If the tensioner is bent out of place or worn change it out, that's what I would do, it certainly sounds shot anyway. Its maybe because it's running skew that caused the belt to split.

 

seems it was a 2 cm long kink/deformation on the outer lip of the wheel that made it look skew. am trying to figure out what sort of force from the belt could possibly have done that??

there is good tension in the tensioner but bearning noise on the wheel itself, which means replacement.

when i got the belt (which chewed up quite easily i will say) guy in the parts store said there were 2 slightly different types, one fractionally longer than the other.
i got the different sized one compared to the previously fitted Gates micro-v XF, 461pp 059-062 as he only had the one in stock and said its was the one recommended for afn with aircon.
anyone heard of this
???

 

For a pulley you can double check but this is the one for the ALH type tensioner, I got one for mine

http://www.amazon.co.uk/Meyle-100-145-0003-Deflection/dp/B0068MUJEQ

Cheaper than a new tensioner for me but best check the price of a tensioner first, if they're cheap enough I'd replace it. Mine is about £80 for a crappy aftermarket thing which is why I went with a pulley instead.


They didn't get the AFN in the states so you might not find much info on the belt length issue. Might be worth checking out the ukpassats forum for more info on these things.

 

Finally got the pulley + tensioner out after getting the fan pulley off, (wrapped with ductape and using a 2ft wrench to counterhold).

it did 'seem' slightly bent as well as having a kinked roller, but after comparing to 2 new ones in a part store (INA 55 + vat) and a nobrand cheapo (35+ vat), the gap between back of roller and body appeared the same on all 3. Fears of it being bent were unfounded, as additionally the lower cambelt casing nut was loose, this giving that illusion.

Decided to go with the INA as it looked better quality, and a dayco belt, which was 2mm shorter than gates, as the parts guy suggested was normal.

is that amazon pulley with only 1 groove??

 

It's a bearing in the centre then two separate pieces of steel clamped round it to form a pulley, but mine is the ribbed belt, maybe yours is the V belt? Probably a completely different looking thing.

I can't keep track of all the tdi's lol

 

yes there are a few variants
all sorted now - engine was chirping like a nest of tweetie birds b4, and now sounds like an idling tug boat after the tensioner and alt swap -afn is a marine /industrial variant i heard somewhere )

one slight concern is that i'm left over with a 5mm allen bolt after wrapping up the jobt -about 2cm, was careful in noting where all the bits were going but this has me struck out. any ideas on whats its place? all the other bolts were not of this type/size.

 

Pulley bolt? Power steering or water pump maybe?


The AFN is just a 110 version of the AHU/1Z