My idler plastic pulley went bad . Everything melted and bearing is completly shot.The belt is half thinner now.
I have two spare tensioners so I took one tensioner pulley to replace the idler,but I dont know what and in what sequence parts between grooved and the other plastic pulley go.There was some washers,shaft etc? There was complete mess and I was in rush to replace that pulley because i was late to one place I needed to be sharp. I did replace pulley in 20 min (it was difficult to unscrew pulley from old tensioner on the street). But I still need to know if anything goes in between those pulleys.i
Anybody has picture or diagram?
I have factory manual but there is no detailed picture of pulleys assembly.

It'* the pulleys that I circled with blue pen.
If anybody has these two pulleys with bolt (can be without) but with everything else that goes when assembled please PM me.

Here is the image.

I went through this once with Morty. As I recall the FSM and owners manuals are completely worthless. It came down to messing with the order enough until the bolt was tight and both pulleys could move freely and independently.

Sorry it'* pretty vague, that'* what we did though.

I put that pulley with some shaft/insert there but there is a gap between grooved and this one pulley like 1/4 ". I recall there was no gap before. What I think that original idler pulley had bigger bearing inner diameter so it sit further on that shaft eliminating gap. It works now. At least rotating freely without any side "plays".
I went to few junk yards and none of them has it. At least that'* what they said. I honestly don't believe it. None of them has 3800 GM engine? Those Tony Soprano types sitting there and this is just something not worth to move their arses for. Probably some small town junk yard would be far more helpfull then here in NY.

Edit: Forgot to say I put metal pulley this time from spare tensioner.

How do I loosen slack on belt tensioner located near supercharger to replace noisy idler pulley? How much pressure do I place on the torque wrench to tighten new pulley to belt tensioner (arm)

Well,I did that on tensioner removed from enginre and that was pain in the neck to hold tensioner body while unscrew pulley. I assume it was much easier unscrew the bolt that hold pulley on thensioner when on engine.
Just unscrew it conterclockwise. And regarding how much pressure to apply to tighten it back I did it by feeling to not overtighten and damage thread.
Just screw it tight enough and make sure pulley rotates freely.

Regards