I am helping a friend replace the alternator on his 87 SDL. I know there is a 12mm hole in the center of the tensioner, but I would like to know if anyone has any tips or tricks. I have not seen the car, but I understand the fan blade is very close.. any certain way to get the tensioner loose without removing the fan or breaking somthing?

Thanks for your help!

__________________
Matt
2003 Jetta Wagon TDI 145,000MI
1999.5 Jetta TDI 287,000MI
2001 Suzuki SV650S 26,000MI
2008 Yamaha Vino 125 11,000MI
http://www.crazymatt.org

Very easy.

Stick an extension into the hole on the side of the upper spring attachment block. Remove the nut from the through bolt, push down on the extension to relieve the pressure, and push the bolt back to clear the block. Release tension and the spring will go slack and you can remove the belt. Installation is the reverse -- use the extension to pull the spring up and shove the bolt through, put the nut back on.

I wish the tensioner on the M103 was this easy!

Take the fan clutch off -- use a 1/8" or 3 or 4mm allen wrench in the "slot" on the bearing plate to lock the clutch and an 8mm allen with a "booster pipe" on it to loosen the bolt. Remove bolt by hand and lift clutch and fan off. Take about two minutes after taking the fan shroud loose (two clips at the top, lay back over fan).

Takes less time to remove the ran than it does to fish the stinking belt in with it on. I've done it both ways, fan comes off now.

Peter

__________________
1972 220D ?? miles
1988 300E 200,012
1987 300D Turbo killed 9/25/07, 275,000 miles
1985 Volvo 740 GLE Turobodiesel 218,000
1972 280 SE 4.5 165, 000 - It runs!

thank you. This makes it seem much easier! Hopefully we can tackle it tonight.

__________________
Matt
2003 Jetta Wagon TDI 145,000MI
1999.5 Jetta TDI 287,000MI
2001 Suzuki SV650S 26,000MI
2008 Yamaha Vino 125 11,000MI
http://www.crazymatt.org

Matt:

It is pretty easy. Beats the H..L out of the tensioner setup on the M103 and M104 engines!

Peter

__________________
1972 220D ?? miles
1988 300E 200,012
1987 300D Turbo killed 9/25/07, 275,000 miles
1985 Volvo 740 GLE Turobodiesel 218,000
1972 280 SE 4.5 165, 000 - It runs!

I definitely advise removing the fan first.

Torque spec on that 12 mm hex head bolt is relatively high and use LOC-TITE on reassembly. There is a TSB on that bolt coming loose. If it does, it can tear up the front cover $$$$. I haven't used loc-tite in the past (didn't know about the TSB) and haven't had a problem, but definitely advise using it.

Dealer belt shocks cost more but last a LOT longer.

There are black plastic covers for the idler pulley and tensioner. Might want to get those if they aren't present to protect the bearings.

__________________
Brian Toscano