Hi Guys, went to replace the alternator belt today and the replacement -which was definitely the correct part- would not (and I mean would not) go on. In fact the old one was a problem to remove too.The alternator appeared to be hitting the engine block which stopped it from travelling far enough to allow the new belt to pop on. Tried everything to get it on, even removing the water pump pulley to use that as leverage but no dice. Any one experienced this or any ideas as to why this is an issue at all?? Car is a 1990 1.4 vario 340 DL (very cheap on tyres btw). Normally I love working on the beast, but today I swore lots.

Yeah, it can be very tight to get on, cos, as you say the alternator hits the engine block. The best way IIRC to get them on is to place it on the water pump pulley and crank pulley first and then really pull it over the alternator, using a bar or long screwdriver if necessary, and then the fun starts trying to torque it up.

There's no adjuster bolt on the 1.4s so you have to man-handle the alternator away from the engine and then tighten up the sliding bolt to get enough tension on the belt.

Yes you probably do have the right part and they can be an arse to get on.

I have found the best way is to get it over the alternator and crank pulleys first and lever it some of the way onto the water pump- enough that it is fairly tight.

I use an old tyre lever which is flat and has a lip that seems ideal for this -doesn`t damage the belt either.

If you take the plugs out you can then wind it on the rest of the way by turning the engine with a spanner on the crank pulley nut. If you are lucky and the belt doesn`t slip ( a quick wipe of the pulleys with meths helps here) it should just snap over the lip as it goes round.

Thanks for that - have solved the mystery tho - the amusing vendor with the great sense of humour didn't actually have the correct size so gave me the closest one he had...10mm too small. Rather than tell me in case there was a problem, he decided to keep quiet in case it fitted. One rant later, truth revealed and the ACTUAL CORRECT part now on order!!! BTW,I did find the easiest way to get the old belt on/off (which was tight) was to go round the alternator and bottom pulley as you say, then fold/roll the belt over the leading edge of the water pump pulley and hold it in situ firmly, then turn the water pump pulley slowly with your other hand until the belt is on (but twisted) and keep turning until the belt has straightened itself out. Pretty easy like that....unless your belt is 10MM TOO SHORT!!!!

I'm sorry mate, whilst that may have caused a lot of stress at the time... I've just spent the last 24 hours trying to get a bit of coursework done, and it's brightened my day up Was it a random independant dude?

Yeah, a reputable (believe it or not!) independant garage near me. Can't be too mad tho - he's my mates dad and in his defence he did allow me to use his workshop and all facilities, which is more than handy. If my arm wasn't aching so much, it would be hilarious....