So i broke my timing belt while outta town. I bought a new one, & replaced it on the side of the road with a buddy. However, I over loosened the tensioner bolt, removing all tension on the spring. No matter what i did, i just couldn't reinstall the spring without that infamous tool. So i installed the belt without the tensioner, just so i could get it home. Well, that was about 10k miles ago. I really need to get it done the right way before the belt inevitably stretches & jumps timing at some point. Pardon the novel, but what do i have to do to get that stinkin spring on without the tool?

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Red 1996 2.3 Flare-side
Manual Tranny.
Totalled Gold 1999 2.5 for parts.

The only tool I have used is a pry bar. The tensioner spring is mounted on a post, and can twirl around freely until it meets the backside of the tension arm which carries the idler pulley/wheel.
The tensioner spring tension is 'factory set'. You just have to use a prybar to move the tension idler away from the belt, and tighten the mouting bolts to hold things in place.
Replace the belt, and loosen a bolt or two, and the tensioner will spring into action, and set proper tension all by itself. Tighten the tensioner mounting bolts to hold things in place. Check that the belt is installed properly by rotating the crankshaft at least two turns, and do a final tightening.
There is no adjustment.
tom

Thx a lot for the info. I'm sure this will all make sense when i open the engine up again. On a side note, i bent the tensioner bolt while trying to reinstall the dam spring.

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Red 1996 2.3 Flare-side
Manual Tranny.
Totalled Gold 1999 2.5 for parts.

I thought I posted this before, but it must have fallen into the bit bucket....

I would replace the bent bolt if it changes the angle of the idler pulley when it bears on the backside of the belt. You may suffer unusual wear if the tensioner is applied at any sort of an angle from flat.
You may find an exact match at Ace Hardware, or Fastenall, though I have not been in a Fastenall store. Both of the local (within 5-10 miles) Ace stores have a huge selection of fasteners, English & Metric.
tom

Very much appreciate the info man, thx.

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Red 1996 2.3 Flare-side
Manual Tranny.
Totalled Gold 1999 2.5 for parts.

Thanks again for all the advice. I was able to get it on finally. However, i seem to have thrown the timing off a bit while reinstalling the spring. Here's my problem. The lower part of the inner/rear black plastic piece that houses the timing belt has broken off. I'm referring to the piece with the diamond mark engraved on it. Is there any possible way to accurately time this engine without that piece?

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Red 1996 2.3 Flare-side
Manual Tranny.
Totalled Gold 1999 2.5 for parts.

Counting the teeth perhaps?

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Red 1996 2.3 Flare-side
Manual Tranny.
Totalled Gold 1999 2.5 for parts.

Find another engine, in a truck or a boneyard, measure where the diamond is located from a piece that is still intact on your engine. Adjust using that measurement. The engine won't care how you did it.
I don't have one like yours, mine's old. The triangle is on the cam sprocket, and the diamond is on the aux shaft, right? If so, you should be able to get close using the above.
tom

Thanks so much. Yeah, it's the cam triangle mark that broke off on the plastic piece.

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Red 1996 2.3 Flare-side
Manual Tranny.
Totalled Gold 1999 2.5 for parts.