Can't get belt tensioner bolt out on 606
 

I have taken the spring off but it won't swing high enough for the bolt to clear the fan/water pump pulley, so I swing it downwards (into the pulley) and it will come almost all the way out. The problem is the captive washer that is on the lower bolt. It won't let the bolt clear the inside of the pulley so I can get the shock off. If the washer weren't there the bolt would clear. The bolt doesn't stick through the opposite end (when tightened) to file any off. Is my only option the removal of the fan and pulley, and if so how do I go about that? I have searched (even other forums) and not found a DIY for either the fan or pulley removal on a 606. I did find one for the tensioner removal but it didn't tell me how to remove the fan/pulley.

Tia

Cal - On mine I can rotate the damper end of the pivot arm down far enough for the washer to clear. Did you try dropping the belt off a pulley somewhere to see if that will gain you a little more movement?

Short of that you have to remove the fan shroud, fan (or the fan clutch) in order to remove the 17mm hex pivot pin holding the pivot arm. You are supposed to pull the radiator first. I did it by unclipping the top supports holding the rad and removing the metal crossmember which supports the top of the radiator and pulling everything forward 1".

It wasnt very fun. If you do it with the rad in place, do yourself a favor and put a piece of cardboard up against the rad after you get the shroud out. Your knuckles will thank you for it....:o

Thanks again, Terry. As you can see I can't keep out from under the hood:D. But that rattle is driving me nuts! I'll try slipping the belt off, if that won't work I'll need to find other means. I don't think I want to tackle the fan, at least not today as I have to take it on a trip on Monday.

Thanks,

PS: has started and run perfectly today too!