Club 80-90 Forums

T25 1.6TD water cooled and 90 amp alternator. I have to replace a broken Alternator belt. The engine is a two belt system. Can anyone point me to a how-to or a video that shows how to do this? I think I need a bit of detail because I obviously have to take off both belts and it doesn't look easy getting the water pump belt off (or even worse putting it back on with spacers and things). I guess I could take it to a garage but I really want to learn how to do it cos it looks like something that could easily go by the roadside. Any help appreciated.

I got this from Volkzone which might be of some help to others who have the same problem:
With your water pump belt, you have to take off the alternator belt 1st to tension. Slacken off the alternator belt by loosening the hinge bolt and slide bracket tensioner. Take off the water pump pulley with the bolts in a triangular formation. The pulley comes off in three parts; Side 1, side 2 and spacer discs. You tension this belt up by taking spacers from between the pulley halves (closing the gap-tightening the pulley) and bolting on the outside of the pulley (for safe keeping). I suggest taking 3 spacers out if so slack the belt screams. Bolt it all back together equally, turning the engine in neutral by hand to prevent trapping the belt when tightening. If all your spacers are already on the outside of the pulley-new belt needed. That's what I did for my 1.6 non turbo as it screamed on start up and low revs in the wet.
and some extra bits from other forums:

Take out the three bolts to split the pulley and allow the belt to come off - reverse to refit. To stop the pulley spinning while you do this you need to improvise something to hold the pulley stationary.

When I remove the pulley I use two Allen keys, one to stop it moving one to undo it;or pipe grip on two bolts and undo the third!

Can anyone recommend a tool for holding the pulley stationery?

killerme wrote:Can anyone recommend a tool for holding the pulley stationery?

I used to do just what you did. Two allen keys and a screwdriver.