Twinspark Aux belt... help!! - Alfa Romeo Forum
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(Post Link) post #1 of 5 Old 03-01-10 Thread Starter
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Moaning Twinspark Aux belt... help!!


That teeny 4-pot in my new '45 is getting a bit cheeky already!

I'm changing the aux' belt, as mine came with a rather cracked and crumbly one... but I dunno how to refit the new belt. It sounds daft and so probably then I'm missing something..

To take the old belt off I loosened that tensioner and it went all limp.. so far so good.. I noticed it had a circular lug in the back that makes it locate to a hole in the engine block... so I relocated the lug in the hole and now I want to put the new belt on.

I can't seem to lever the tensioner pulley wheel enough to get the belt over it. How do I do it? It seems as it there's just not enough movement in the sprung pulley to give me enough slack.

I'm assuming there is no other way to introduce play into the belt circuit except by levering the idle pulley against its spring tension, hooking the belt over it and then letting the pulley go..

It seems blinkin' impossible though..? They can't hook the belt on this way in the factory can they?

Anyone have any crafty tips? I'm stuck at the momemnt...

Ralf S.

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stick a 15mm spanner on the tensioner and push the tensioner while fitting the belt. that's how I do it anyway
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The spring is quite fierce, much easier with 2 people although i did manage on my own in the end. The tensioner can sieze though in the tensioned position, maybe thats the problem.
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Use a 15mm combination spanner.

Put the belt on the top pulleys (Alterrnator etc)

Thead the spanner under the belt (this is so the belt ends up the correct side of the spanner when you lever over the tensioner)

lever the tensioner over using the open end of the spanner (anti-clockwise) , then wedge a long screwdriver through the ring end so that it sticks between the brake caliper and the cars body. (use the handled end on the brake caliper).

You can thread the belt around. Then release the spanner screwdriver.

Thats roughtly how I do it and it normally works.

Giulietta 2.0JTDm (170), BMW 120d M sport
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(Post Link) post #5 of 5 Old 04-01-10 Thread Starter
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Ah... most splendid advice and it worked.... so loads of virtual beers for you fellas.

Saved me sitting in the frost for a few hours.. though once inside my hands de-frosted and all the bruises, scrapes and blisters started to hurt...

That 15mm nut on the pulley and the spanner is what I didn't work out... I thought turning it would "undo" the nut... but it doesn't and it's the only way to get enough leverage on the tensioner.

I only had an open end 15mm spanner (no room for a socket) but apart from it frickin' hurt to put that much effort on it, the beast went on really (relatively) simple. Top marks to the AO Forum once again..!

Ralf S.
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