I have to replace the pulley and belt do i need extra tools ? why wont the belt adjust with the adjustable bolt it is still 2 small?

undo the big nut in front of the pulley. release the tension on the belt by adjusting the small bolt at the rear of the adjuster bracket . Take the nut of the shaft and pull the pulley off. Remember where the spacer goes at the back of the pulley.

Adjusting aircon belt on HZJ75 motor.
1 Loosen bolt at centre of idler pulley. Idler pulley is smaller pulley adjacent to the Aircon pulley.
2 Rotate the adjuster bolt clockwise to tighten belt. The adjuster bolt head sits directly above and behind the idler pulley.
3 Anti clockwise will loosen the belt. Wind to end of the adjustment to remove or replace belt then rewind bolt clockwise to required belt tension.
4 Retighten bolt at centre of idler pulley following any adjustments.

INSPECTION

Inspect the belts for signs of glazing or cracking. A glazed belt will be perfectly smooth from slippage, while a good belt will have a slight texture of fabric visible. Cracks will usually start at the inner edge of the belt and run outward. All worn or damaged drive belts should be replaced immediately. It is always best to replace all drive belts at one time, as a preventive maintenance measure, during this service operation.

CHECKING TENSION AND ADJUSTMENT

See Figure 1
The belt tension on most driven components is adjusted by moving the component (alternator, power steering pump etc.) within the range of a slotted bracket. Some brackets (toothed) use a rack and pinion mechanism which moves the alternator side-to-side to adjust the belt tension. With this configuration, no prying tools are required. On Quantum (except 5 cylinder) and Fox models, the air conditioner compressor drive belts are adjusted by varying the number of discs (shims) between the halves of the crankshaft pulley. Before adjusting the belt tension on any engine, look at the mounting and determine what kind of bracket is used.
To check belt tension, push in on the drive belt about midway between the crankshaft pulley and the driven component. If the belt is less than 39.4 in. (1m) long, it should deflect between 0.80-0.120 in. (2-5mm). For longer belts, it should deflect between 0.40-0.060 in. (10-15mm). Belt size is usually printed on the back side of the belt. If it can't be read, it's probably time to replace it.

Fig. Fig. 1: To check belt tension, push in on the drive belt about midway between the crankshaft pulley and the driven component
Slotted Brackets
See Figures 2, 3 and 4

1. Loosen the adjustment nut/bolt in the slotted bracket. Slightly loosen the pivot bolt.
2. Pull (don't pry) the component outward to increase tension. Push inward to reduce tension. Tighten the adjusting nut/bolt and the pivot bolt.

Fig. Fig. 2: Alternator mounting with slotted brackets

1. Components, such as the power steering pump and some air conditioner compressors, may be mounted with a double slotted adjusting bracket using a threaded bolt and locknut to adjust and maintain tension. Loosen the locknut(s) and slightly loosen the bolt(s) in the slotted groove(s). Turn the threaded adjustment bolt(s) in or out to gain correct tension. Tighten locknut(s) and slotted bracket bolt(s).
2. Recheck the drive belt tension, readjust if necessary.

Fig. Fig. 3: Some components use a double slotted adjusting bracket with a threaded bolt and locknut to adjust and maintain tension. Loosen the locknut (shown) before adjusting the tension bolt

Fig. Fig. 4: An extension is helpful when adjusting the tension bolt. Be sure to loosen the nut/bolt on the rear slotted bracket first
Toothed Brackets
See Figures 5 and 6

1. Loosen the tension bolt and the alternator pivot bolt. These bolts should be loosened until the alternator swings freely under its own weight.

Fig. Fig. 5: Loosen the tension bolt (shown) and the alternator pivot bolt until the alternator swings freely under its own weight

1. Adjust the V-belt by turning the nut on the tension bolt while checking the belt deflection with your thumb.
2. Once the proper tension is achieved, tighten the tension bolt to 26 ft. lbs. (35 Nm). Tighten the pivot bolt to 15 ft. lbs. (20 Nm).
3. Recheck the drive belt tension, readjust if necessary.

Fig. Fig. 6: Adjust the V-belt by turning the nut on the tension bolt
Split Pulley
See Figure 7
On Quantum (except 5 cylinder) and Fox models, the air conditioner compressor drive belts are adjusted by varying the number of discs (shims) between the halves of the crankshaft pulley.

1. Remove the nuts/bolts securing the tensioner plate and crankshaft pulley halves.
2. Add or remove the amount of spacer discs between the pulley halves until the belt tension is correct.

Fig. Fig. 7: Belt adjusting shims on Quantum (except 5 cylinder) and Fox models. Extra shims are stored behind the tensioner plate on Fox and turbo diesel Quantums (shown)
If there are any shims left over, do not throw them away. On Fox and turbo diesel Quantum models, store the extra shims in front of the split pulley (behind the tensioner plate). On Quantums with 4 cylinder gas engines, store the extra shims behind the split pulley (in front of the crankshaft hub).

1. Secure the pulley halves. Torque the pulley nuts or bolts to 15 ft. lbs. (20 Nm).

REMOVAL & INSTALLATION

If a belt must be replaced, the driven unit must be loosened and moved to its extreme loosest position (usually by moving it toward the center of the motor). After removing the old belt, check the pulleys for dirt or built-up material which could affect belt contact. Carefully install the new belt, it may appear to be just a little too small to fit over the pulley flanges. Fit the belt over the largest pulley (usually the crankshaft pulley at the bottom center of the motor) first, then work on the smaller one(s). Gentle pressure in the direction of rotation is helpful. Some belts run around a third or idler pulley, which acts as an additional pivot in the belt's path. It may be possible to loosen the idler pulley as well as the main component, making your job much easier. Depending on which belt(s) you are changing, it may be necessary to loosen or remove other interfering belts to get at the one(s) you want. Some models have a front engine mount installed through the air conditioner compressor belt circle. Support the engine and remove the mount prior to belt removal and installation.
When buying replacement belts, remember that the fit is critical according to the length of the belt, the width of the belt, the depth of the belt and the angle or profile of the V shape (always match up old belt with new belt if possible). The belt shape should exactly match the shape of the pulley; belts that are not an exact match can cause noise, slippage and premature failure.
After the new belt is installed, adjust it for proper tension. This is sometimes a three or four-handed job; you may find an assistant helpful. Make sure that all the bolts you loosened are retightened and that any other loosened belts also have the correct tension. A new belt can be expected to stretch a bit after installation so be prepared to re-adjust your new belt.
After installing a new belt, run the engine for about 5 minutes and then recheck the belt tension.

Welcome to FIxYa.com

Image

Image

Image

GENERATOR DRIVE BELT INSPECTION

1. Check the drive belt and pulley for wear, cracks, and fraying. Replace if necessary.

2. Measure the drive belt tension with a tension gauge.

Tension lb (N)

3. Measure the deflection by applying moderate pressure (221b,[9S N]) midway

between the pulleys. Adjust if necessary.

Deflection lb (N)

Adjustment

1. Loosen the generator mounting bolt and adjusting bolt.

2. Deflect the generator to achieve the specified deflection.

3. Tighten all bolts and recheck the tension.

Image

Replacement

1. Remove the A'C and PS drive belt, if equipped.

2. Loosen the generator mounting bolt and adjusting bolt.

3. Remove the generator belt.

4. Install the new generator belt and adjust it to specification.

5. Tighten all bolts to the specified torque.

Tightening torque:

Mounting bolt:

2 7-38 ft-lb (37-52 Nm)

Adjusting bolt:

14-19 ft-lb (19-25 Nm)

6. Install the AC and PS drive belt: if equipped. and adjust to specification.

Thank you for using FixYa.com

Regards, Lee Davidian

To Install:
NOTE: Clean balancer belt drive pulley, timing belt pulleys and upper/lower timing cover prior to belt installation.

1. Set timing belt drive pulley to TDC by aligning dimple on pulley with dimple on oil pump.
   
   
2. Set camshaft pulley to TDC so that "UP" mark is at top and grooves align with top of cylinder head. Timing belt installation
   
   
3. Starting with driver pulley, install timing belt in a counterclockwise sequence.
4. Loosen and ten retighten adjusting nut.
5. Install balancer belt drive pulley. NOTE: Inspect rubber seal on lower cover and replace as necessary.
   
6. Install lower cover.
7. Install crankshaft pulley and bolt.
8. Rotate crankshaft pulley counterclockwise several times to seat belt.
9. Loosen adjusting nut 1 turn.
10. Rotate crankshaft counterclockwise 3 teeth on camshaft pulley.
11. Tighten adjusting nut to 33 ft lb (44 Nm).
    
    
12. Turn crankshaft pulley until TDC is achieved.
    
    
13. Ensure that camshaft pulley "UP" mark is at top and grooves align with top of cylinder head.
14. Remove crankshaft pulley and lower cover.
15. Rotate crankshaft to TDC again and lock timing belt adjuster arm with a 6 mm timing cover bolt.
16. Loosen adjuster nut 1 turn and ensure that belt tensioner freely moves.
17. Push tensioner up and tighten adjusting nut. Balancer shaft alignment
    
    
18. Remove bolt and washer from maintenance hole.
19. Using a 6 X 100 mm bolt, scribe a mark 2.9 in (74 mm) from end.
20. Insert bolt into maintenance hole and hole in balancer shaft.
21. Install bolt up to scribed line. Balancer shaft alignment
    
    
22. Align groove on balancer shaft with pointer on oil pump housing.
23. Install balancer belt and loosen adjusting nut 1 turn to tension.
24. Retighten bolt. Balancer shaft alignment
    
    
25. Remove bolt from maintenance hole and install bolt and washer. Tighten to 22 ft lb (29 Nm).
26. Reinstall crankshaft pulley.
27. Loosen adjusting nut 1 turn.
28. Rotate crankshaft pulley counterclockwise 1 turn and tighten adjusting nut.
29. Remove bolt from timing belt adjuster arm. NOTE: Inspect rubber seal on lower cover and replace as necessary.
    
30. Remove crankshaft pulley.
31. Install lower cover.
32. Install seal at adjusting nut. NOTE: Crankshaft pulley, bolt and washer must be cleaned prior to installation.
    
33. Lubricate crankshaft pulley bolt between head and washer and bolt threads with clean engine oil.
    
    CAUTION
    Do not use impact wrench to perform following step.
    
34. Install crankshaft pulley and tighten bolt using special tools to 181 ft lb (245 Nm).
35. Install dipstick/tube assembly.
36. Install upper cover. Tighten bolts to 9 ft lb (12 Nm).
37. Install cylinder head cover.
38. Install alternator bracket and alternator.
39. Install power steering pump belt and alternator belt. Upper bracket installation
    
    
40. Install upper bracket and tighten fasteners in proper numbered sequence.
41. Install stop.
42. Install battery and enter radio anti-theft code.

Hello... Yes there is an adjustable pulley.... It is called a belt tensioner. You can find it, with the engine off, pull up on each pulley. The one that moves the most is the tensioner...

To release the tension on the belt, a special tool or a 3/8 or 3/4 in rachet is used...

Once the tension is released, the belt is easily removed and installed.

Good Luck....

What is needed Tools: 6mm and 8mm allen wrench socket, 5mm allen wrench. 8mm, 13mm, 19mm socket and ratchet. 10mm combination wrench. Long ratchet extensions (at least one 6in, more are helpful). 5inch Wheel puller (for main shaft pulley). (Some models may need a special spanner tool to adjust the timing belt tensioner) Parts: 2 gal of anti-freeze mixed with distilled water. All three V-belts. (Alt, A/C, P/S) $32.95 New water pump top. $91.91 New gasket for WP. $9.13 New timing belt. $26.13.


Procedure:

Remove battery cable (either power (+) or ground (-)) remove alternator remove A/C remove power steering pump .Remove water pump pulleys remove main shaft pulleys remove timing belt covers remove A/C mounting hardware remove timing belt (don't turn any of the wheels its connected to) replace timing belt adjust belt tension remove water pump face put on new gasket and new part.

Leave pulleys off. replace bottom timing belt cover, replace crank shaft pulley, replace steering pump, replace A/C, put small belt on A/C (hang loose) put large belt around A/C, Main and water pump pulley. put middle size belt on Main water pump and power steering pump reattach bolts for the steering pump pulleys put alternator back on adjust all belts. connect battery

Problem areas:
Main pulley: There are 4 6mm hex head bolts. These must be removed. The main 19mm hex head can be used to turn the engine it the timing belt slips and you have to readjust the timing.

Putting on new belts: This can be a real pain if you get VW belts. The adjustments won't give enough to put the belts over the edge so the easy way is to remove the pulley on the water pump. Then its real easy.

Timing: If you turn the wheels that the timing belt goes on you will have to reset the timing. Mark the timing points with something like whiteout so its easy to see. The timing mark on the toothed gears are small dots. The timing mark for the crankshaft is a small cut on the outer pulley. When its aligned with the intermediate wheel timing mark (there is an arrow on the cover as a hint) should intersect as viewed from the right wheel well. The camshaft timing mark should line up with the top of the engine near the front.

Power steering pump: It is held on with lots of bolts. One is in a channel that is hard to see but can be found with a 6" extension. If you look at the pump you will see three bolts that go into the housing. This should give you an idea where the forth is.

REMOVAL & INSTALLATION

See Figures 1 and 2


Fig. Fig. 1: Rear terminal alternator


Fig. Fig. 2: Side terminal alternator

1. Open the hood and disconnect the battery ground cable.
2. Remove the adjusting arm bolt.
3. Remove the alternator through-bolt. Remove the drive belt from the alternator pulley and lower the alternator.

Some engines are equipped with a ribbed, K-section belt and automatic tensioner. A special tool must be made to remove the tension from the tensioner arm. Loosen the idler pulley pivot and adjuster bolts before using the tool. See the accompanying illustration for tool details.

1. Label all of the leads to the alternator so that you can install them correctly and disconnect the leads from the alternator.
2. Remove the alternator from the vehicle.
3. To install, reverse the above procedure. Torque the pivot bolt to 58 ft. lbs.; the adjusting bolt to 25 ft. lbs.; the wire terminal nuts to 60-90 inch lbs.

BELT TENSION ADJUSTMENT

The fan belt drives the alternator and water pump. If the belt is too loose, it will slip and the alternator will not be able to produce it rated current. Also, the water pump will not operate efficiently and the engine could overheat.
Check the tension of the belt by pushing your thumb down on the longest span of the belt, midway between the pulleys. Belt deflection should be approximately 1 / 2 inch; (13mm).To adjust the belt tension, proceed as follows:

1. Loosen the alternator mounting bolt and the adjusting arm bolts.
2. Apply pressure on the alternator front housing only, moving the alternator away from the engine to tighten the belt. Do not apply pressure to the rear of the cast aluminum housing of an alternator; damage to the housing could result.
3. Tighten the alternator mounting bolt and the adjusting arm bolts when the correct tension is reached.

Hi,according to what year you have.Look for either an adjusting bolt and through bolt at the alternator.Loosen both and push the alternator back.If it has an extra pulley look for a belt adjusting bolt close to this pulley.You have to loosen the bolt that goes through the front of this pulley.(the bolt that holds the pulley to engine).Then turn the adjuster to loosen belt.Some of the later models have automatic belt tensioners.You have to put a wrench on the tensioner pulley bolt and relieve the spring pressure.I hope this helps!!!Please rate this answer.Thanks and Good Luck!!!

STEP 1 Remove Air Filter. STEP 2 Loosen the bolts securing the crankshaft pulley. Remove the load from the belt tensioner by turning the belt tensioner pulley locking bolt forward in the car using a 15 mm wrench. Remove the belt from the coolant pump pulley and slowly release the belt tensioner. STEP 3 Remove the belt tensioner and remove the steering pump pulley STEP 4 Remove the water pump pulley use the engine bracket to pry against. STEP 5 Remove the timing cover and Remove the right-hand front wheel and the cover in the wheel housing. STEP 6 Remove the crankshaft pulley (undo the six bolts but do not remove the centre bolt). STEP 7 Place the engine top dead center and Zero the engine. The markings on the camshaft sprockets and timing cover should be in alignment as also should the marking on the crankshaft. Use locking tools 83 95 006 and KM-800-2 for the camshaft sprockets and locking tool KM-800-10 for the crankshaft (These tools can be purchased from Saab (18774177222) or from Baum Tools). STEP 8 Before removing the toothed belt mark its direction of rotation . To facilitate refitting the belt can be marked at both the camshaft marking and the crankshaft marking. STEP 9
STEP 10 Fit the toothed belt according to the marked direction of rotation. Use setting tool 83 95 006 to keep the belt in place and adjust the tensioning roller loosely by hand to prevent the belt from jumping off. Adjust counterclockwise. Fit a section of the toothed belt and fit tool 83 93 985 to measure the belt tension. Loosely tighten the centre bolts of the adjusting rollers. Adjust the lower adjusting roller counter clockwise to a belt tension of 275-300 Nm. Turning torque 30 lb.ft ft ******The adjustment of the belt tension is for preparation ONLY and must not be used as a check when the belt adjusted for the final time! STEP 11 Turn the engine over two revolutions until just before the zero mark and place the locking tool on the crankshaft. Carefully turn the crankshaft in the direction of engine rotation until the arm rests against the coolant pump's flange and then tighten the arm. Fit setting tool 8395006 and check that the markings on the camshaft sprockets are aligned with the markings in the tool. ********Check that the A marking is approximately 2mm above B marking. If the distance is less readjustment is necessary. STEP 12 Fit the crankshaft pulley and Tighten to a torque of 15 foot lbs. STEP 13 Reinstall the inner wheel cover and front right wheel.
STEP 14 Reinstall Timing Cover.
STEP 15 Reinstall the water pump pulley use the engine bracket for leverage. STEP 16 Reinstall the power steering pulley and tighten to 6 foot lbs. STEP 17 Reinstall the belt tensioner and tighten to 30 foot lbs. STEP 18 Remove the belt tensioner load/pressure by turning the belt tensioner pulley locking bolt forwards in the car using a 15 mm wrench. Install the belt on the coolant pump pulley. Carefully release the belt tensioner. STEP 19 Reinstall the Air Cleaner and hoses that accompany Release the belt tension and remove the toothed belt.