What is the proceedure for replacing the tensioner pulley once the belt is off? Anything special to make it easier or is it pretty straight forward? Thanks

 

one bolt holds it in place, you can do it from the bottom with the fan shroud in place.. I would go with the newer ones that have a metal pulley, replace the belt while your at it and keep that one for a spare..

 

I just replaced the belt about 5k miles ago but like a dummy it didn't dawn on me at the time to change the pulley while I had the belt off. I assume the bolt just backs out and you swap the pulley and put the belt back on. I did keep the old belt as a spare when I changed it out.

 

So simple a CTD driving cave man could do it.. it's kinda tight working between the shroud and engine but you can do it. take note of the line up tab / hole and re-install it.

Here is the belt routing pic if you need it:

 

FYI if the tensioner is still fine and just the pulley bearings are shot you can purchase just the pulley from Autozone (Dayco brand, same plastic pulley that came stock on mine anyway). Much cheaper alternative to replacing the whole assembly.

 

I replaced mine at 200,000. It was worn maybe about .060". Pretty bad. I also replaced the top stock idler. It was OK but definitely not as smooth as the new one. Slapped in a new belt, water pump and thermostat too. Still going strong at 256K.