belt in proper rotation direction marked prior to removal.
5. Install timing belt onto timing belt pulley first, then idler pulley, exhaust camshaft pulley, intake camshaft pulley, and tensioner pulley in that order.
6. Check that there is no looseness in belt between idler pulley and exhaust camshaft pulley or between intake and exhaust camshaft pulleys.
7. Loosen tensioner pulley lock bolt and allow tensioner spring to apply tension to timing belt.
Do not add additional tension.
8. Tighten tensioner pulley lock bolt to specified torque.
Tightening torque:28~38 lb-ft (38~51 N·m, 3.9~5.2 kg-m)
9. Rotate crankshaft two full revolutions (clockwise only) and align timing mark on timing belt pulley with timing mark on engine block.
10. Check that "I" mark on intake camshaft pulley and "E" mark on exhaust camshaft pulley are aligned with marks on seal plate.
11. If they are not aligned, remove timing belt and start process from tensioner installation.
12. Measure timing belt deflection by applying moderate pressure midway between camshaft pulleys. If deflection is not correct, repeat from tensioner installation.
Deflection pressure:22 Ib. (98 N, 10 kg)Deflection:0.39~0.50 in. (11~13 mm)
13. Install lower and upper timing belt covers in that order.
Tightening torque:5.8~8.0 Ib-ft (7.9~10.7 N·m, 0.8~1.1 kg-m)
14. Install timing belt guide plate and crankshaft pulley.
Tightening torque:9.0~12.6 lb-ft (12.3~17.2 N·m, 1.3~1.8 kg-m)
15. Install water pump pulley.
Tightening torque:9.0~12.6 lb-ft (12.3~17.2 N·m, 1.3~1.8 kg-m)
16. Install generator belt and adjust the tension.
17. Install P/S and/or A/C drive belt and adjust the tension.
18. Connect negative battery cable.

INSPECTION
Never forcefully twist, turn inside out or bend timing belt. Do not allow oil or grease to come in contact with timing belt.
1. Replace timing belt if it is contaminated with oil or grease.
2. Check timing belt for uneven wear, fraying, peeling, cracking and hardening. Replace timing belt as necessary.
3. Bend timing belt into a "U" shape as shown in figure. Distance "A" must be at least 1.0 in (25 mm).
4. Inspect both idler pulley and tensioner pulley for uneven wear and smooth bearing operation.
5. Inspect camshaft pulleys and timing belt pulley for broken teeth or damage.
Replace any component that shows damage, excessive wear, or that appears prone to a possible failure.

Feb 26, 2011 | 2002 Kia Spectra

2 Answers

MY BELTS SNAPPED AND BENT PULLEY IS IT TENSIONER OR PULLEY NEEDS REPLACING


Kind of a vague question here. I am assuming you are speaking of the pulley that is attached to the tensioner is bent. Either way I would suggest in replacing the tensioner. They have just he pulley you can take off your tensioner and rebuild it, but it is easier for the cost, and as a point of preventive maintnace to replace the entire tensioner, for the entire tensioner either 4 cyl or 6 is around 96$

Jan 10, 2011 | 1999 Volkswagen Passat

1 Answer

I have replaced the tension pulley and the other free spinning pulley "same size" pulley s and also replaced belt and the belt keeps falling off tension pulley and it is a very very strong...


The tensioner is most likely bad and not just the pulley. If the spring is weak look at the original marks on the original pulley. The belt should ride towards the engine side of the pulley and not the rounded outer edge.

Jan 01, 2011 | 1993 Chrysler Town & Country

1 Answer

Replace serpentine belt



Removal & Installation

  1. Rotate the drive belt tensioner clockwise and remove the drive belt.
    WARNING Never suddenly let go of the tensioned idler pulley. The force of the spring pressure suddenly released may damage the idler pulley mechanism. Always release the spring pressure gradually.


    0996b43f80204f01.jpg enlarge_icon.gifenlarge_tooltip.gif

    Fig. Rotate the belt tensioner to relieve tension on the belt-4.6L engine shown, others similar


To install:
  1. Route the belt over the pulleys making sure all the grooves in the pulleys and the belt line up correctly. Refer to the accessory belt routing section of this manual.
  2. Rotate belt tensioner clockwise and slip drive belt over idler pulley on tensioner.

  1. Rotate the drive belt tensioner clockwise and remove the drive belt.
    WARNING Never suddenly let go of the tensioned idler pulley. The force of the spring pressure suddenly released may damage the idler pulley mechanism. Always release the spring pressure gradually.


    0996b43f80204f01.jpg enlarge_icon.gifenlarge_tooltip.gif

    Fig. Rotate the belt tensioner to relieve tension on the belt-4.6L engine shown, others similar


To install:
  1. Route the belt over the pulleys making sure all the grooves in the pulleys and the belt line up correctly. Refer to the accessory belt routing diagrams above.
  2. Rotate belt tensioner clockwise and slip drive belt over idler pulley on tensioner.
If for any reason, the tensioner is crooked, replace it!!! Also, install the belt with the writing facing you like you are trying to read a book. This WILL (a trick I learned at Mercedes) prevent even a new belt from squeeling!!

Dec 16, 2010 | 2003 Ford Explorer

1 Answer

Cant get belt around alternator pulley tried to let tension off by tension pulley could not get pulley to move


Try the tension pulley in both directions. If it won't move you'll have to replace the tension(idler) pulley.

Aug 22, 2010 | Ford Windstar Cars & Trucks

2 Answers

How to adjust de belt to grand cherokee 8 cilinders 4.7


  1. Step 1 Find the belt tensioner pulley. The tensioner pulley is generally between the crankshaft and a component toward the top of the hood area.
  2. Step 2 Check the belt routing so you know how to replace the belt. You may be able to find a belt routing diagram on a decal on the fan shroud or in support documentation. Otherwise, make you own sketch for reference.
  3. Step 3 Rotate the belt tensioner pulley, using the wrench, to and relieve tension on the belt.
  4. Step 4 Slip off the old belt and slowly release the tensioner pulley.
  5. Step 5 Use your belt routing diagram to put the new belt onto all of the pulleys. Pay close attention to the water pump pulley, as incorrect routing can cause the water pump to run backwards and overheat.
  6. Step 6 Make sure the belt is correctly routed and seated on all pulleys. Rotate the tensioner again to allow for the belt to slip onto all pulleys and then release the tensioner again to regain correct tension on the belt.

Jun 01, 2010 | 1999 Jeep Grand Cherokee

1 Answer

Tension pulley for serpentine belt making noise


The Tensioner Pulley Bearings are failing and either the Tensioner Pulley or the Tensioner Assembly (Pulley, Arm and Base) must be removed and replaced.

Click on the following free direct Link. It has several of the Serpentine Belt Diagrams and Tensioners that are possible with your 4.3L V6 engine.
http://www.2carpros.com/car_repair_information/year/1998/make/gmc/model/jimmy/1998_gmc_jimmy_drive_belt_routing_diagram.htm
1. Remove the Serpentine Belt.
"HOW TO":
Standard Rules to Removal the Serpentine Belt with a Tensioner:
A. Find the Tensioner(s). (See Diagrams on Link)
B. Using a Serpentine Belt Tensioner Tool, Or Wrench OR Ratchet, Rotate/Move the Tensioner USING THE AVAILABLE NUT (on the Pulley or Arm Base) OR the OPENING (3/8ths or 1/2 inch square opening) rotating the Tensioner Pulley/Arm - moving it away from contact with the belt and towards the area where the belt is not in contact with the Tensioner Pulley. The Tensioner is spring loaded, and is hard to rotate/move.
C. Remove the loosened belt off one of the other more easily accessed Pulleys.
D. DO NOT quickly release the Tensioner, but gently allow the Tensioner to rest in its closed position.

Removing the Tensioner Pulley: See the Diagrams in the Link.
After the Belt has been removed, with the Tensioner resting:
DEPENDING ON WHAT TYPE TENSIONER:
IF the Tensioner Pulley itself HAS a Bolt Head showing, SOME of these bolts can be removed and the Tensioner Pulley replaced.
IF the Tensioner Pulley itself DOES NOT HAVE a Bolt Head showing, then go to the Tensioner Base located at the end of the Tensioner Arm. This should have a Bolt Head Showing. Remove this Bolt and the whole Tensioner Assembly will com off.

When replacing the Tensioner Assembly - MAKE SURE you place the protruding "nipple" on the underside base of the Tesnioner into the appropriate cavity on the engine face.

Standard Rules for Installing the Serpentine Belt with Tensioners:
a. Pick a Pulley that is most easily accessed. This will usually be on top. This will be the last Pulley that the belt will go on.
b. Using the Diagram: Install the new Serpentine Belt on the remainder of the Pulleys....over, under, left right.
c. Using a Serpentine Belt Tensioner Tool or Wrench or Ratchet Tool: Rotate/Move the Tensioner Pulley/Arm "away" from Belt contact area on the Tensioner. This spring is pretty hard and with a new belt, it will be even harder to install. Rotate/Move this to as-close to the maximum allowed inorder to have enough slack in the belt to get it up and over the last pulley.
d. Using your other hand - Pull the Belt up and over the Last remaining Pulley.
e. Before releasing the pressure on the Tensioner, visually inspect the remainder Pulleys and the Belts' Positioning on them

Let me know if this helped, or if you have additional information or questions. Feel Free to contact me at FixYa.Com!

Mar 29, 2010 | 1998 GMC Jimmy

1 Answer

Cant find 97 ford taurus serpentine belt diagram


Drive Belt Replacement ani_caut.gif WARNING: IF EQUIPPED, DO NOT ALLOW DRIVE BELT TENSIONER (6B209) TO SNAP BACK AS DAMAGE TO DRIVE BELT TENSIONER OR PERSONAL INJURY COULD RESULT.
NOTE: Minor cracks in the V-grooved portion of the serpentine drive belt (8620) are considered normal and acceptable. If the drive belt has chunks missing from the ribs, the drive belt should be replaced.

NOTE: Conditions requiring drive belt replacement are excessive wear, rib chunk-out, severe glazing, frayed cords or other conditions. Replace any drive belt exhibiting any of these conditions.

NOTE: When installing drive belt on pulley, make sure that all V-grooves make proper contact with pulleys.



q1834c.gif

Drive Belt, Serpentine—Except SHO
Removal
  1. ani_caut.gif WARNING: USE CAUTION WHEN REMOVING OR INSTALLING DRIVE BELT TO MAKE SURE THAT TOOL DOES NOT SLIP FROM DRIVE BELT TENSIONER OR PERSONAL INJURY AND/OR DAMAGE TO DRIVE BELT TENSIONER AND DRIVE BELT MAY OCCUR.
    Using a 15 mm socket or wrench on bolt attaching drive belt tensioner pulley, rotate drive belt tensioner clockwise on 3.0L (2V) and 3.0L (2V) FF, rotate the drive belt tensioner counter clockwise on 3.0L (4V) to remove drive belt from pulleys. Make sure spring keeper engages into slot.


    Drive Belt Tensioner—3.0L (4V)


    q3759a.gif

Installation
  1. Install drive belt over all pulleys (except drive belt tensioner).
  1. Rotate drive belt tensioner as described under the removal procedure and install drive belt over drive belt tensioner pulley. Make sure that all V-grooves make proper contact with pulleys. Make sure spring keeper releases or improper belt tension will occur.


    Pulley, Routing—Accessory Drive Belt 3.0L (2V)/3.0L (2V) FF Engine


    q3244d.gif


    Item Part Number Description 1 10300 Generator 2 6C348 Idler Pulley 3 3A674 Power Steering Pump 4 19703 A/C Compressor 5 6312 Crankshaft Pulley 6 6B209 Drive Belt Tensioner 7 8501 Water Pump 8 8620 Drive Belt

    Pulley, Routing—Accessory Drive Belt 3.0L (4V)


    q3735a.gif


    Item Part Number Description 1 3A674 Power Steering Pump 2 8501 Water Pump 3 19703 A/C Compressor 4 8620 Drive Belt 5 6312 Crankshaft Pulley 6 6B209 Drive Belt Tensioner 7 10300 Generator
3.4L SHO Engine
Removal
  1. Remove the right front wheel and tire assembly. For additional information, refer to Section 04-04.
  1. Remove the inner fender splash shield.
  1. Remove the alternator shield.
  1. ani_caut.gif WARNING: USE CAUTION WHEN REMOVING OR INSTALLING DRIVE BELT TO MAKE SURE WRENCH DOES NOT SLIP FROMDRIVE BELT TENSIONER OR POSSIBLE PERSONAL INJURY AND/OR DAMAGE TO DRIVE BELT TENSIONER AND DRIVE BELT MAY OCCUR.
    Using a 3/8 inch ratchet on the lifting lug, rotate drive belt tensioner counterclockwise (upward) and engage spring keeper. Remove drive belt from drive belt tensioner.
  1. Lower vehicle.
  1. Remove drive belt.
Installation
  1. Install drive belt over all pulleys (except drive belt tensioner ).
  1. Raise vehicle on hoist.
  1. Rotate drive belt tensioner , as described under Removal procedure and install drive belt over drive belt tensioner pulley. Make sure all V-grooves make proper contact with pulleys. Make sure the spring keeper is released or improper belt tension will occur.
  1. Install the alternator shield.
  1. Install the inner fender splash shield.
  1. Install the wheel and tire assembly. For additional information, refer to Section 04-04.


    Pulley Routing—Accessory Drive Belt, 3.4L SHO


    q3736a.gif


    Item Part Number Description 1 3A733 Power Steering Pump Pulley 2 6B217 (RH) Idler Pulley 3 19703 A/C Compressor 4 8620 Drive Belt 5 6312 Crankshaft Pulley 6 6B209 Drive Belt Tensioner 7 10346 Generator 8 6B217 (LH) Idler Pulley 9 6B217 (Center) Idler Pulley
Drive Belt, Water Pump
Removal
  1. NOTE: If removal of the water pump drive pulley is required, refer to Section 03-03.

    Rotate drive belt tensioner clockwise by hand and remove drive belt from drive belt tensioner .
  1. Remove drive belt from water pump drive pulley and water pump pulley.
Installation
  1. Position drive belt onto water pump drive pulley and water pump pulley.
  1. Rotate drive belt tensioner clockwise by hand and install drive belt over top of drive belt tensioner pulley. Make sure all V-grooves make proper contact with pulleys.


    Pulley Routing—Water Pump Drive Belt


    q3737a.gif


    Item Part Number Description 1 6B209 Drive Belt Tensioner 2 6A312 Crankshaft Pulley 3 8501 Water Pump 4 8620 Drive Belt

Jun 01, 2009 | 1997 Ford Taurus

1 Answer

Have a 1993 f250 with A/C, power steering. Is


There is a pulley on the tensioner but it may be best to replace the whole tensioner pulley assembly. There should be a bolt through the tensioner above the pulley. Once you remove that bolt you will be able to replace the tensioner.

Feb 26, 2009 | 1993 Ford F250

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