Issues with drive belt tensioner and viscous fan!!

[Hormone]

Hi All.

I'm Brian and a Newbie to this forum and like most Newbies that join a forum I have a problem!

I have a 1997 Diesel Passat with the 1.9 TDI AFN engine and the drive belt tensioner is cream crackered, (I also have a classic VW beach buggy).

I've been able to get access without putting the front into service mode and, thanks to the threads on this forum have been able to undo the tensioner but the problem I have now is that I can't remove the viscous fan pulley to enable me to change it over.

The head of the bolt seems OK and the 8mm allen key has a good hold but it seems that the bolt is seized.

I have put more leverage and pressure on than I would like but the bolt is just not moving. It is so solid that it is just bending the bolts that I put through the hole in the pulley to stop it rotating and I think I could sheer the bolt if I put more pressure on it.
I've given it a good blasting with penetrating oil, tried tightening it, as that sometimes 'cracks' it, and tried giving it a sharp jolt, as best I could in the limited space but nothing seems to work.

It would be a shame for this to consign an otherwise good car to the breakers but the tensioner is so bad that it is visibly askew to the point where the belt took the lip of the plastic pulley off so there is little point just replacing the pulley.

Has anyone any other ideas to remove the pulley or alternative ways of getting the tensioner out and the new one in?

Thanks.

Brian


Edited to add:

Had a thought this morning, as you do on 3 hours sleep!

On at least one thread it states that the tensioner is removed using an 8mm allen key (not sure why it has the allen hey fitting, unless it is to adjust the tension of the spring) but it is actually held in place by a 16mm nut.
Could this be the same?

Using a small inspection mirror it looked like this was a round headed bolt with an allen key head and this is the removal method shown in the Haynes manual but I'm clutching at straws here to save the car.

Am I right in that this will be a normal thread ie. anti clockwise to undo?


Anyway it's Sunday morning so not expecting many, if any, replies so I will whip the alternator off completely so that I can get a better look.

[Hormone]

All very helpfull.
Thanks

[Crasher]

The bolt is a fine pitch M10x1x65 (VAG # N 103 026 01) and the torque is 45Nm so due to age and probable previous over tightening it may be very tight. It must be counter held with a pin tool and these can be difficult to engage, I use a Gedore 44/9", also see https://www.vwaudiforum.co.uk/forum/s...529#post414529