806189Q 1 Mercruiser ANODE

Introduction
The problem that is identified below does not have a known permanent solution. Until a permanent solution is known, use the solution that is identified below.Problem
There have been instances of the 369-1255 Tensioner reported to be noisy. Most of the issues have been reported below 100 service hours.Solution
Do not operate or work on this product unless you have read and understood the instruction and warnings in the relevant Operation and Maintenance Manuals and relevant service literature. Failure to follow the instructions or heed the warnings could result in injury or death. Proper care is your responsibility.
Perform the following steps to identify the route cause of the issue.
Table 1
Troubleshooting Test Steps Values Results
1. Assembly Alignment
A. Visibly check the alignment between the following components:
•Refrigerant Compressor
• Belt Tensioner
• Alternator
• Idler Pulley
• Crank Pulley
Auxiliary assembly
Result: There is visible misalignment between the components
Repair: Remove and reinstall the components. Refer to Disassembly and Assembly for the correct procedure.
Result: The alignment is visibly correct.
Proceed to Test Step 2.
Illustration 1 g06276401
(1) Belt tensioner wheel
Table 2
Troubleshooting Test Steps Values Results
2. Spray Water on the Tensioner Wheel
A. Spray water on the belt tensioner wheel (1) to reduce the friction between the wheel and the belt.
B. Run the engine.
Noise
Result: The noise is still present.
Proceed to Test Step 3.
Result: The noise is no longer present. There maybe an issue with the tensioner.
Proceed to Test Step 4.
3. Condition of the Belt
A. Check for rubber debris from the belt around the refrigerant compressor.
B. Check the belt for worn patches.
Belt condition
Result: The alternator drive belts are worn or damaged.
Repair:Replace the belts. Refer to Disassembly and Assembly, Alternator Belt - Remove and Install.
Result: The belts are in a good condition.
Proceed to Test Step 4.
Illustration 2 g06276469
Typical view of the 369-1255 Tensioner
(2) Arm
(3) Arm case stops
(4) Spring case
(5) Spring case stops
(6) Pulley
Table 3
Troubleshooting Test Steps Values Results
4. On-Engine Inspection of the Belt Tensioner
A. Leave the belt and tensioner installed. Determine if arm case stops (3) are contacting or very close to spring case stops (5).
B. Determine if the belt is tracking toward either side of pulley (6).
Inspection
Result: The arm case stops (3) are contacting or very close to spring case stops (5).
Repair: Check that the correct belt is installed. If necessary, replace the belt. Refer to Disassembly and Assembly, Alternator Belt - Remove and Install.
Result: The witness mark created by the belt on the pulley is considerably wider than the belt or the belt is tracking away from the pulley center.
Repair: Inspect the system for misalignment of the pulleys.
Illustration 3 g06276750
Illustration 4 g06276753
(7) Locator pin
Table 4
Troubleshooting Test Steps Values Results
5. Remove the Belt and Tensioner for Inspection
A. Remove the belt. Refer to Disassembly and Assembly, Alternator Belt - Remove and Install .
B. Use a suitable tool to move the tensioner arm over the full range of movement between stops (3) and (5).
C. Turn pulley (6). Check that the pulley turns smoothly and quietly.
Note: New bearings may not turn as freely as used bearings.
D. Ensure that the pulley surface (A) is parallel to the tensioner mounting surface (B). Refer to Illustration 3.
E. Remove the belt tensioner. Refer to Disassembly and Assembly, Belt Tensioner - Remove and Install.
F. Check for evidence of metal-to-metal contact between arm (2) and spring case (4).
G. Inspect arm (2) and spring case (4) for cracks and damage.
H. Inspect arm case stops (3), spring case stops (5), and locator pin (7) for damage.
I. Inspect the tensioner for excessive bearing wear.
Result: The tensioner does not move smoothly over the full range.
Repair: Replace the belt tensioner. Refer to Disassembly and Assembly, Belt Tensioner - Remove and Install.
Result: Pulley (6) does not spin smoothly or the pulley makes a noise when spinning.
Repair: Replace the belt tensioner. Refer to Disassembly and Assembly, Belt Tensioner - Remove and Install.
Result: The pulley surface is not parallel to the mounting surface.
Repair: Replace the belt tensioner. Refer to Disassembly and Assembly, Belt Tensioner - Remove and Install.
Result: There is evidence of metal-to-metal contact between (2) and spring case (4).
Repair: Replace the belt tensioner. Refer to Disassembly and Assembly, Belt Tensioner - Remove and Install.
Result: There is evidence of damage to any part of the belt tensioner.
Repair: Replace the belt tensioner. Refer to Disassembly and Assembly, Belt