[ZStig]

tips for replacing the hydraulic belt tensioner, difficulty is about 2.5 out of 5:

1. Remove the plastic cover above the radiator. Remove the plastic bumper undertray too that is under the radiator
2. Unplug the electric fan and remove it. There is a star shaped bolt on the bottom right, and top left corner. Then it pulls up, rubbing against some rubber hoses a bit.
3. Locate the ~2" diameter dust caps on the 2 pulleys, and remove them. One pulley is near the bottom, the hydraulic tensioner is near the middle of the setup
4. Draw the belt diagram for reference, to show how it is routed. Or find one online
5. In the middle of each pulley is a hole for a T50 star bit, which moves clockwise (I think; feel it out) on the pulleys to release pressure, use other hand to grab the belt and pull it off
6. Remove the smaller, air con belt first.
7. Remove the main belt
8. The pulley on the old hydraulic tensioner must be unscrewed while still on the car, to access the bottom screws to the hydraulic tensioner. T50 star bit, in counter-clockwise action.
9. Use 13mm socket to remove the 3 pictured bolts on the hydraulic tensioner. You may need an extension on your socket wrench for the bottom 2, of about 2 inches or so. The top one is easiest to take off with a 4 inch extension to protrude the tool past the metal frame
10. Carefully record which bolt goes where, so you can install them correctly on the new one.


11. Install new hydraulic tensioner by lining up the holes and feeling the top bolt in. I believe it is screwing into an aluminium oil filter housing which is expensive to replace, so don't OVER tighten it.
12. Re-install the old pulley on the new hydraulic tensioner. A new pulley is preferred though.
13. Re-install the main belt first, and the AC belt second.
14. Put everything back together

Attached is a picture of a new hydraulic tensioner, with the pulley removed. You can see where the three 13mm bolts are!