1992 Saturn A bolt has broken off from my tensioner pully. How do I remove it? there are so many things in the way.

Clearly something else is happening. You didn't say whether it is a manual or automatic tensioner or what specifically has broken.

Mostly these are very reliable.
In the case of a manual tensioner it is important no to over-tension the belt.

Other possible causes are bent or misaligned pulley(s), wrong belt or defective torsional vibration damper (crankshaft pulley).
One final possibility I can think of is an egg-shaped pulley...

loosen of the big nut in the middle of the pulley. use the adjusting bolt behind the pulley to release the tension on the belt. remove the big not and the pulley will slide of the shaft. Take care as to where the spacers go for re-fitment of the pulley

If you can remove the bolt remnant without damaging the parent metal, you should be able to reinstall the tensioner. Get a new bolt directly from Ford so that you are sure you have the correct length, thread pitch, and hardness. If you are not very experienced in removing broken bolts, you may want to seek some help with this.

You have to go to parts store and barrow a pully puller. Autozone will let you barrow for free, This holds the pully andlets you remove the bolt. They will help you out if any further question. Good luck to you.

Look like this http://www.1aauto.com/1A/Drivetrain/Saturn/SSeries/1AEBT00011/286234?utm_source=google_base&utm_medium=comparisonshopping&utm_campaign=gb_api_br&year=1995&utm_content=EBT








Tensioner cannot be tightened. The tensioner is a automatic spring tensioner with now manual adjustments. if the tensioner is loose, it must be replaced. the instructions are as follows:

Remove the front passanger side tire (19mm lug nuts)
3. In the wheel well, remove the splash shielding to gain access to the motor.
4. Place a decent size peice of wood on your jack, and slide it under the oil pan, raise the jack so it firmly presses on the oil pan.
5. Under the hood, remove the motor mount on the left side of the motor, the mount is held on by Three 15mm nuts with studs on the motor itself, and Two 15mm nuts holding the mount to the body. remove the mount completely.
6. slowly lower the jack supporting the engine untill the engine sits all the way down.
7. from inside the wheel well, place a 14mm wrench on the belt tensioner pully bolt. swing the tensioner to remove tension on the belt, remove the belt from the tensioner or main crank pully.
8. You should have access to the lower bolt on the tensioner. the bolt is 10mm in head size. i recommend using a 1/4" ratchet. Remove the bolt.
9. raise the jack as far as you can, making sure the vehicle stays on the jackstands!!! this should allow you to reach down and beable to remove the top bolt on the tensioner. the motor will come up on an angle.
10. once the bolt is out, the tensioner should just fall out of the motor. reinstall the tensioner with the top bolt first, lower the engine, reinstall lower bolt, reinstall belt, reinstall the upper motor mount, and raise the engine to level out with the upper mount.
The job sounds complicated if you are not mechanically inclined, but its accually simple. you will not break anything by moving the motor. the job should take a average person about 30-45 minuites to complete.
Please visit my bio page for access to my saturn help site. there is a picture of your belt tensioner located in the serpentine belt folder.

Disconnect battery earth lead. Do not turn crankshaft or camshaft whn timing beld removed. Remove spark plugs to ease turning engine. Turn engine in normal direction of rotation (unless otherwise stated) Do not turn engine via camshaft or other sprockets. Observe all tightening torques. Remove engine, remve RH engine mounting. Remove auxiliary drive belts, water pump pulley, crankshaft pulley, timing belt upper cover, timing belt lower cover. Turn crankshaft clockwise to TDC on No. 1 cylinder, slacken tensioner bolts 5 & 6. Move tensioner away from belt and lightly tighten bolts. Remove timing belt. Remove water pump and replace with new one. Suggest to replace cambelt as well.
Installation
Ensure timing marks aligned3 & 4. Fit timing belt in anti-clockwise direction, standing at crankshaft sprocket. Ensure belt is taut between sprockets on non-tensioned side. Slacken tensioner bolt 5. slacken tensioner bolt 6. Allow tensioner to operate. Tighten tensioner bolt 6. Tighten tensioner bolt 5. Turn crankshaft on turn clockwise. Ensure crankshaft sprocket timing marks aligned 4.
Slacken tensioner bolt 5. Slacken tensioner bolt 6. Allow tensioner to operate. Tighten tensioner 6. Tighten torque: 20 - 26 Nm. Tighten tensioner bolt 5. tighten torque: 20 - 26 Nm. Apply thumb pressure to belt at middle. Approximately 5kg. Belt should deflect to 1/4 of tensioner bolt head width 7. Belt tention can also be set using burroghs (BT-33-73F) tension gauge 10 at middle. Turn crankshaft 90 ° anti clockwise. Check belt tension is 9.5 16,5kg (engine must be cold). Install components in reverse order of removal. Fit cranckshaft pully. Tighten crankshaft pully bolts 8. G4-J: Tightening torque: 12-15Nm.
G4-N/G4-k: Tightening torque: 10-12Nm
G4EA: Tighten crankshaft pully bolt 9. Tighten torque: 140-150Nm.

Which One?
The one on the left has two 14mm fasteners 1 nut & 1 bolt. The one on the right has the same 1 14mm nut and 1 14mm bolt. Both are simple to replace. Step 1: Relieve the tension on the pully you wish to replace. Step 2: remove the pully (front) by removing the 14mm nut. To remove the rear tensioner pully, remove both nut & bolt.

The tensioner should have a bolt in the middle of it. But also there should be a bolt in the mibble of the pully. If you are replacing the tensioner assy. 1st remove the belt 2nd remove the bolt. the tensioner assy. will have a specific way of going on If you tighten the new one down ad it will not move it is on wrong and try again. If just replacing the pully just remove the belt take the bolt out of the old pully and install new one. Do to space constraints this can be a knuckle buster be careful. If any more questions please ask. Have a great day. PS. I recomend to everyone who does work on there vehicles to buy a chilton or haynes manual from their local auto parts store. It has detailed instructions and pictures to help. These are usualy about $20

Take the Right hand front wheel off, remove the plastic splash panel. Obviously, first remove tne belt. the tensioner should be slightly up in the wheel opening. Remove the pully, center bolt, remove the bolts attaching the tensioner asm. Local autoparts store should have replacement for around $30.00. Replace follow instructions backwards. While at auto store reference saturn manual for torque to tighten bolts when replacing. Do not over torque into aluminum block.

The idler pully can be removed without removing the engine. I have replaced mine in my 97 SL2. As to the bolt breaking off, that is strange. I assume that if the bolt broke off, then the idler pully also fell off. If I remember, the space is somewhat limited, so getting a removal tool in there could be very difficult, especially if the bolt is flush with the mounting hole. That doesn't sound like a fun project. If bolt protrudes, maybe you can get some vise-grips on it and turn it out.