1. Excessive tensioner movement at idle (more than 1/4”)

1. Internal wear
2. Pulley is out of round
3. Loose mounting bolts

1-3. Check mounting bolts, if ok, replace tensioner

2. Tensioner tilted, misaligned or gap exists between tensioner and arm base

1. Environmental damage
(i.e. heat, water, stones)
2. Poor tensioner mounting surface
3. High internal wear

1-3. Check mounting surface, if ok, replace tensioner

3. Cracked/broken tensioner arm

1. Incorrect installation/removal
2. Long-term fatigue failure
3. Tensioner was allowed to snap back against stops

1-3. Replace tensioner

4. Chipped/cracked pulley
(plastic pulley)

1. Foreign material damage
(i.e. stones)
2. Faulty installation procedures

1-2. Replace tensioner or pulley

5. Wear in belt tracking area
(more than .25 mm) (plastic pulley)

1. Extreme environmental wear
(i.e. heat, water, stones)

1. Replace tensioner or pulley

6. Excessive wobble (run-out)

1. Bearing failure
2. Excessive load on pulley
3. Belt is not tracking properly over pulley

1-3. Replace tensioner or pulley

7. Grease appears to be leaking out of the bearing

1. Grease purge
2. Seal degradation
3. Abnormal internal bearing clearance

1-3. Replace tensioner or pulley

8. Pulley has been marred in belt tracking area (steel pulley)

1. Foreign material damage (i.e. stones)
2. Faulty installation practices

1-2. Replace tensioner or pulley

9. Corrosion (steel pulley)

1. Extreme environmental exposure

1. Replace tensioner or pulley

1. Belt Squeal

1. Belt worn or stretched to maximum take-up length of system
2. Tensioner is seized
3. Tensioner is tilted

1. Replace belt
2-3. Check belt length gauge, if length is correct, replace tensioner

2. Tensioner clatters or rattles during engine operation

1. Internal wear/interference

1. Replace tensioner

3. Belt chirping

1. Worn pulley or tensioner (tilted)
2. Cracks in tensioner base or arm
3. Loose mounting bolts
4. Damping system failure
5. System misaligned

1. Replace tensioner or pulley
2. Check mounting bolts, if ok, replace tensioner
3. Re-torque mounting bolts
4. Replace tensioner
5. Check system alignment

4. Pulley makes a high-pitched whine or howling noise after the engine is started

1. Worn bearing
2. Incorrect bearing fit

1-2. Replace pulley if noise continues after 3 minutes

5. Pulley exhibits noise during normal operation.

1. Worn bearing
2. Balls in bearing are loose; grease is degraded.
3. Insufficient bearing lubricant

1-3. Replace tensioner or pulley

6. Pulley and bearing assembly exhibit noise when shaken

1. Broken bearing cage
2. Balls in bearing are loose
3. Insufficient bearing lubricant

1-3. Replace tensioner or pulley

1. Belt does not track properly on pulley

1. Bearing is not fixed to the correct depth in pulley
2. Belt tracking surface is not square to bearing mounting surface
3. Internal tensioner wear
4. Loose mounting bolts
5. System misalignment
6. Incorrect belt length

1. Replace tensioner or pulley
2. Check mounting bolts, verify system alignment, verify proper belt for application, if ok, replace tensioner
3. Replace tensioner
4. Re-torque mounting bolts
5. Replace tensioner and/or components
6. Replace belt

1. Pulley is seized and will not rotate

1. Damaged/failed bearing

1. Replace tensioner or pulley

2. Sticky/notchy feel when rotated

1. Abnormal internal bearing clearance
2. Incorrect bearing fit (in pulley)

1-2. Replace tensioner or pulley

3. Tensioner does nor operate smoothly or will not move

1. Internal thrust surface damage/wear
2. Internal damage/wear
3. Broken spring

1-3. Replace tensioner