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year 2008 1.8 petrol auxiliary belt woes

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Hi
I'm trying to help a friend that owns year 2008 1.8 petrol C-Max
He removed the auxiliary belt because the old one was so cracked up.
According to Haynes you are supposed to fit the new one by removing two bolts from an idler pulley on the front of the head and loosen the bottom one, and then rotate the pulley bracket over to the left, then fit the belt, then insert a bar in the pulley bracket and pull it straight again to tension the belt.
When he tried this he smashed the hole in the bracket that the bar pulls on.
When I went to look the belt is so short that I can't easily get it over the pulley even with the bracket rotated.
We looked on GSF car parts and the pulley that they sell looks different, with bracket being in two parts so that the pulley can move. It's part number INA534024910 on GSF.
So I have questions:-
1. Is this different part actually correct?
2. Does it need a different belt or is it designed to take the same belt as the fixed pulley?
3. Is the fitting procedure the same? so just fit one bolt and lever it up straight?
thanks



  • Author

apparently Ford changed the design of the auxiliary belt in 2008.  The old design had a tensioner whilst the new design was a fixed pulley with a stretch belt.  On this particular car the GSF and Eurocar parts database is wrong and it's suggesting the old tensioner when it should have the stretch belt.

Anyway my friend needed to get back on the road for work tomorrow and the old style was available so we reverted to the old design with a 1304mm belt and it works fine.   The older tensioner is thicker so it needs longer M8 bolts.  So the car no longer has an auxiliary stretch belt which it will be easier in the future if the belt ever has to come off again.

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