Help me diagnose my problem please - pics included of random damaged parts!

TimG

TimG

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So driving home yesterday my 2004 8P TDI starts making an intermittent squeaking noise and it got progressively worse, to an almost constant squeak noise. Sounds like its belt related to me. On closer inspection when home it is definitely from the engine bay and I think from the left hand (looking into the bay, alternator) side. I also found these two piece of sheared metal laying in the bay. One odly made it to the where the dip stick goes through the engine cover and the other had fallen to the undertray. There must be more somewhere I guess!







Having spoken to a fellow forum member I have my suspicions as to what has happened, but thought I would ask the open forum for suggestions before I comment any further.

Any comments appreciated on what my squeak is and where these rather important pieces of metal have come from!

Thanks
Tim
 
Just advise us what your suspicions are, as they're obviously very small parts, but from those pics its hard to work out what they are, apart from being cylindrical.
 
Ok, having discussed this with the engineer (member on here) I think it might be a part of a pulley, possibly the alternator pulley.

Although having looked at it again today, I don't know how these parts could have made in out without the pulley coming off the spindle!

There does seem to be some movement in the pulley (toward and away from the alternator) by a few mm (marked on the photo), although I cant move it by hand. Is this normal?







I would be super grateful if someone could have a look at their own pulley and see if they have a gap the size of mine between the alternator and pully itself?

Thanks
 
Remove the belt & have a look for play.
 
The block of metal behind the alternator pulley in your pictures is the belt tensioner, if you look at the outer edge of it there is a square shaped 'nob' get an open ended spanner on this part of the tensioner & lever it to relieve the tension off the belt so you can pull it off the alternator pulley.
 
Get a spanner, you can see the aux belt tensioner in your pic with a piece of metal sticking out of the end, put the spanner open end on this & move it so it takes the tension of the belt allowing you to drop it of, do the reverse to put back on & make sure its sat in the grooves properly before turning over.

& thats what you get for eating dinner whilst replying, 2 replies lol.
 
2 replies is better than none! Sounds too easy, I was expecting to have to remove the tailgate, the roof lining and a headlight to get to it, in typical PITA style of most things on modern cars these days! :)

Shall get on this tomorrow!
 
Took the belt off today and this is the outcome. As suspected lateral movement of about 6mm and squeaky when turning!

Look at the splined part in the middle and how much the outer section of the pulley moves in and out in the two pics.





And a short video of why it squeaks/chatters. Quite rough and hard to turn too.

 
Replaced using the guide in the link, all is well. £33 from euro car parts and £13 on tools I didnt have. Happy with that to be honest!
 
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