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Corsa C alternator belt tensioner problem URGENT

Discussion in 'Astra, Corsa, Zafira, Meriva, Adam, Agila, Tigra & Nova [Includes AstraVan & ComboVan] owners forum' started by johnscotty, Dec 18, 2008.

  1. johnscotty

    johnscotty New Member

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    Location:
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    Changed the alternator on my daughters corsa today. In order to get to the bottom alternator bolt, I loosened the top tensioner bolt and had to remove the bottom one. Fitted the new alternator no problem.................but I can't get the bottom bolt back on the tensioner. I tried a G clamp, coil spring compressors but just can't get the spring back enough to get the bolt in.

    Is there a technique to do this or is there a special vauxhall tool?

    Your comments would be much appreciated since the car is currently off the road!

    Thanks

    John
     
  2. fronteratech

    fronteratech VXON Resident 4x4 and diesel specialist

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    Location:
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    you should be able to hold in position with small bolt holding tension there is a hole on tensioner body that aligns with rotating part of tensioner

    remove after lining up belt
     
  3. les mason

    les mason New Member

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    belt

    if its the same as the 1700 di or similar,
    like the previous post.
    full explaination in haynes manual.
    there is a small hole to put a bolt in which holds the tensioner in place. to slacken the tension, ise a spanner to grip the centre bolt in the tensioner as a lever to move it into position then put the holding bolt in to keep it there.
    i may not of explained very well, but if you get a haynes manual it tells you clearly in there, under auxillary belt change.
     
  4. greasemonkey

    greasemonkey VXon Frontera Monkey VxON Club Member

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    Location:
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    Drives:
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    hi there is only one long torx bolt for the tensioner as said use a 15mm spanner to release the tension then lock it off using a split pin
     
  5. johnscotty

    johnscotty New Member

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    Location:
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    Thanks people - typically I am away from home doing the job unscheduled (my daughter had been due home at christmas for me to do it then where the manual was but the alternator took a turn for the worse and I was working away from home and diverted enroute home). Unfotunately Halfords didn't have the correct Haynes manual tonight (they never seem to have the one I want!) Does the tensioner I have (corsa C 1.2) feature on any others specifically (I could get a manual for something else (older newer) if it is the same? It is the one with an elongated spring with a pulley in line at the top, held by the bolt in the pulley and a bolt at the bottom.

    Just to enlighten me a bit more whilst I don't have any literature to guide me, I just had a quick look with a torch - is the hole you refer to in the pulley above the tensioner spring, I presume to the outside of the large washer held by the torx bolt. (I have torx sockets by the way). I couldn't just see anything by torchlight but I may have been looking for something bigger than a splitpin (I presume the hole is in one of the pulley segements).

    Once again your help is much appreciated.

    Thanks

    John
     
  6. johnscotty

    johnscotty New Member

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    Location:
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    A friend sent me some copies of a Corsa B manual which shows the belt tensioner - however this is not like the one fitted to mine, That one indeed shows a pin being used to lock the tensioner. In the picture, the spring appears set behind the pulley, I imagine mounted on the engine block.

    With mine the tensioner sits tranverse from the camshaft towards the drivers feet, with the pulley then the spring in line elongated down towards the alternator. I notice on ebay one which looks similar to mine (item No
    [FONT=&quot]230312197467) though I hadn't been aware of the top mounting (if this is the same (it certainly looks similar in style)).

    If this is different from the one requiring a pin, any advice on this one?

    Re-looking at it, I notice there is a top bolt - I presume undoing this will then allow me move the tensioner in order that I can then refit the lower bolt?

    Thanks

    John

    [/FONT]
     
  7. JnX

    JnX Member

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    Location:
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    Vauxhall Corsa B 1.2L 16V Petrol (1993 - 2000) - Auxiliary belt and tensioner replacement. IT IS NOT A FAN BELT as these cars have electric fans.


    Pretty advanced and intense piece of work and requires a reasonable amount of mechanical knowledge. Torx (E14, E12 and E10) sockets (both 3/8 and 1/2 inch drive,
    different overall lengths) are required and colourful language.


    The auxiliary (or accessory) belt is located at the front of the engine (o/s/f), left, as you look under the bonnet. It is a multi ribbed belt approx. 20mm wide and drives the
    alternator, water pump and A/C (if fitted) from the main crankshaft pulley. The tensioner provides automatic belt adjustment as it stretches with age.


    Incidentally, as of 10/2011, a GM genuine tensioner is £85 retail, although it's complete and compressed (has a steel pin located in a ribbon fed thru the spring that has to
    be removed after completing a total install).
    A new belt from Halfords costs £8. An E14 3/8 socket, £3.99.


    To see the belt, proper, you need to remove the airbox. Straight forward if you're able to do an air filter replacement.
    i. Remove the elbow that links to the airflow sensor housing. You don't need to remove the sensor section.
    ii. Remove the intake section at the front by turning the plastic latch a quarter of turn, lever out and remove.
    iii. Pull the airbox up from the front and coax the rubber feed thru grommet with a blunt screwdriver, nothing sharp.
    iv. Pull the filter box forward to release it from it's rubber mountings and remove.


    The bolt that secures the tensioner (not the bottom one) is almost obscured by the centre engine mounting casting and obstructs getting a spanner or socket in there (E14).


    Removing the front engine mount can be done with a lot of patience and improvising.


    These are suggestions that worked for me.


    1. Remove the airbox gubbins as described above.
    2. Remember how the belt routes through the engine mount and around the accessories and tensioner (draw a diagram if necessary).
    3. Remove the o/s/f wheel, ensuring you've jacked the car up and left it on an axle stand. You'll need the hydraulic jack to support your engine.
    4. Remove the plastic splash guard, 2x hex screws, visible in the wheel arch and 2x Torx T front underside.
    5. Remove the spring tensioner bolt (E12) visible through the wheel arch and swing the spring up. (This works for a failed alternator so far).
    6. Remove the crankshaft pulley making sure you mark, with a wax crayon or scriber at it's current position (it has a nick on the outer edge for TDC indication so needs to be put back exactly as it was removed).
    7. Remove the water pump pulley (use a 25mm spanner or adjustable to hold the spindle) 3x E10.
    8. Position your jack under the sump, with a block wood and lightly apply support.
    9. Remove the nut and bolt (15mm hex) securing the engine mounting to the bulkhead from below.


    Engine Mounting Removal


    1/2 inch drive sockets are too deep, unless you have a really slim set and a slim ratchet driver. Enter the 3/8" E14 from Halfords. The exposed bolt is easy to remove, although
    you can't pull it all the way out due to length and the bulkhead.
    The centre bolt can be loosened and withdrawn once the jack under the engine is lowered below the wheel arch. But, don't lower the engine just yet.
    The front most mounting bolt is the challenging one. As it's so close to the chassis and recessed by about 25mm or so, use your 1/2" drive E14 with a t-bar to loosen the bolt. From there on,
    I used the 1/2" (approx 2" long) adapter from my reversible torque wrench and a 1/2" spanner to fully disengage the bolt.


    At this point, lower the jack slightly supporting the engine. The engine mounting won't lower unless you provide a bit of brute force (gets stuck on the bolt).
    You can manoeuvre the engine mounting to remove the tensioner in it entirety.
    As we removed the crank pulley earlier, you can now pull the engine mount through the bottom.


    All good so far, we've tightened the top bolt of our new tensioner, positioned the belt roughly around our re-fitted crank pulley and the tensioner.


    Remove the visible engine mount bolt (the 1st bolt). Removal of the water pump pulley allows far more manoeuvrability while making sure the belt routes
    correctly through the engine mount and allows us to insert the 1st bolt whilst almost in position.
    If you don't remove the 1st bolt, you can't reposition the mounting around the new tensioner and belt.


    Make sure bolt 2 and 3 are in the mounting - It's almost impossible to put them back otherwise.


    Position the engine mounting and tighten back onto the engine.


    Re-fit the water pump pulley. The belt will be too tight to just re-fit, so get an edge onto the water pump pulley and rotate the crankshaft to fully engage the belt.


    Jack up the engine to secure the engine mounting nut and bolt.


    Re-fit the lower tensioner bolt. Sounds straightforward, but not quite as simple as it sounds. For a new tensioner, the bolt almost lines up, but requires a bit pressure
    from the jack, bit of wood and a bar. The same applies to an old tensioner but requires using screwdrivers to basically get it into position and applying the same
    techniques as in the previous sentence. For a new new tensioner, as mentioned before, the steel pin can be removed by hand from the top.


    If you've got this far, you're home.
     
  8. clutchman-2008

    clutchman-2008 Corsa c specialist

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    Location:
    dartford,kent
    Im asumming its a 1.0 or 1.2 petrol? if so fit the bottom bolt first and screw it in 4 or 5 turns,then you will be able to push down from the top and the top bolt will locate,tighten them both up and then fit the belt
     
  9. clutchman-2008

    clutchman-2008 Corsa c specialist

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    Location:
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    Just saw how old this was!!!!!!!!!!!!!!!!
     
  10. JnX

    JnX Member

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    Location:
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    Clutch, I know - but I hadn't done one of these for ages and my daughter had bought a Corsa B and hadn't seen a similar post ..
     

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