Mondeo TDCI Belt Tensioner Pulley

[deathrider666]

Trying to change the alternator on my 2002 TDCI, I've managed to get the old one off but only managed to get the tension off the belt by undoing the bolt by the bottom of the alternator (it's the tensioner which is like a V shape with a pulley each end and a pivot point in the middle not the easier looking type which has the tensioner easily accessible at the bottom of the engine). When I get the new alternator on, can I move the tensioner without buying a special tool that I've read about? Which way does the tensioner move, clockwise or anti?

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[NEEDFORSPEED]

i normally just use a prybar on the tenioner never had an issue just be carefull not to crack the edge

[deathrider666]

I've tried to get a crowbar on it and lever it against the engine mount to push it clockwise (near the bottom pulley) and anti clockwise (near the top pulley) but doesn't seem to move.

Which way is it meant to move?

[DanW@FastFord]

It's a tricky one, and is definitely easier with the correct tool. Some people have made up a socket to fit, but you may find it easier to get the tool and sell it on eBay after.

[NEEDFORSPEED]

OR put the belt on but off the top middle guide pulley and push the belt down onto it

[DanW@FastFord]

It's easiest as a two person job, and even with the tensioner 'untensioned' it's still a tight fit!

[plumbobing]

This is my next job for this week end, i can't be bothered to struggle with some dodgey tool so for £15 i couldn't say no to buying the proper tensioner tool.
One thing i would like to know though is the torque settings for all of the components of the auxiliary belt setup. Does anyone have any info on these please?

[GVK.]

Correct way of doing it is to remove the alternator, then the support bracket complete with the tensioner , swap the tensioner then refit the bracket etc.

Some people may 'cheat' by undoing the tensioner off the bracket in situ, but there is little room to get an Allen key in there to undo the bolt.

Alternator comes out between chassis and subframe once os track rod end is undone.

Alternator lower mounting studs 15nm

Alternator nuts and top bolt 47nm

Track rod end 40nm

Alternator support bracket - block bolts 47nm

Tensioner retaining bolt 23nm

Tensioner to alternator support bracket bolt 55nm

Idler bolt 48nm

Crank pulley bolts 45nm + 120 degrees.

BEFORE you take the belt off draw a picture of it's routing and note how the tensioner sits in the bracket as if you get it in the wrong place you won't get the belt on

[DanW@FastFord]

Originally Posted by GVK.

BEFORE you take the belt off draw a picture of it's routing and note how the tensioner sits in the bracket as if you get it in the wrong place you won't get the belt on

Or you'll spend bloody ages getting the braket back on only to realise that you haven't routed the belt through it, so have to take it all off again!

[GVK.]

Exactly that!