1. Chipped/cracked pulley

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

1-2. Replace tensioner

2. Wear in belt tracking area (more than 0.25)

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

1. Replace tensioner

3. Excessive wobble (run out)

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

1-3. Replace tensioner
4. Check mounting bolt(s) problem

4. “Irregular” belt tracking area (mold sink)

1. Poor plastic molding
2. Abnormal plastic shrinkage rate

1-2. Replace tensioner

5. Melted pulley

1. Component in system is failed or failing

1. Replace tensioner
1. Replace suspect component

1. Cracked/broken tensioner arm

1. Incorrect installation/removal
2. Tensioner was running with stop contact

1-2. Replace tensioner

2. Excessive tensioner movement during engine idle

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

1-3. Check mounting bolts and – re-adjust tensioner if bolts are tight, replace tensioner

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

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

1. Check mounting surface
2-3. Replace tensioner

4. Tensioner will not operate smoothly or will not move

1. Internal thrust surface damage/wear
2. Internal damage/wear
3. Tensioner adjusted incorrectly

1-3. Verify tensioner installed position. If tensioner appears worn, replace

1. Belt noise

1. Belt worn or stretched to maximum take-up length of system
2. Tensioner adjusted incorrectly

1-2. Check tensioner installed position. Verify if belt is correct

2. Tensioner clatters or rattles during engine operation

1. Tensioner incorrectly installed; stop contact
2. Loose mounting bolts

1-2. Check tensioner installation

1. Belt does not track properly on pulley running surface

1. Loose mounting bolts
2. System misalignment
3. Faulty component (i.e. water pump)

1-3. Check mounting bolt, verify system alignment. Replace tensioner