Ford Automobiles Forum banner
1 - 20 of 382 Posts

·
Premium Member
Joined
·
3,834 Posts
Discussion Starter · #1 ·
just thought i write a How to Replace the
TDCI Aux Belt Tensioner
The kit that i got was made by gates and cost me the total of £105 inc vat part number is k036PK1640 and was purchest from Unitpart
Tensioner/Belt/3 Pullys


Tools for the job
Wheel Brace / Trolly Jack / Axel Stand / Wood.
Sockets
8mm/10mm/13mm/15mm/18mm + Extender Bars
Spanners
13mm/15mm
Torq's Bits
T40 and 10mm allen Key

1 loosen the wheel nuts then jack up the car so the wheel is off the ground and support the car with the axel stand . take off the wheel completely ...


in this Picture you will see a dirt cover that needs to be removed using your 8mm & 10mm sockets remove the


Now you need to jack up and Suport the engine with some wood using your trolly jack see picture


Engine mount removel it would be wise to move the water header tank using 10mm socket on extender now remove engine mount using 10mm Socket for the Sound deadner 18mm for the Top Nuts and 15mm for lower Bolts See Pictures



Now when lowering the engine becarefull not to damage your CV Joint as it can rest on the subframe


Now you can eather Pull of your belt or cut it REMEMBER how it goes on !!

Now to remove the Tensioner you need to undo the altenator using 15mm socket on the bottem Nuts and 13mm socket on the top bolt


Now comes the removel of the Belt Tensioner
3 13mm Bolts hold the frame on 2 from under the car other at the top


Getting it out is a little tricky i had to push the altenator up high from under the car and take the Tensioner out beside the exhaust pipe

Now you can Repace parts using Torqs T40 and your 10mm Allen key


Removing center Pully you will have to take the remainder of the engine mount off 1x 13mm Nut 2x 18mm Bolts 1x 15mm Twin Ended Bold that holds the center pully



Remember when refitting that the Belt goes through the Tensioner :)

i made a little tool for releasing the tensioner so the belt can be put back on the pullys with no Fuss
i used a 13mm bolt and 2x 13mm nuts i did have to File/Grind to small flat spots so it would fit in the 1/2" hole i used a spanner to Lever



Hope this helps

Cheers
Mark
 

·
Premium Member
Joined
·
3,834 Posts
Discussion Starter · #3 ·
ok then so how you put it in there ?
 

·
MEG Corporal
Joined
·
1,117 Posts
Excellent post, great pictures, and will prove invaluable to many, wish this had been put on before i had to do mine:)
 

·
Big Megger
Joined
·
559 Posts
Yeah Great post do you have a time from start to finish? mine rattles like a b!tch so want to get it sorted but I wil need a new jack and axle stands more expense I don't need at the moment.
 

·
Premium Member
Joined
·
3,834 Posts
it tuck me about 1.45hrs started around 11ish finished at 1:30ish i all so did my manifold seals as well as i had some oil on my aircon pump that i noticed when working on car ...
just to say im very handy with spanners and know my way around engines but there would be a few things i should'nt of done that i thought would of been faster ... like Cuting down a Allen key to undo a bold and messening about trying to get the center pully off without taking the mount off so in all my time could of been cut down by 15 mins or so
 

·
MEG Corporal
Joined
·
1,117 Posts
took me about 3 hours, but i could not work out the belt (my wife pointed the way out!)
 

·
Big Megger
Joined
·
559 Posts
markderby said:
it tuck me about 1.45hrs started around 11ish finished at 1:30ish i all so did my manifold seals as well as i had some oil on my aircon motor that i noticed when working on car ...
That quick ! Might have a go at it as it seem I will be having a few weeks of free time coming my way courtesy of Mr Brown and his mates :annoyed:
 

·
Registered
Joined
·
1,614 Posts
Well done Mark. There's been many posts re getting a write up done and you were the one that came up with the goods :driving:

BUT, seeing as you're only down in Derby, I may have to pop down and pay you a few quid :} Mines not ready yet for doing but I suspect it may not be that long. Every morning after first starting, there is a light rattle as the battery is re charging. It maybe the alternator, not sure. But it doesn't rattle when the aircon is switched on so not sure.

Well done again
 

·
Premium Member
Joined
·
3,834 Posts
Discussion Starter · #11 ·
Adi69 No probs ... you recode injectors right ?
 

·
Megger
Joined
·
77 Posts
mondeo2674 said:
i fitted this kit 5000 miles ago and the tensioner has already started going again rattling like the ford one, gonna use a ford part next time....
Doesn't help, i have changed all the parts 40k ago and rumbling again :angryfire:

Changed tensioner, belt, rollers and bottom pulley. Was silent about 10k.
 

·
Little Megger
Joined
·
45 Posts
Top job mate.!!!
Think our 140k TDCi needs the same.
I have two new rear hub assemblies sitting here under my desk. Planning to fit them tonight so will take a few pics as I go. I know, piece of p*@# job, but if it helps someone it will be time well spent.
Going to fit a new tow-bar later this week, so will do the same for that.
 

·
Big Megger
Joined
·
774 Posts
That quick ! Might have a go at it as it seem I will be having a few weeks of free time coming my way courtesy of Mr Brown and his mates :annoyed:
[/quote]

he is a pain mr brown. have some time off atm due to him and his clowns :)

when my m8 workied on my tddi we had to utdown a snappon 8mm key [email protected]@ hard work.

tim
 

·
Premium Member
Joined
·
3,834 Posts
Discussion Starter · #19 ·
....
 

·
Big Megger
Joined
·
254 Posts
Lads reading this..is it worth changing at all..if they just keep failing!..anyone any comments..maybe the problem is elsewhere on this part..is something else causing them to fail?
 
1 - 20 of 382 Posts
Top