well I finally got there, the belt is on!
was a job of patience wich i have very little of these days. However, it sounds as rough as hell still with the new pulley
and the belt is flapping around, the noise is coming from the pulley area made sure its tight...could this be crank shalf
end float? its a real heavy mechanical sound which go when the engine rpm is picked up.

gary brion said:

well I finally got there, the belt is on!
was a job of patience wich i have very little of these days. However, it sounds as rough as hell still with the new pulley
and the belt is flapping around, the noise is coming from the pulley area made sure its tight...could this be crank shalf
end float? its a real heavy mechanical sound which go when the engine rpm is picked up.

Click to expand...

I'm no expert and am usually wrong but aren't TD4's known to break crankshafts? Could that be what you hear?

After some quick research, yes they have been known to snap but with mine its running smooth as silk
over 1200 rpm, I did move it out of the barn without the pulley on, (to get more light) and was running fine even at tick over
So not sure what's going on.

As so many mechanics tried to fit the belt perhaps you could share what they were doing wrong to help others? Read my crank broken thread for more info on this.

Ok looking at the pulleys from the wheel arch, I put the belt over the two top pulleys,w/p, and p/s
this holds the belt in place, coming down from my left inside the tensioner, back out and around the crank, once round the crank,
this is the strange bit..go up to the alternator make a loop with the belt and bring the loop back down and finally
over the idler whilst getting the spanner on the tensioner and pulling towards the front of the car.

I made a nice spanner for the tensioner nut, got 24mm socket cut it in half with the grinder then welded an old flat tyre lever to the top of the socket, nice and shallow and fits in the tight area a treat.
As for the belt slap and noise after fitting the new crank pulley, I got under there today and asked my Son to lock the steering
fully to the right with the engine running, as he was doing that I gave a squirt of wd40 to the bottom idler pulley
and the noise and slapping when immediately, so can't really say what it was at a guess maybe air in the p/s system
or the idler pulley needed some form of lube ....all good now Thanks all for the help

Hi Gary.
Nice to hear you got it sorted, next time I would try routing the belt so it goes over the crank pulley last, works for me