[Jeremy03Sport]

I have a 2003 Sport, AWD, V8. Tensioner pulley bearings failed. It was bad long enough that I was unable to just replace the pulley. The shaft on the tensioner was worn. FYI, the pulley is only $20 from auto parts store. To remove, bolt is reverse thread - righty, loosey.

I purchased an aftermarket tensioner from autoparts store for about $55.

To replace:
1. Disconnect ground from battery - 10mm socket
2. Pull front skid plate - 4 bolts, 12mm socket
3. remove plastic engine cover plate - 2 nuts, 10mm socket
4. remove air intake from airbox to engine - loosen 2 clamps on either end with 10mm socket. remove vacuum hoses and set aside
5. remove serpentine belt, if not removed already. use 14mm socket on pulley and pull to left (ccw) to remove tension
6. Next remove the timing belt cover, there are two pieces. The left side has 3 bolts and 1 nut, 10mm (pictured). The right side has 2 bolts, 12mm (not pictured, but just to the right of the tensioner).

7. Remove tensioner fasteners - 1 bolt and 3 nuts, all 12mm. One nut shares a stud with alternator. (I put arrow by wrong nut, arrow on lowest left nut, should actually point to one just above and to left). The one I'm pointing to is strictly a alternator fastener.

8. Remove alternator fasteners - 1 bolt (accessed from below), and 1 nut from top side of alternator, both 14mm. The third nut (12mm) is shared with the tensioner and was removed in step 7.

9. Remove power steering pump fasteners - 2 bolts and 1 nut, all 14mm. Access through the hole in the power steering pulley.

10. slide power steering pump toward front of vehicle. Slide alternator off stud shared with tensioner. Pull out tensioner.
11. Assemble in reverse.

I have more photos available if more detail is needed.

[captaininsano]

This post as well as this recent video post on youtube helped with the install of the new assembly.

https://www.youtube.com/watch?v=jCbXOUcRBLs

https://www.youtube.com/watch?v=hkiSgype2Qk

Took me about 6 hours as the stud that holds the plastic cover on the timing belt threaded off instead of the tophat nut.

I also was able to do the entire replacement without removing the radiator hose and having to mess with the re-fill of the fluid. I will say it would have definitely made things easier.

[JoeToyota]

I also just used this post as reference. Was a lot of help. Solid pictures.

Chirping at idle was my issue. Previous owner had replaced serpentine belt about 7k miles ago for the same reason. Turns out the tensioner was the original issue.

I was able to do %99 of the work from the top. I only was below the car to remove the shield and remove the bottom alternator bolt, then to tighten that lower bolt upon reinstalling and replacing the shield. I did not open the cooling system. I've got long arms though.

The friggen top-hat nut gave me a bit of grief. I just left it stuck and continued turning until the stud came out of the block. From there I was able to work around the timing belt cover by just shifting it. Without that top-hat nut getting stuck I could have gotten close to 2 hours work time..

Took me 2 hours 40 mins in my garage which is about 0F right now and no power tools. Seemed like a terrible job upon researching. If you can work in tight spaces with your hands, then with this write-up you will get it done in no time.

[Swimupstream]

Thanks for all this gang. Anybody know of any of the same for a 4th gen V6? Can't find a stinking thing. Hope I'm just looking past it.

Got no problem giving it a shot, but I know, like you said, might save me a couple struggle points by reading ahead and getting to my cocktail early enough!

[grocery_getter]

I've removed the bolts to the p.s. pump and can't get the dam thing to budge. I was tempted to bang it woth a 4lb hammer bit dont want to damage the pulley. Any suggestions?

I know this thread is dead but I figured it give it a shot.