It's the longer belt. Does it need to go up on ramps or is it manageable with it on the ground? I've done rear hubs and shoes and replaced the high pressure fuel pump in the past so assume its no more difficult than this?
Thanks for all your help Andy, much appreciated. Nothing looks wrong with the pulleys so I think it was just worn with age. In all fairness I don't know when they were last changed!
Should the small aircon belt be really tight? I've took the tensioner off completely and still can't get it on...Sometimes they can be straight forward to fit, then some other times a nightmare, if the tensioner when pulling back starts to undo then you are going to have to tighten it up from the rear 15mm nut, very hard to get to, also use some superglue or loctite threadlocker,
I now this because only last week when i have to changed the belt on my R40 same engine this happened so a 15minute job took hours as the glue had to dry, then when i tired again it failed, so back to square one, got there in the end you need the tensioner to be pulled back at it full arch, putting the belt on the crank pulley last, once you get it started if it hard to fit round use a ratchet spanner on the crank pulley to pull the belt on.
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I was just in time i think
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Put reg in euro car parts and this is the one it gave me. Dug the old belt out the bin and its probably 3/4 " longer than the new one. Does the face lift 2006 TD4 have a slightly longer belt than the original TD4 by any chance?
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