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[Osprey]

No, super-human strength wasn't required.  

I routed the belt over all the grooved pulleys leaving a loop in front of the smooth water pump pulley.  Then a firm shove on a 15mm ring spanner on the tensioner, about a quarter turn clockwise against the spring tension.  The belt then slipped over the water pump pulley quite easily. 

Can you put up a photo of your pulleys?  Someone will soon spot if there is anything unusual. 

[GrahamK]

Still got probs with this aux belt. Have spoken again to the dealer and also the trade club helpline. No new ideas at present. I'm sure I'm routing it correctly, the belt is the correct part no and the proper length. The only thing I can think of is I have one or more non-standard pulleys on the car.
If possible will people have a quick look at the photo's attached to see if all looks OK.

Regards,

Graham

http://s920.photobucket.com/albums/ad45/thekezzers/Aux%20belt/?albumview=slideshow

[Hannah Judes Dad]

Does this help with the routing ?

http://i190.photobucket.com/albums/z257/belisensis/OMEGAFORUM/V6AuxBeltRoute.jpg

[GrahamK]

Hi HJD,

Thanks for that, it is the routing I'm using.

I'm starting to lose the will to live. 6 hours to strip down, do cambelt, waterpump and thermostat, then 6 days (and counting) to fit the fan belt.

I must be missing something?

Regards,

Graham.

[Marks DTM Calib]

Is the belt correctly located on the PAS and aircon pullies, its not riding on the outer flanges?

Similar for the crank, alternator and tensioner (easier to see)

[Brikhead]

The only thing I can think of is I have one or more non-standard pulleys on the car.

Judging by your picture the pulleys all look standard when compared to my 2.5 v6.

[Brikhead]

I've just popped out and (very) roughly measured the pulleys...
Tensioner is 80 m.m.
Alternator is 60 m.m.
Crank is 158 m.m.
A/c comp. 125-130 m.m.
P/s pump is 153 m.m.
My belt measures approx 2200 m.m.

[GrahamK]

Hi Brik,

I'll just go out and check those sizes now.

Did you mean 2200mm or 2020mm belt length. (mine is 2020)

[albitz]

Im wondering if the tensioner pulley isnt being pushed far enough forward. Have you tried getting someone else to put all their weight against the pulley while you try to slip the belt on ?

[GrahamK]

I've just been out to measure my pulleys, which match Briks.

My water pump pulley (Brik didn't mention) is 130mm.

[GrahamK]

Hi Albs,

I was pushing so hard I started to tighten the bolt, which is already pretty tight.
It also stops quite suddenly and feels as if you are hard up against the cast stop.
I reckon total arc from rest to stop is about 70 deg, which the guy I spoke to on the helpline said sounded about right.

it looks right, but Can I have put the tensioner on the wrong way around? Is it possible? I don't think so?

I haven't fully tightened and torqued the pulleys yet, but they are all centred and concentric.

[albitz]

Sounds about right to me. I have a spare used belt in the shed I will measure shortly, just for curiosity.

[albitz]

My used belt measures approx 2050.
Which is probably no help at all.

[GrahamK]

On the contrary Albs, that's 30mm longer!! oo-er, which is probably enough to make a difference.

I know I'm asking a lot, but you haven't got records of when you bought that belt have you? Part no's etc.

Thanks

[albitz]

Its from a 2002 3.2, and I suspect its the original belt. 133,000 miles.