9000 Belt Tensioner Broken Bolt Repair - Saab 9000 Bulletin Board - Saabnet.com
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9000 Belt Tensioner Broken Bolt Repair
Posted by Tom Remedios [Email] (more from Tom Remedios) on Tue, 13 Sep 2011 21:09:43
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The upper belt tensioner bolt on my 94 9000 Aero broke for the third time. This is the one that goes into the timing cover. The first time it happened I was able to extract about 2/3 of the broken bolt and then helicoil the hole for a stronger M8 fastener. This bolt is under a lot of stress and experiences a shock load from the tensioner movements. It broke a second time but I was able to drive the car home since there was still sufficient tension left to run the water pump and other accessories. This third time there was no tension to run the water pump etc so I came home on the hook.
The fix is to remove and repair or replace the timing cover – huge pain in the rear and may also damage the head gasket (double the fun). So I decided to build a supporting bracket to avoid this problem once and for all. The bracket I came up with attaches to 2 bolts on the head and the lower tensioner bolt. I reinforced the bracket (16 gauge) with a brace and made a bolt retainer clip. Even if the bolt breaks at the timing cover, the brace will support the tensioner and the retainer clip will hold the broken bolt in place. The tensioner pivots freely and I can still use my tensioner tool and remove the tensioner pulley without removing the bracket.
It’s been about 2 weeks so far and it’s working great!
Tom
posted by 99.8.18...
Posts in this Thread:
- 9000 Belt Tensioner Broken Bolt Repair, Tom Remedios, Tue, 13 Sep 2011 21:09:43 <-- Viewing This Message
- Re: 9000 Belt Tensioner Broken Bolt Repair, RodM, Wed, 14 Sep 2011 14:20:53
- Re: 9000 Belt Tensioner Broken Bolt Repair, James, Wed, 14 Sep 2011 03:38:26
- Very ingenious, derf, Tue, 13 Sep 2011 21:38:40
- Re: 9000 Belt Tensioner Broken Bolt Repair, Tom Remedios, Tue, 13 Sep 2011 21:11:59
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