How to remove drive belt tensioner pulley - Kia Forum
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#1 (permalink) Old 11-25-2011, 07:03 PM
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Default How to remove drive belt tensioner pulley

Does anyone know how to remove the drive belt tensioner pulley (not the idler pulley-see red area on attached picture)? Its the ribbed thermoplastic one that is between the alternator and A/C. A T40 star bit fits but there is only about an inch of space and nearly impossible to get any tools there. I tried removing everything (being a newbie) such as the headlight and black plastic cowling that is in the wheel area and under the car. I was able to replace the idler pulley and drive belt but there is still a howling noise. I am assuming it's a bad bearing in the pulley I can't get off. Bonus question. How do you isolate where the noise is coming from. Tried a mechanics stethoscope but for that pulley there is no-where to touch as everything is spinning.

https://skydrive.live.com/redir.aspx...B2923E3A22!220
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#2 (permalink) Old 11-26-2011, 09:53 AM
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HI
usual story/with most new cars to day as with kia ,
little or no room to work in.
any way back to your problem and to get things right
the tension pulley i think is the one between the crank pulley and the alternator
its the idler pulley between the alternator and the A/C pump.
have you tried using the T40 bit in some locking grips /pliers as a side rench
hope this helps
regards kia mad uk
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#3 (permalink) Old 11-26-2011, 09:59 AM
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Thanks for the reply. Liked it better way back when you could reach everything. I did try a T40 in vice grips and with a 5/16th wrench but could not break it free (the wrench worked much better but offered only a fair amount of leverage). I had to actually shorten the T40 bit by cutting part of it off with a Dremel tool. I am a newbie and was wondering if I am missing something? How do the tensioner pulleys usually come off when there is no standard nut on them? Is there another way to get this thing off (from the back of the tensioner pulley)?

Bonus question; what is the best way to isolate a bearing noise. Many pulleys, one offender...
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#4 (permalink) Old 12-03-2011, 10:54 AM
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Hi
a temperature probe comes to mind
run engine up to temp should be enough time
a probe may give you some indecation of how the bearings are functioning
ie friction give you heat hot bearing may be the fault
regards kia mad uk
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#5 (permalink) Old 12-05-2011, 07:26 PM
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I'm trying to isolate a bearing noise on my '02 as well. I've done the timing belt and replaced all but the timing belt idler so it's either that idler or it's something exterior toward the front (A/C compressor or alternator).

I can tell you that trying to remove the idler pulley with it still on the vehicle is a booger. There is a bracket that it mounts to, I believe there are 3 bolts that hold it on. Once you get the bolts out of the bracket you can wrestle it out and then try to back out that Torx (or star) fastener that goes through the center of it. I say "try" because I tried to get mine off (after I got it out of the way) and my Torx bit sheared clean off. I pulled the one off my '03 parts van and installed it (bracket and all) instead.

To isolate the bearing noise (whether it's external or internal) you can just remove the A/C and alternator belt and run the engine. The noise should disappear with the belt off if it's in the A/C, alternator, tension or idler pulleys.

You should then be able to spin all of these with the belt removed and listen for noise.

The tension pulley is removed by popping the bolt running through the center of it loose and then turning the tension bolt that runs up behind it (from the bottom). You can see both of these much easier from underneath or by removing the wheel and tire and then the vertical splash shield that hides the crank.

The noise mine makes broadcasts through the motor quite a bit so I haven't been able to put a scope on it and isolate the noise. I getting close though, just not wanting to work on it out there in that freezing Oklahoma weather.

Hope this helps.
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#6 (permalink) Old 01-24-2012, 12:36 PM
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Quote:
Originally Posted by tulsacarman View Post
I'm trying to isolate a bearing noise on my '02 as well. I've done the timing belt and replaced all but the timing belt idler so it's either that idler or it's something exterior toward the front (A/C compressor or alternator).

I can tell you that trying to remove the idler pulley with it still on the vehicle is a booger. There is a bracket that it mounts to, I believe there are 3 bolts that hold it on. Once you get the bolts out of the bracket you can wrestle it out and then try to back out that Torx (or star) fastener that goes through the center of it. I say "try" because I tried to get mine off (after I got it out of the way) and my Torx bit sheared clean off. I pulled the one off my '03 parts van and installed it (bracket and all) instead.

To isolate the bearing noise (whether it's external or internal) you can just remove the A/C and alternator belt and run the engine. The noise should disappear with the belt off if it's in the A/C, alternator, tension or idler pulleys.

You should then be able to spin all of these with the belt removed and listen for noise.

The tension pulley is removed by popping the bolt running through the center of it loose and then turning the tension bolt that runs up behind it (from the bottom). You can see both of these much easier from underneath or by removing the wheel and tire and then the vertical splash shield that hides the crank.

The noise mine makes broadcasts through the motor quite a bit so I haven't been able to put a scope on it and isolate the noise. I getting close though, just not wanting to work on it out there in that freezing Oklahoma weather.

Hope this helps.
I am taking our 2002 KIA Sedona LX to the dealer on Thursday morning. They have to put a scope to it. I could use the old way of screwdriver; but, on slip and would not be nice. I had a 02 VW GTI that was brand new and the VW dealer said it was the belt. The car shipped to Germany, the local German dealer near Ramstein pulled the scope and belt-tensioner was the issue. The noise we have in the KIA is almost the same; but, I am not ruling out anything until the dealer.

Also, the dealer told my wife the compressor is bad, not putting out A/C - this was late summer of 2008; A/C to us is almost optional. I would not be surprised if the compressor pulley is bad. I did turn on the A/C if the noise changed, no change.

I will post the outcome Thursday.
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#7 (permalink) Old 02-10-2012, 06:28 PM
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Default Idler pulley removal

FSUDAL, not sure if you ever got this problem resolved. I just finished removing my alternator, and at this point, the idler pulley bracket can be removed by taking out three 14mm bolts that sit in a tight triangular formation. I pulled out my pulley (and bracket) as it definitely needs replacing, and the other side of the T-40 torx is a 14mm nut that is pretty tight. I pulled that out on the bench, but now you end up with the pulley with a 14mm bolt running through it. I put this on the vise to see if I could hold the bolt on one side and then use the T40 on the other side to remove it, but I could sense that I was going to shear off the head of the T-40, so something is weird here. Tomorrow I am going to the dealer who wants $60 for the idler pulley (hopefully with the bolt attached) I can get the pulley by itself as cheap as $19 at Pep-Boys, but I am back to how the hell do I get that T-40 off?

if you figured this one out, please update. If I figure it out I'll do the same.
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#8 (permalink) Old 02-11-2012, 10:59 PM
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No way around it. All my sources came up empty in how to get the Torx off. Talked to a couple of KIA mechanics at a couple of dealerships, and both said KIA will not replace just the pulley. Their part comes with the bolt attached. Second dealership had the part in stock and gave me a 40% discount which still had me pay $36 for it. Better than $60, but they still made me pay an extra $20 for a frigging bolt with a Torx.

I am glad this is on the way to being over.
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#9 (permalink) Old 02-11-2012, 11:54 PM
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Have you tried to use a torch? It works for me every time on tough bolts.
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#10 (permalink) Old 01-30-2013, 05:47 PM
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hello!

my name is Anny, someone can send me picture of the tensioner pulley, I know how it looks or how many pieces are, because I have been searching the pulley and can not find it, because I get the pulley loka and that's not what I need the pulley is driving me off and I did not realize and now no need to buy it as pictures and show them that mark here in mexico barely handle it, I mean it's not commercial, anyone can help me please ...
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