Re: Bryan's Tensioner -- AD# 857

["Eric Hambleton" <ejham@domain.elided>]

Having done this job within the last month it's still pretty clear in
my head: the mechanical tensioner 'upgrade' kit should include a stud
that serves as a replacement for the upper bolt used on the hydraulic
tensioner. Also included, should be the revised method for setting
belt tension which, while not difficult, should be followed TO THE
LETTER according to those in the know.

To perform the new method it's helpful to have a mirror in order to
see the tension indicator's position. Also, because of the importance
of accurate tension, I'd recommend cutting a hole in the belt cover
over the tensioner  so that the tension can be checked and reset if
required without removing the cover. (Why couldn't AR have put a
pop-off cover there as they do with the cam pulley caps?!?)

If you don't have the instructions for tensioning, perhaps Alfa Bill
at Mastro could fax you a copy in exchange for a Newcastle on his next
lap of the US. Or perhaps you could make your next purchase through
Mastro? I would, but the sheet (as with the majority of my
possessions) is in storage at the moment.

If no options for obtaining the instructions are available to you,
accept this procedure from my memory:

This all should be done at 'high room temperature' (80-90 degrees).

1. Align the engine to TDC.
2. Using a torque wrench and a 6-inch 3/8 extension placed into the
square opening on the tensioner, loosen the tensioner's retaining
bolt, apply 17 pounds of torque, and tighten the bolt.
3. Roll the car forward in 4th or 5th gear, fully rotating the engine
4 times and returning to the TDC mark. If you miss the mark, DO NOT
ROLL THE CAR BACKWARD!!! Continue forward until you reach the mark
again.
4. Apply your wrench to the square hole again and carefully loosen the
retaining bolt until the tensioner begins to move.
5. Reduce tension until the tension indicator points to the mark and
then tighten the retaining bolt. Note: If you allow the tensioner to
slip past the optimum mark, you MUST repeat the entire process! (Go
slow! I speak from experience.)
6. Rotate the engine 4 more times to verify that the tension remains
at spec. If it does not...guess what?...repeat the process.

You are done. If anyone has anything to add, I heartily encourage them
to do so!

- - Eric Hambleton, Marietta, GA
1983 GTV6 -- Felicite

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