Question about 2004 Kia Sorento

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Belt tensioner need to replace the serpentine belt tensioner on 2004 kia with a V6 and not sure how to take off the tensioner

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It is a very involved process of removing and replacing. You will have to remove all of the belts, the front timing belt covers, (upper and lower). You will also have to remove the front bracket that is mounted to the front of the block, which serves as the mount for the power steering pump, the alternator and the A/C compressor.You will also have to remove the crankshaft pulley. You cannot remove the plastic lower timing belt cover unless you remove all of these things first. The tensioner is located underneath the lower cover along side the timing belt on the passenger side. It has two bolts that hold it in place. You will have to remove these two bolts.

The crankshaft pulling bolt is a right handed thread and loosens by turning counter clockwise. The pulley will slip off but is a very tight fit. Do not try to turn it while removing it as there is a small pin that keeps it aligned to one position. Use a small ball pine hammer to tap it loose.

It is also a good idea to remove the electric cooling fan shroud that is mounted to the inside side of the radiator and the radiator hoses to give yourself more room to work. It has only two bolts at the top holding it in place. And then slips into two retaining clips at the bottom. Lifting it will pull it out of these retaining clips.

When you remove the small bypass hose located at the top of the radiator , to the passenger side, be careful not to break off the small nipple protruding out of the radiator tank. It is plastic and will break easily if you try to pull the rubber bypass hose from it. This will have to be taken to a radiator shop to have repaired if you accidentally break this off. Be sure to carefully loosen the hose from this nipple before trying to pull it off.

And one more thing, if you go to that much trouble to replace the tensioner, it is a good idea to go ahead and replace the timing belt as well. It is a maintenance item and you will have to go through the same process to replace it as well. Do it once and do it right.

I hope this helps.

Posted on Nov 15, 2008

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I keep having the serpentine belt come off, tear to shreds, then fall off. I have gone thru 3 belts so far, all thru the dealer. what is wrong 2004 kia optima


I would replace the tensioner, this is an spring loaded arm with a pulley which keeps tension on the belt. That tension keeps the belt running in the grooves on the items being spun by the belt. Seems if you had the belt changed at a dealer they would have checked this. Inadequate tension means the belt rises out of the grooves and takes flight

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Click on the following free direct Link. It has the correct Serpentine/Drive Belt Diagram for your 2004 Ford Freestar. You either have the 3.9L or 4.2L V6 Engine. I am not sure what Engine options (AC/No AC, etc.) you have. If this Diagram is not correct: check on the underside of your Hood for the correct Belt Diagram. However the below "How To" remains accurate.

http://www.2carpros.com/car_repair_information/year/2004/make/ford/model/freestar/2004_ford_freestar_drive_belt_routing_diagram.htm

"HOW TO":
Standard Rules to Removal the Serpentine Belt with an Automatic Tensioner:
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3. Remove the loosened belt off one of the other more easily accessed Pulleys.
4. DO NOT quickly release the Tensioner, but gently allow the Tensioner to rest in its closed position.

Standard Rules for Installing the Serpentine Belt with an Automatic Tensioner:
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 questions. Feel Free to contact me at FixYa.com!

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You will see a square hole on the tensioner and that is where the breaker bar goes. Put the breaker bar in there and pull on it until it gives you enough slack to pull the belt off. Make sure to pull the right way to release the tension. IF it wont release the tension don't yank on it try going the other way, It will help to have two people to do this job. You only need to pull it off one pully then slowly let the tensioner go back.

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