Setting water pump belt tension question

Discussion in 'Gen 2 Prius Care, Maintenance and Troubleshooting' started by pasadena_commut, Feb 21, 2026.

  1. pasadena_commut

    pasadena_commut Senior Member

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    Out of curiosity, if one were to loosen the tension bolt for that belt by exactly N turns (whatever it takes to remove the belt), swap on the new belt, and then turn that bolt the other way exactly the same amount, would the belt be at the correct tension? Naively it seems like it would, at least as long as nobody ever readjusted the tension after the previous belt was put on.
     
  2. PriusCamper

    PriusCamper Senior Member

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    That's how they do it on spacewalks outside the spacestation... They have two different people at ground control to help count your rotations too. Of course when not in the vacumm of space you get dirt and grime and belt wear which can slightly change the number of rotations you need. Also a brand new belt will stretch a little and so a tiny bit tighter would be better than a tiny bit looser.
     
  3. BiomedO1

    BiomedO1 Senior Member

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    The short answer is NO. The old belt is worn and stretched and your assuming the new belt is within millimeters of length of your old belt. Tension the replacement belt per OEM manual/procedures. Don't over-tighten them or your going to have bearing and bushing issues.
     
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  4. pasadena_commut

    pasadena_commut Senior Member

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    I'm assuming that nobody ever adjusted the tension on the current belt after it was installed. If that assumption is false it was probably (re)adjusted shortly after the initial installation. Is it common to readjust the tension on this belt on this car in that manner? I have no memory on any of the cars I have owned of a mechanic ever adjusting a belt tension (except when replacing a belt), and I'm certain I never did it myself.
     
  5. ChapmanF

    ChapmanF Senior Member

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    I wonder what the manufacturing tolerance is on the length from one new belt to another.

    I'd probably just set the tension per the instructions and move on to life's next question.
     
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  6. pasadena_commut

    pasadena_commut Senior Member

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  7. Mendel Leisk

    Mendel Leisk MMX GEN III

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  8. PriusCamper

    PriusCamper Senior Member

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    Because there's not a belt adjustment process in the maintenance instructions for modern cars it's safe to assume that there's a wide range a variability for belt tension without issue. And clearly too loose you'll get belt noise and too tight you could get damage parts.

    And clearly, you can always count on someone sitting at home in front of their computer convincing you something irrelevant is really important.

    Kind of like proper torque on on a bolt. Majority of bolts will not be an issue at all if the torque is off... But if you're talking about headgaskest bolts or cam or crankshaft bolts you're gonna want those to be as accurate as possible because doing those wrong can't be easily fixed.

    In other words just go with counting rotations on the tensioner and make it a little tighter than before after you've matched up the two belts to confirm how much tighter than before.
     
  9. BiomedO1

    BiomedO1 Senior Member

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    There's no belt tension adjustment on most modern cars because, they use a spring tensioner on one of the idler pulley.
    You over-tighten a belt, the car won't stop running. Your just going to have to replace your water pump or alternator or whatever that belt is driving a few hundreds or thousands miles down the road. Because your placing an excessive load on those bearings or bushings. If you trash an idler pulley and it seizes up, your going to snap that new belt anyways. Things will last a long time, WHEN properly maintained and kept within specs......

    Generally, you should be able to get anywhere between 1/2 to an inch deflection between your longest pulley runs... That's better than counting bolt rotations and praying that the belt you bought is the EXACT length of the OEM belt - NOT a generic belt that will fit your make and model if properly adjusted.

    Again; your car your money - do whatever you like.....

    @PriusCamper; I'm surprised at your answer since you claim to repair cars for a living. Then again, I guess if it isn't an immediate failure, that's more repeat business for you.....(n)
     
    #9 BiomedO1, Feb 22, 2026
    Last edited: Feb 22, 2026
  10. Mendel Leisk

    Mendel Leisk MMX GEN III

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    Here’s the specifics, the deflection test option, seems fairly typical:

    IMG_3310.png
     
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  11. pasadena_commut

    pasadena_commut Senior Member

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    It is interesting that the "used belt" criterion is applied after only 5 minutes of service. Suggests to me that the belt stretches almost immediately on use and then stabilizes. Also that it doesn't continue to stretch further (unless damaged somehow, for instance one of the rotating parts not rotating freely and applying significant drag).
     
  12. BiomedO1

    BiomedO1 Senior Member

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    It's mostly rubber and subjected to a very harsh environments in a longitudinally mounted engine - behind the radiator, condenser, turbo cooler and possibly transmission cooler. The transverse mounted engine environment is a lot easier on belts, away from all that heat being blown onto them. Since the belt manufacturers don't know where that belt is going to be placed, it's engineered to withstand the harsher climates; so heating them up will seat/settle them into the pulleys. Then a final adjustment can be made. Not as important on a transverse mounted engine, but a requirement on a longitudinally mounted engine; IMHO. If you want to do it correctly.

    Just my 2-cents.....
     
  13. pasadena_commut

    pasadena_commut Senior Member

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    By the way, is the manual correct? It says that bolt B is used to adjust belt tension and bolt A to lock/unlock the pulley position. Every other video and written description I have seen has it the other way around. For instance:

    V-belt and plugs, 200,000 km maintenance. (pictures) | PriusChat

    Looking at the mechanism, it makes a lot more sense for bolt A to control the position of that top pulley, moving it in a direction parallel to the longest span of the belt (and to bolt A), and for B to lock that pulley in place after A has moved it, because B is perpendicular to A..
     
  14. dolj

    dolj Senior Member

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    If you mean in the 2006 RM floating around, then no, it isn't. I posted about that quite awhile ago. I have corrected it in my copy:

    upload_2026-3-15_16-26-42.png

    upload_2026-3-15_16-27-18.png
     
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  15. pasadena_commut

    pasadena_commut Senior Member

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    The funny thing about this pulley, part number 1663021020, is that while it isn't a complicated device, it is really hard to find a decent picture of it. The Toyota parts sites just have a drawing.

    This site has a picture of one taken apart (assembly is an exercise for the user)

    16630-21020 Genuine Toyota Idler Pulley Assembly

    and here is the picture (in case the link breaks)

    TPD.jpg

    These two are from an Ebay ad (not linking it since that link will inevitably break) and show it assembled. Except note the parts don't quite match! The part to the left of the nut on the site above has a smooth side, but on the Ebay part that looks instead like a stack of two washers.

    ebay1.jpg ebay2.jpg

    Anyway, from this it is pretty obvious that the tensioning bolt goes through threaded hole in the head of the odd bolt (so that it can pull the pulley up the groove and stretch the belt), the odd bolt goes through a slot in some piece of metal, and that the locking nut just tightens the flange on the head of the odd bolt and that part (which may or may not have a groove on its side) onto the metal on both sides of that slot (keeping the pulley from moving).

    Aftermarket replacements from RockAuto only have the bearing/pulley part. So best not to break any of those metal pieces!
     
    #15 pasadena_commut, Mar 15, 2026 at 1:43 AM
    Last edited: Mar 15, 2026 at 1:53 AM