This procedure may come in handy to remove the main serpentine drive belt tensioner assembly. Also, it is highly recommended to remove the tensioner to replace the pulley or install a new tensioner assembly which should come with the pulley.
Note: Make sure engine is cool.
Note: Disconnect battery negative cable before starting work.
1) Sufficiently drain coolant.
2) Remove serpentine drive belt. Use a 15mm socket on the tensioner pulley bolt and turn counterclockwise to loosen belt. For clearance to get to the tensioner pulley bolt on '99-'03 models remove the coolant reservoir first.
3) Remove alternator. Use 15mm short and deep sockets on mounting bolts.
4) Remove heater hoses from tensioner fittings. <-- Or you can leave them connected if doing just a LIM job.
5) Remove tensioner retaining bolts. Total 3 bolts 15mm socket size. See pic.
6) Remove tensioner from engine. Note: While removing tensioner you will be removing the large 90 degree plastic elbow that connects to the lower intake manifold and at the same time the shorter 90 degree elbow to the water pump. You may have to pry or pull hard on the tensioner to get it off.
7) Installation is reverse.
8) Use new o-rings on the elbows. GM/Delco elbows will have the two o-rings. Inspect elbows for cracks or damage. Replace, if necessary. In most cases the ends of each elbow will break off during tensioner removal requiring replacement. See pic at this
post.
9) Torque tensioner bolts to 37 ft-lbs.
Applicable to all '99-'03 Grand Prixs with SII 3800 VIN "K" and "1".
Elbow to Lower Intake Manifold (LIM) - GM Part # 24503423
Elbow to water pump - GM Part # 12565082
Tensioner bolt location. Total 3 shown by red arrow and circles. Use 15mm socket.
