Defender - Drive belt will not go back on!!!!!!!!!!!

This is driving me bloody mad. Thought it would be a nice simple 30 min job but no such luck.

Replaced the pulley idler with no problems, as expected.

Couldn't get the fan off so decided to route round it, managed that after a bit of swearing.

Finally got the wretched belt wound the right way - I started with the alternator/tensioner side routed through until the final one left is the idler pulley.

Tensioner is 100% fully down there is no more give in it but I need an extra 100mm or so, just cant get it to go on!

Any tips or tricks? Everything I've read so far just says 'it just slips right on'

Thanks...

Did you check the belt was the same length as the old one?

Same belt, zero damage or fraying

You sure you've routed it correctly? 100 mm is a lot to be short!

This is for a Disco TD5, dunno if a Defender is different RAVE dunt say much

Drive Belt - Land Rover Workshop

I've heard some are different lengths 1820mm and 1801mm, whether that covers air-con or whatever I dunno

bankz5152 said:

Same belt, zero damage or fraying

Click to expand...

I had the same on my td5 defender, fortunately I had a spare belt and when I measured the old one was shorter? Both were LR OEM with same part No.Have you pulled the pulley down as far as it will go, go from underneath that way you can get a few more degrees on your spanner.

Thats the diagram i followed. No ace, no ac.

Ill have another go tonight after work, pulling the tensioner from below. It must go on as the garage have had the belt on and off at least 3 times in the past 5 months!

Also oops mistyped i meant 10mm... [emoji6] [emoji28]

[emoji35] [emoji35] [emoji35] [emoji35] [emoji35]

Mate came round to have a look...

Garage fit the wrong f-ing belt! No wonder it wouldnt fit! We also worked out because the belt was FAR too tight it caused the far right (passanger side) idler to fail. You can see where its been rubbing!

Not happy.

So went to my local motor factors they gave me a new belt. 1mm shorter than the one I had!
Rang Gigglepin they confirmed the length so im confused. Hes getting me a 1740mm belt which should fit

1740 fit easily but squeeked like mad so didnt like that. Tried a 1730, fit better with less play but equally mad a noise I didnt like.

Next step I suppose is to bite the bullet and buy a genuine one direct from the dealer.

Or phone them up and ask what length it is?

I shall. I rang Gigglepin and they said it is 1715 but theres no way in hell that will go on. Also deffinately doing it right as the 1740 & 1730 went on and it drove. One squeeked madly ther other mad a new noise

Worn pulleys? Making the noise

More of a light thud/slap as though its not quite tight enough, which i suppose makes sense as its offically 15mm longer but the 1715 wont fit!!!

both idlers are near enough brand new
Tensioner & alt have 1.5k on it

So should be all good, all move freely as they should.

Could be that im just paranoid, didnt make the noise before so why should it now?

How much slack/play should there be in the belt? Currently with the 1730 belt there is a bit of play pushing down between the two idler pulleys. The tensioner is also fully "in"

youtube

Settled for the 1730 belt. It fits, its tight with 10mm or less of play, tensioners tight. Drives fine....

Turns out the belt had been cut too short.... about 10mm too short!!

bankz5152 said:

Settled for the 1730 belt. It fits, its tight with 10mm or less of play, tensioners tight. Drives fine....

Click to expand...

I thought it was just me, couldn't get the garage fitted belt back on, all idler bearings knackered. Even with tensioner removed. Belt length 1720. Not an access problem as the engine is on a pallet!