Disco 1 300tdi Fan pulley bypass bodge query (Need a short belt)

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Goc3k

Goc3k

Well-Known Member
Posts
300
Location
Hampshire
Just a hopeful query someone might know this off hand. Noticed the fan pulley bearing was chattering and grinding, confirmed it today.

I've been running the disco without the fan assembly since last june, all the while of course the existing belt still needed the pulley to run, so that remained on. In order to merely save a few quid and a bit of time (as i'd need a new timing case cover for a new bearing as you all know no doubt), what size belt do I need to simply bypass the pulley? I'll go and waste tomorrow stringing a tape measure around it if nobody knows off hand, but no doubt someone has done it before, and might save the trouble ;)

Edit - Cock up, couldn't find anything searching on the forum but did on google, apparently 7pk 1380mm is the ticket, wahey!
 
Worked a treat if anyone was interested ( 1380mm belt ), nice easy fix to save a few quid for the time being!
 
Goc3k said:
Worked a treat if anyone was interested ( 1380mm belt ), nice easy fix to save a few quid for the time being!
Click to expand...
SOudns good, got any pictures?

How much does it miss the fan pulley flange by? Have my timing cover off at the moment and the pulley bearing although not bad does not run as smooth as to be expected. Apparently you can get replacement ones that need to be cut to fit.

Cheers
 
I'll take a pic tomorrow and stick it up. I took the fan pulley off for the sake of neatness, but the short route misses it quite safely by a good measure with it left on. Might be worth a look in for just a bearing then if it can be done (I've a great history with presses pullers and aluminum casings :D), otherwise I'll see how it gets on between now and late spring / summer when the cam-belt gets changed and stick my hand in my wallet...
 
Looks promising! I'll have a look in, will see how easy it is to get the old bearing and flange out of mine purely for curiosity eventually even if nothing more comes of it
 
WhatsApp Image 2018-01-24 at 17.57.50(1).jpeg


WhatsApp Image 2018-01-24 at 17.57.50.jpeg



Couple of shots. Tensioner also sounds like its on its way out now I've got rid of the fan pulley, the loud grind was hiding its slight grind :eek:

On an extra stingy note, having looked at new tensioners, it seems that once you remove the snap ring from the pulley wheel the bearing is a reasonably easy to remove. The bearing itself is an imperial standard, part number for an SKF one is 6203-2RSH or 885802RS from Koyo. Pinched that tidbit off lr4x4 (so don't quote if it is correct or not), but more importantly it means if you get a local shop to machine up an oversize billet pulley, then the short belt bodge would be sorted a goodun with the stock tensioner arm!
 
Goc3k said:
View attachment 140031

View attachment 140032


Couple of shots. Tensioner also sounds like its on its way out now I've got rid of the fan pulley, the loud grind was hiding its slight grind :eek:

On an extra stingy note, having looked at new tensioners, it seems that once you remove the snap ring from the pulley wheel the bearing is a reasonably easy to remove. The bearing itself is an imperial standard, part number for an SKF one is 6203-2RSH or 885802RS from Koyo. Pinched that tidbit off lr4x4 (so don't quote if it is correct or not), but more importantly it means if you get a local shop to machine up an oversize billet pulley, then the short belt bodge would be sorted a goodun with the stock tensioner arm!
Click to expand...

Thanks, Looks like the tensioner is almost at the end of its stroke. So as you are saying, a longer arm / larger dia pulley would help from the way it looks.
Changing the bearing is easy enough to do, I did one a while back on My old Disco. A few quid for the new bearing and a little work to swap it out.

I am thinking more of an " oh bugger" that has broke scenario, and keeping a belt in the tool box as a get me home spare.

Just one thing to double check, you may already have done it, the hose that sits above the water pump pulley quite often can end up rubbing on the pulley and wearing through, so best to adjust it and make sure it does not cause a problem.



Cheers
 
Aye the tensioner arm is completely maxed, the belt tension is spot on currently but probably 10-15k miles max and it'll be thrown or slippy - so either a longer arm or say 30-35~% bigger wheel would be great. Ah good to hear! I hadn't actually noticed until yesterday the wheel is cast iron. Proper old fashioned!

That's probably the best bet, make use of the current setup til the end and all that.

Thanks for pointing that out, luckily I noticed it when doing the p-gasket and water pump a few months back - got a nice polished spot on the hose, should replace them all really as they're largely original but you know how these things go.
 
Goc3k said:
Aye the tensioner arm is completely maxed, the belt tension is spot on currently but probably 10-15k miles max and it'll be thrown or slippy - so either a longer arm or say 30-35~% bigger wheel would be great. Ah good to hear! I hadn't actually noticed until yesterday the wheel is cast iron. Proper old fashioned!

That's probably the best bet, make use of the current setup til the end and all that.

Thanks for pointing that out, luckily I noticed it when doing the p-gasket and water pump a few months back - got a nice polished spot on the hose, should replace them all really as they're largely original but you know how these things go.
Click to expand...

I wonder if the td5 tensioner is the same / similar, I have a new one in the garage in the AM I will have a butchers at both side by side and see if there is any way / benefit to use that instead.

Looks like you have the small diameter alternator pulley fitted, is that right?.

Cheers
 
Had a quick look on google, hard to tell without scale. Promising idea!

I wouldn't know in fairness, I think its the later 100a bosch alternator but that's as far as my knowledge on it goes. And that it also needs a set of brushes :rolleyes:. Can always measure it
 
Goc3k said:
Had a quick look on google, hard to tell without scale. Promising idea!
Click to expand...

I checked the td5 tensioner and it is actually a smaller dia pulley and a shorter arm when compared to the 300tdi unit.

I also measured around the pulleys and I got 1380ish.. So I am going to look for a cheapie emergency spare belt to do the same.

Cheers
 
Cheers for looking, guess i'll just have to put my hand in my wallet if i ever fancy sorting it out. Shouldnt be too dear, 20 quid ~ for a round ally billet, probs an hour max of machine time to drill the hole and then turn it up.

Aye dont go any smaller, had to bicycle chain the 1380 on as it was.
 
Goc3k said:
Cheers for looking, guess i'll just have to put my hand in my wallet if i ever fancy sorting it out. Shouldnt be too dear, 20 quid ~ for a round ally billet, probs an hour max of machine time to drill the hole and then turn it up.

Aye dont go any smaller, had to bicycle chain the 1380 on as it was.
Click to expand...
Hi, I know this a year on, but how’s the belt conversion doing? Any problems? I’ve just converted mine - I had to change the alternator pulley as mine was the early (large) type & the belt wouldn’t fit. It was hellish tight to get on & I wondered if a 1388 would fit better - I may buy one to try. Did you manufacture a bigger tensioner pulley btw?
 
I'd forgotten to upload the photos of what I did, here they are

Tensioner small.jpg

Tensioned belt small.jpg


Not much to see really, I took the pulley to my helpful local engineer and he suggested just banding an ally strip onto the existing pulley, £30 and a bottle later and job was a goodun, followed by another few bottles as I went back and had a bit turned off on two occasions - think the band ended up about 5mm thick, made all the difference to final tension. Changed to a bigger alternator with the larger pulley, and swapped to a 1395mm belt once the tensioner had been enlarged.

Got about 9-10k miles on the setup now, doesn't squeal or slip at all with usual driving - it does chirp a bit when wading with load on the alternator but that's to be expected for the most part. It's wearing well at the moment and looks like it'll go a few more years easily.

Tecam said:
It was hellish tight to get on
Click to expand...

My method without a helper is to get it on is: remove tensioner completely, wrap belt onto all pulleys apart from the bottom of the crank pulley, then while holding the belt edge (so it stays on the edge of the pulley). Proceed to then turn the engine over slowly by hand, and worm the belt on like a bicycle chain until fully seated. Then slide the tensioner back onto the stud, but not all the way - keep the pulley tracking half on/off the belt (so the dowel does not engage the housing). Then roll the tensioner into position (the pulley should run nicely against the belt and not slip off) and give it a slap or two until the dowel just starts to engage, then begin turning the engine over again slowly by hand and pushing the tensioner in as you do so, until it is fully seated. then once you have replaced the nut, ease the tensioner back (as you would with the usual setup to engage / remove the belt), and then let it rest back - mine then sat with a small amount of spring still in the arm rather than at max, after modifications.
 
Excellent! Thanks for the pictures & info. Yes, that’s how I got the belt on to finish with, winding it on to the crank pulley. I was a bit wary of a longer belt in case it touched the belt opposite the tensioner on the pas pump pulley, it it looks fine on yours and those belts don’t stretch. Excellent job, thanks again!
 
Aye it doesn't rub, think there is a good 4-5mm between the belt at Pas / tensioner pulley so all's well
 
Goc3k said:
Aye it doesn't rub, think there is a good 4-5mm between the belt at Pas / tensioner pulley so all's well
Click to expand...

Hi Goc3k - i know this post is a few years old, but I’m curious how it has held up so far?

I added a 12v electric fan and have been considering doing the same.
 
Bkeller16 said:
Hi Goc3k - i know this post is a few years old, but I’m curious how it has held up so far?

I added a 12v electric fan and have been considering doing the same.
Click to expand...
Hi, looks like you’ve not had a reply - I did the same to mine in Jan 2019 - I got a new aluminium pulley turned & fitted, & it’s been in constant use without any problems to date.
 
Tecam said:
Hi, looks like you’ve not had a reply - I did the same to mine in Jan 2019 - I got a new aluminium pulley turned & fitted, & it’s been in constant use without any problems to date.
Click to expand...
Hello

thx for the reply. Where did you install a new pulley? The tensioner? If so, what did you have done to it? Or did you get a bigger pulley with a new alternator?

ultimately what belt size did you use? 1380 still?

thx
Brandon
 
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