Hi Everyone - I've just had a week of Auxillary Belt and Tensioner problems this week, so thought I would post something to help those of you that are having the same problems.
This is what happened on my 147 (1.9 JTD 16v, 94000 miles, 2004 54 plate) this week:
I've had a chirping sound coming from the auxillary belt area (engine bay behind the drivers side front wheel) for many months. Sometimes it would make sound other times it would be silent. There was really no pattern to when the belt would decide to chirp away but would tend to chirp more often when starting from cold or/and when it had been raining. It could however, start chirping after 40 miles of driving for a matter of seconds. You may also be getting belt squeal too...
These video links will help you determine causes and solutions to any belt noise you might be getting:
BELT NOISE - Causes & Solutions (by Dayco)
DAYCO - SOLUTIONS TO BELT CHIRP
DAYCO - SOLUTIONS TO BELT SQUEAL
Anyway, the belt eventually decided to flip off on the way back home from work and left me with no power steering and a 'battery low charge' error on the HUD. The steering was very heavy and the auxillary belt area was completely silent when the engine was running. Opening the bonnet, I could see the belt was loose and not sitting on the front pulley (I believe this is for the air conditioning).
So after a little investigation in the alfaowner.com forums, it confirmed my suspicion that the belt and tensioners would need replaced. I ordered a new belt, adjustable tensioner and a fixed tensioner from shop4parts. The lot cost around £85 and was delivered in 2 days:
Aux Belt - With Air Conditioning
Auxiliary Belt Tensioner (Adjustable)
Air Conditioning Belt Tensioner
To get at the belt and tensioners you need to remove the drivers-side front wheel. Removing the plastic wheel arch may help you to see all the components a little easier. When I removed the belt I could see it had been shredded down one side. This would explain the chirping sound and therefore, misalignment of the belt. It turns out the main problem was with the fixed tensioner (the one that is just a plastic wheel by itself - used to tension the air conditioning pully). Grabbing the tensioner, I could wobble it about in my hand - an indication that it is buggered! I believe this is what was causing misalignment of the belt. So I fitted the new parts...
I used this video as a guide to fitting the parts:
DAYCO TRAINING COURSE 01 (English) WWW.DAYCO.COM
Here is a diagram for the routing of the belt:
Alfa 147 1.9 JTD 16v - Auxillary Belt Routing Diagram
Getting familiar with all this information and fitting the parts should take around an hour to complete. I wish I knew all of this information before getting started on this job - it took me over 6 hours without all of this information at hand! So, if you experience the same problems, I hope you'll find this information very useful!