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Two people may help to do it. Here is how i did it. BEFORE i had loosend the tensioner plunger body, i put a little rivit(or nail) in the tensioner holes to keep the tensioner depressed when i loosened it. Works great.(assuming proper belt tension was there previously) When putting it back on, you want to have the crank gear arrow 1 belt notch toward the firwall, in front of the arrow on the block. Then thread on the new belt, staring at the crank gear, then around the waterpump, then the cams. when its around the last cam gear, it should be tight to that point. Be sure the cam gear marks are still lined up ( - - ) Now thread the belt over the tensioner pulley,then turn the crank back to line up the marks, and I used a 1/2" drive, click-type torque wrench, put it on the tensior pulley, and pull back on the wrench till it clicks at the setting of 20 ft lbs. Hold the wrech steady with that torque. Now, at the same time, you want to push up on the tensioner plunger body as tightly as you can, up against the tensioner pulley. I used a big flat blade screw driver to pry up on it tightly against the tensioner pulley. Now while you are doing both of these things, tighten down the tensioner body to the block. Now, if the tension is correct, you should be able to let off the torqure wrench, and pull out the pin from the tensioner. If you cant, or the pin is really tight, RE DO THE TENSION!! Its not perfect until that pin pulls out with very little resistance. IMO, you may have damaged the old tensioner plunger, or its just plain worn out. I would get a new one if i were you...unfortunately, they are not cheap, 100+ bucks, only available at the dealer...but i wounldnt put it back together without a new one IMO. Using a vice, gently compress it, and put in the nail. It should be rather hard to compress with the vice also..
 13.5 @108 MPH-2.2 60ft(stupid FWD!) S16G @ 18 PSI/FMIC/Running on MegaSquirt II (Now with sequential fuel injection) My webpage: http://eclipsed4evr.home.comcast.net -1998 Mitsubishi Eclipse RS-T- "Toy" -1992 Plymouth Laser Turbo AWD(SOLD) -2000 Honda CR-V(daily)
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