Accessory Drive Belt — Tensioner Replacement (Opel Zafira A)

The tensioner is automatic. The device is subject to replacement if there are signs of insufficient tension of the auxiliary drive belt: with a sharp increase in the crankshaft speed, when powerful electrical consumers or the air conditioner are turned on, a squeal (whistle) is heard from the engine compartment. If play or jamming occurs, the roller can be replaced separately, without resorting to removing the entire device.

Recommendation: Replace the tensioner assembly with the roller.

Note: The work is shown on the example of replacing a 1.6 DOHC engine. On other engines, the operation is performed similarly.

Replacing the tensioner roller

1. Loosen the tension of the auxiliary drive belt and fix the tensioner in this position (see "Accessory Drive Belt - Checking Condition and Replacing").

2. Using a 15 mm open-end wrench, unscrew the bolt securing the roller to the device.

Warning! The roller mounting bolt has a left-hand thread - turn it clockwise!

3. Remove the roller and its mounting bolt.



4. Install the parts in reverse order.

Replacing the tensioner

1. Prepare the car for work (see "Preparing the car for maintenance and repair"),

2. Remove the accessory drive belt (see "Accessory Drive Belt - Checking Condition and Replacing"),

3. Using an 8 mm socket wrench, unscrew the rear mudguard mounting bolt.



4. Unscrew the bolts securing the mudguard to the front bumper trim (see "Front fender liner - removal and installation").

5. Move the mudguard back and use an 8 mm wrench to unscrew the front mudguard mounting bolt.



6. Using the same key, unscrew the two lower bolts securing the mudguard and remove it.



7. Using the TORX E14 key, unscrew the tensioner mounting bolt.





8. Remove the tensioner.



9. Install the parts in the reverse order. When installing, align the protrusions on the tensioner...



...with recesses on the cylinder block.