Accessory belt tensioner replacement the EASY way HOWTO
 

Hello Friends,

Yesterday after work, I tackled the accessory belt tensioner on my wife's 99 A6 Avant. The car has 90k miles and the accessory belt tensioner was making grinding noise. Unfortunately, I live in the cold state of Michigan so I was hoping for a quick way to do this. I did not feel like spending hours in my unheated garage doing the job the the "proper" way (by placing the radiator support in service position). I think, I stumbled on an easier way.

Here is what you need to do:

1. Remove the top engine cover (4 pop screws).
2. Remove the front air intake scoop (2 screws).
3. Remove one screw that holds the electric fan to the rad support. The screw is easy to see, it is very small but located on top of the electric fan . After you remove that screw, you can unclick the electric fan and swing it out of the way to your left. This is the trick that makes it work. Otherwise, you will NOT be able to remove the tensioner due to lack of space.
4. Remove the tension on the tensioner - 17mm socket and breaker bar is used for this.
5. Unbolt the tensioner - 10mm allen bit.
6. Now you will be able to maneuver the tensioner out of the way and fetch it from the top.
7. Lower the new tensioner the same way and start the bolt a few turns by hand. Then you will notice that there is a notch on the tensioner that has to find its place on the engine block. After you find its position, bolt the tensioner all the way.
8. Route the belt over the new tensioner. Release the tension (remove the pin that comes with new tensioner).
9. Remember to re-install the electric fan back.
10. Start the engine and marvel at how quietly it idles!
Good luck!

Nice work. I usually just pull the nose.. I've never messed with the fan..

Damn. Next time I think I'll do it that way! lol

ditto. Now... figure out a similar method for the TB and I'll share some of my garage peanuts.

Good job! I have to admit I wouldn't have even thought of doing it that way.