3800 belt tensioner replacement/coolant elbow replacement
 

Been meaning to wright this up for some time now, if I did sorry this may be a duplicate

My belt tensioner failed I replaced it and here is a guid of how I did, not only can this be used for tensioner replacement guide but coolant elbows aswell
**your exact tool and socket sizes may very this is on my 2001 pace car

Tools needed,
10mm,13mm(deep)15mm,16mm(deep) ratchet, pliers,

Parts needed
Tensioner assembly, coolant elbows, belt(if needed)
Attachment 28664
**I also did my power steering pump at the same time
****great time to change the power steering fluid


Step1:
like any project remove negative from your battery,

Step 2:
Remove strut crossbar by removing the 4nuts that hold it into place, set side
(If equipped if not skip to step:3)
Attachment 28665

Step 3:
Remove the belt from, using a ratchet and a 15mm socket, I also use a long pipe for a little extra leverage
Attachment 28666

Step 4:
Remove the brace that goes from the alt to a bracket
Attachment 28665

Using a 15mm socket on the alt side
Attachment 28668

And a 10mm on bracket side
Attachment 28669


Step 5:
remove the alternator
Start with removing the power out wire using a 13mm
Attachment 28670

Remove the top 2bolt from the altenator
Attachment 28671

Remove the lower bolt from the alt
Attachment 28672

Remove the plug from the back side of the alt
Attachment 28673

Step 6:Remove the clamps and heart hoses
Attachment 28653

Attachment 28654

Step:7 remove the tensionor assembly by removing the 3bolts
**please see first picture for bolt locations

Attachment 28655


Step8 prep your new part for installation,

Remove the connection for the coolant outlet to the hoses clean, check orings and place into new tensioner assembly
Attachment 28656

Put new coolant elbows into tensioner
(If using aluminum ones use antisieze on the engine side
Attachment 28657

Step 10:

Reverse the process for installation
Attachment 28658

Than you for you time, I hope this can help!

great write up but if all i want to do is replace the coolant elbows, do i still have to take the belt tensioner off or could i just remove the alternator?

Yes you do.:thumbsup:

You may be able to get away with taking the lower bolt of the alt off and just leaving it bolted to the tentioner but will make things harder toine up when you put it back together

Good write up, I also jus changed ma tensioner a little while ago

Guys i need some help. On my tensioner where the heater hose is connected the bolt for the fitting sheared off. Im drilling it out but i need to know what size the bolt is or what size i can use for the hole. My dad said to try running it without a bolt but I dont trust leaving it open like that. Im not sire if i can get it from my work even tho i work for GM so i need to know what size it is just in case

Also the other bolt didnt break but when i tightened it down the bolt stopped but i could still move the hose up and down with plenty of room. Why is that? Is that normal?

Great write up Justin. :congrats: Just found out the SS, old TAZ63, is leaking at the plastic 90deg elbow. Your instructions will help assure I don't remove too much stuff.