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With the Air-con belt removed, thread the new serpentine belt between the tensioner and fan first with the grooves against the tensioner, and work counter clockwise i.e. crank, idler power steering.Then lever the tensioner away from the fan (counter clockwise) with a 15mm spanner, and slip the belt over the alternator, that way there’s no need forthe service position. Refit your air-con belt and your good to go.
Scoured the net without luck for the right belt route for my trusty 99 Passat .Eventually figured it out myself but thought I would post this for anyone else in my predicament.
I also replaced a failed tensioner bearing/pulley without removing the cars nose, as mine was red with rust and lying to one side. it was a little more awkward but do-able.
With a 15mm spanner slacken the tensioner pulley nut by turning it clockwise (left hand thread) slip on your new pulley and tighten it up again by turning it counter clockwise be warned though, the gap between it and the fan is severely limited it took me over an hour to do the tensioner.
