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Front belt tensioner bearing replacement - with pictures
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ridgeback_moor
 


Member Since: 11 Mar 2008
Location: Gateway to the Moors
Posts: 1789

United Kingdom 2010 Discovery 4 3.0 TDV6 HSE Auto Stornoway GreyDiscovery 4
Front belt tensioner bearing replacement - with pictures

After a few weeks of loud squealing (initially at 2000-2300rpm, but eventually at all revs), the bearing of the front serpentine belt tensioner finally failed recently. I wasn't able to get hold of a complete tensioner on the day I needed it, so I opted to change just the bearing. The following pictures may help anyone looking to do the same.

Here you can see the failed tensioner, sitting off centre due to the lack of ball bearings! I drove about 30 miles with it like this Shocked
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Removing the belt shows the problem a bit clearer. A 3/8 square socket drive (as shown) is used to rotate the tensioner, allowing the belt to be slipped off.
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Once the tensioner is off (by removing the long bolt on the lower part) the problem is quite obvious!
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Removing the remains of the bearing from the tensioner pulley. A hammer and screwdriver will get it out, although it will take a bit of time as it needs to come out bit by bit, rotating it after each tap.
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That did the trick Very Happy
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The remains of the inner bearing are easily unbolted from the tensioner arm:
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Tensioner pulley, remains of old bearing, and brand new bearing. The bearing is a standard size - 40mm OD, 17mm ID, 12mm Thick, sealed on both sides. This one's from Brammer (BSL), SKF part number 6203-2RSH. 6203 relates to the sizes, 2RSH is the seal spec. I'm not sure what the H stands for, but a 6203-2RS is also fine. They are cheap on eBay - just google the part number. I needed mine asap hence Brammer, where it cost about 7 quid.
Click image to enlarge


New bearing ready for pressing in:
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Using a suitable socket (my 32mm socket had a 39.5mm OD which was perfect - make sure the pressure is on the outer part of the new bearing, not the inner) the bearing can be pressed in with the help of a vice and smear of grease. No need to heat anything up - it's not that tight.
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New bearing in place:
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Pulley bolted in place on the tensioner arm:
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Job done Cool
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The tensioner is then bolted back onto the front of the engine - ideally the fan should be removed to give you enough room to work. An extra pair of hands is also useful to slip the belt back onto the pulleys whilst the tensioner is held back with the 3/8 socket drive, as in the 2nd picture. I didn't take any photos of this stage because I was too busy swearing and trying to make a tool to remove the fan. 1 divorce and 3 upset neighbours later, job done Mr. Green
 Previously:
2005 D3 2.7 TDV6 S
1984 90 2.25 Petrol CSW
1992 90 200TDi Hard Top
1995 Discovery ES 300TDi
2003 90 TD5 Truck Cab

 
 
Post #59250129th Jan 2010 3:32 am
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Bushwanderer
 


Member Since: 27 Nov 2007
Location: Northern Rivers, NSW, Australia
Posts: 2048

Australia 2005 Discovery 3 TDV6 S Manual Buckingham BlueDiscovery 3

Hi RM,
Great explanation! Thumbs Up

Best Wishes,
Peter
 The Bearded Dragon  
Post #59250429th Jan 2010 4:02 am
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Matty 2332
 


Member Since: 02 Dec 2008
Location: West Yorkshire
Posts: 580

United Kingdom 2005 Discovery 3 TDV6 Base 7 Seat Manual Vienna GreenDiscovery 3

Thanks RM, very interesting Thumbs Up
  
Post #59252229th Jan 2010 6:46 am
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bellautos
 


Member Since: 02 Feb 2006
Location: NorthYorkshire
Posts: 2518

United Kingdom 2010 Discovery 4 3.0 TDV6 SE Auto Santorini BlackDiscovery 4

Nice job mate. This should be in a wiki
  
Post #59259329th Jan 2010 9:38 am
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Slimer
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Member Since: 06 Jan 2005
Location: Last Exit to Nowhere
Posts: 16289

United Kingdom 

I'll add it to the Wiki (just as soon as I've got Martin the fix it!)
 The End  
Post #59260929th Jan 2010 9:51 am
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discoBizz
 


Member Since: 20 Sep 2008
Location: Manchester
Posts: 1394

United Kingdom 2008 Discovery 3 TDV6 HSE Auto Tonga GreenDiscovery 3

Nice one RM! Thumbs Up

Cheers!
  
Post #59268429th Jan 2010 11:25 am
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MikeT
 


Member Since: 31 Aug 2008
Location: Lancs
Posts: 258

United Kingdom 2007 Discovery 3 TDV6 HSE Auto Java BlackDiscovery 3

great article - well done.

As a foot note, it took my stealer's three, yes 3 visits to do this job under warranty!
  
Post #59292529th Jan 2010 4:21 pm
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wiggs
 


Member Since: 03 Sep 2006
Location: Manchester
Posts: 14363

United Kingdom 2015 Discovery 4 3.0 SDV6 HSE Auto Fuji WhiteDiscovery 4

Excellent work again Thumbs Up

Thanks for sharing Bow down
 G4 Gone ...but not forgotten  
Post #59293629th Jan 2010 4:43 pm
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ronp
 


Member Since: 29 Nov 2006
Location: 🌲Galloway⛰
Posts: 14021

Scotland 2014 Discovery 4 3.0 SDV6 HSE Auto Corris GreyDiscovery 4

...... and here's one I made earlier Rolling Eyes

Click image to enlarge
 🌲🌲in the forest & the hills ⛰⛰  
Post #59294229th Jan 2010 4:48 pm
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DISCOJASE
 


Member Since: 07 Dec 2008
Location: Harrogate / London
Posts: 679

United Kingdom 2015 Discovery 4 3.0 SDV6 HSE Lux Auto Montalcino RedDiscovery 4

Great write up! I had the same problem a few weeks ago, took mine out and was caked in mud Whistle Didnt bother trying to clean it or anything as my local dealer had one it stock (about £30 something). All better now and no squealing now at all! Thumbs Up
 Filming something somewhere...  
Post #59300529th Jan 2010 6:44 pm
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drmcw
 


Member Since: 10 Mar 2009
Location: 9/10 people have trouble Reading
Posts: 1575

United Kingdom 

Nice one Thumbs Up
Wonder where the ball bearings are Question
  
Post #59301729th Jan 2010 7:02 pm
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ridgeback_moor
 


Member Since: 11 Mar 2008
Location: Gateway to the Moors
Posts: 1789

United Kingdom 2010 Discovery 4 3.0 TDV6 HSE Auto Stornoway GreyDiscovery 4

The ball bearings will be on the A30 somewhere between Redruth and Bodmin! Surprisingly, it made less noise without them, but I wouldn't recommend driving far with it like that. Ron, yours looks about the same as mine did - when was that? I think deep mud wading caused mine to eventually fail, but I've done 100,000 miles now so not bad going.
 Previously:
2005 D3 2.7 TDV6 S
1984 90 2.25 Petrol CSW
1992 90 200TDi Hard Top
1995 Discovery ES 300TDi
2003 90 TD5 Truck Cab

 
 
Post #59324930th Jan 2010 2:49 am
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ronp
 


Member Since: 29 Nov 2006
Location: 🌲Galloway⛰
Posts: 14021

Scotland 2014 Discovery 4 3.0 SDV6 HSE Auto Corris GreyDiscovery 4

ridgeback_moor wrote:
Ron, yours looks about the same as mine did - when was that?


Mine went around 115k last year.
When I first heard it I was pulled up outside an industrial unit in North Tyneside.
Thought the clatter was someone opening up a chain pull roller shutter.

All my bearings would've been strewn down the A19,
as I managed to drive it the 90miles back to North Yorks.
Looking at the condition of it, I was in total amazement that I actually made it
 🌲🌲in the forest & the hills ⛰⛰  
Post #59335930th Jan 2010 11:49 am
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J@mes
 


Member Since: 10 Nov 2008
Location: Bomber County
Posts: 4449

England 2014 Discovery 4 3.0 SDV6 XS Auto Corris GreyDiscovery 4

Great guide, thanks! Mine has just started to squeal every so often, so I think I'll get it changed before it goes properly!
 2014 D4 XS
2005 D3 SE - Gone 
 
Post #59336330th Jan 2010 12:06 pm
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J@mes
 


Member Since: 10 Nov 2008
Location: Bomber County
Posts: 4449

England 2014 Discovery 4 3.0 SDV6 XS Auto Corris GreyDiscovery 4

Got any dimensions for your fan removal tool?
 2014 D4 XS
2005 D3 SE - Gone 
 
Post #59411431st Jan 2010 5:42 pm
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