Im in the middle of rebuilding my alternator and having removed it I thought Id better the check the condition of the belts and pulleys etc while I was in there. Ive noticed one of my idler pulleys and my tensioner pulley are both noisey so I figured it best to change them.

I have removed the nut on the back of the tensioner arm as per the Rave manual instructions but the arm seems really stiff to remove. Ive withdrawn it a certain amount but Im slightly worried that when I pull it clear the spring inside the tensioner itself is going to "SPAAAANG" out of place and I will never get the new arm back in again. Can anybody reassure me thats its just a tight fit and nothing bad will happen.

 2002 TD6 Epsom Green

Can't help bud, but have you tried a BMW forum? possibly a search for M57 idler might reap rewards... after all they have been stripping these engines long before they were fitted in to a Range Rover  Yesterday I couldn't spell Engineer... Today I are one!
Inventor of the 'Guide-o-Matic automatic wheel alignment tool'
Former long term L322 owner, Up/Down graded to a Classic Tractor!

You should just be able to withdraw the pulley and arm, then unbolt the tensioner from the rear, if it's the same as the aircon tensioner.
If the arm is not seized and tensioner ok, then new arm and pulley should do it, sure I've read it in rave.
dont forget the other two idler pulleys as well, those are easy to change.
Hope it helps. Greg.

Sorry jpz, just reread your post, if it's stiff to pull out but is moving, then give the hole a good clean out, my aircon shaft is frozen solid and I will need to take off the complete bracket, but virtually the same set up, only the aircon from where it is situated, gets all the road crap.
anyway, I would give it a good greasing when you pop it back in, think because of the different types of metal aluminium and steel, they could be reacting, you may see a white powdery residue, give it a good clean.

Just pulls straight out

bit like the injectors then  Yesterday I couldn't spell Engineer... Today I are one!
Inventor of the 'Guide-o-Matic automatic wheel alignment tool'
Former long term L322 owner, Up/Down graded to a Classic Tractor!

Thanks chaps. Just to clarify it was the tensioner pulley for the alternator belt. I havent gone near the aircon belt and pulley yet but I assume its a similar story. I got it out with a pry bar and some genltle teasing. The belts look pretty new to me so will leave them be. 2002 TD6 Epsom Green