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TK 61753-2-MM-EN
Tensioner Assembly Replacement
1. Release the Tension on the belt by loosening the Lock Plate Fastener and Tensioning Bolt. Bolt need not be fully
removed.
2. Remove the Belt from Tensioner Pulley and Motor Pulley.
3. Remove the fasteners securing the Compressor Flange to Flywheel Housing. And pull the Compressor away from
the Engine.
4. Remove the Lock Plate from the Tensioner Arm by unfastening the Lock Plate fasteners.
5. Take the Tensioner Assembly out from the Machined Bracket Slot.
6. Fit the new Tensioner Assembly pressed in the Machined Motor Bracket and held it in position using Lock plate.
7. Fit the Compressor to the Engine, install and tighten the fasteners securing the Compressor.
8. Align the Motor Pulley with respect to Clutch Pulley using Laser Alignment tool. Ensure the Tensioner bolt is
unscrewed and Tensioner is moved to extreme end while doing alignment.
9. Align the Motor Pulley with respect to Clutch Pulley using Laser Alignment tool. Ensure the Tensioner bolt is
unscrewed and Tensioner is moved to extreme end while doing alignment.
10. Lock the Motor Pulley and wrap the belt around Motor Pulley.
11. Ensure the fasteners in Lock plate of Tensioner arm is hand tight. Screw the Tensioner Bolt such that the Tensioner
moves and tensions the belt.
12. Use the Belt Frequency measuring tool to check for Belt tension while adjusting Tensioner position.
13. Torque the Lock Plate Bolts and re-check the Belt Tension.
14. Tensioning the Belt. See (“Tensioning the Belt,” p. 89)
1. M10 Bolt
2.
Lock Washer
3.
Washer/Shield
4. Idler Assembly
5. Tensioner Arm
Water Pump Belt
The water pump pulley is a split type. Adjust the tension by adding or removing shims between the pulley sheaves. See
“Belt Tension,” p. 18 for the correct water pump belt tension settings.
EEnnggiinnee MMaaiinntteennaannccee
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