Technical Alternator tensioner or shorter belt?

[csj2k]

(T ('98), 1.6 16v HSX)
Hi all. My altenator jammed so it melted the tensioner. I didn't realise this at first as I'd asked a garage to look at it but then they started picking figures out of the air so I decided to have a go at some D.I.Y. I've replaced the alternator and have the belt but then realised there was a bit missing lol!

Someone suggested just putting a shorter belt on instead of a new tensioner - is this a bad idea and also what size? Does anyone know where I might obtain a cheap tensioner if this is the way forward?

 

[JoskeJTD]

(T ('98), 1.6 16v HSX)
Hi all. My altenator jammed so it melted the tensioner. I didn't realise this at first as I'd asked a garage to look at it but then they started picking figures out of the air so I decided to have a go at some D.I.Y. I've replaced the alternator and have the belt but then realised there was a bit missing lol!

Someone suggested just putting a shorter belt on instead of a new tensioner - is this a bad idea and also what size? Does anyone know where I might obtain a cheap tensioner if this is the way forward?

The 1.6 doesn't have an auto adjusting tensioner but it does have a tensioner. The tensioner is required to keep the belt at the correct tensioner aswell as aid with renewal of the belt. I strongly advise against a shorter belt, as you;ll never get the tension correct.

Fiat charge around £32 for the tensioner.

Replacing the alternator is a pig of a job to do i was wondering how you managed to remove the alternator?

 

[csj2k]

Thank you.
The alternator was off as the garage had already removed it. After reading advice on this forum.....I put the car up on a trolley jack (don't have axle stands so just used the jack which I know is NOT reccomended), removed the wheel and the garage had left the the plastic trim inside the wheel-arch off so saved me a job there. I balanced the alternator to the rear of the space and then put the bracket on. I then raised the alternator and got a friend to pop the top bolt through to hold it in-place while I persuaded the bottom part to go into the bracket. Tightened the lower bolt from under the car and then did the top one and connected the wires from above the engine.

 

[JoskeJTD]

Seems wierd you had room unless the 1,6 alternator is small. To remove mine, you can't just pull it out, you need to either remove drive shafts and suspension or other things depending on which way your removing.

Anyway i'd get a new tensioner. Its very easy to fit and to tension.

 

[csj2k]

Don't get me wrong, it was tight and I have the battered & bloody knuckles to prove it lol. I could see that if I had put the bracket on before balancing the alternator just rear of it I wouldn't have got it in so for removal I think you would have to do the opposite (unbolt alternator, move to rear, unbolt bracket, drop out, drop alternator out). The trickiest part was access to tighten the bottom bolt particularly as I didn't have the right size spanner and had to use an adjustable. It took me about 2 hours but I think I could do it in less than one now I've done it once.

 

[csj2k]

I've looked at a couple of tensioners and in some pictures there are two wheels and in others only one. There looks to be two bolt holes but even after looking at a brava service manual I still don't know what I need, one or two wheel things! Please help!

 

[The Professor]

On the 1.6 you've got a single adjustable tensioner pulley wheel. This pulley sits on a shaft which is part of the mounting bracket. The bracket is held on the engine with two 15mm A/F bolts, one of which goes through an eccentric sleeve. There is an 8mm Allen socket in the eccentric in which you insert an Allen key to twist the eccentric and thus move the tensioner pulley against the belt. There is also a hexagon on the eccentric but I think the Allen key is easier and lets you tighten the 15mm bolt whilst holding the tension on with the other hand - without having to do too much of a contortionist act.

 

[csj2k]

Hi Professor

I've been round a couple of salvage yards today and the only thing I could find is this

It doesn't seem right to me I couldn't find one with the 8mm allen you mentioned, nor one with a bracket held on by 2 15mm bolts. It only cost me £10 so I'll stick it on ebay if it's no use to me lol.

 

[The Professor]

'Fraid that's not the one. The one you've got there looks like a self tensioning one which isn't off the 1.6 litre engine.
Sorry, I haven't worked out how to upload an image to this site yet, (where do the instructions live?) but try this link for the tensioner arrangement.
Hopefully you can get an idea of the shape of the bracket from it:
http://i42.photobucket.com/albums/e338/DenisR/AuxBeltTensioner.jpg

 

[csj2k]

The box you reply in has a picture icon. Click on this then insert the url of the image. Thank you for the picture - nothing I've seen today looks like that and I've looked at several bravo's, brava's and marera's. It seems the 1.6 just has to be an awkward beggar. Doncaster Motor Spares say they have one so they're sending it through to their branch in Hull for me to collect.

 

[The Professor]

The box you reply in has a picture icon. Click on this then insert the url of the image.

That's what I thought I'd done! Obviously not properly otherwise the picture would have appeared....:bang:
Make sure you've got the eccentric sleeve I keep going on about, else it'll be a nightmare and a right bodge to tension the belt and hold the tensioner securely.

 

[csj2k]

If you're putting in a pic from photobucket you can just copy and paste the option that says IMG Code on photobucket.

I'll be sure to make sure it has the eccentric sleeve (just not sure what one is)

 

[JoskeJTD]

Hi buddy, this will help you too. Use an allan key to tension etc.


Click to enlarge

 

[csj2k]

Thank you for the picture JoskeJTD, that's fantastic. I just need to hope they send the right part now and the alternator saga should finally come to a close!

 

[JoskeJTD]

Technically you shouldn't use 2nd hand tensioners, not when its so important to the running of the car and a snapped belt could easily find its way fitting the cambelt and cause complete engine failure.

Anyway heres a picture from eper to show you how it goes together.

​

 

[csj2k]

Thank you JoskeJTD. You'll be glad to hear I've ordered the parts now brand new from Fiat and was suprised to find that they gave a better price than the scrappy! Lesson Learned!

I was able to use the last diagram you posted to confirm the exact parts with Fiat when I ordered.