Drive belt issues 2.5tdi AKE

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robotplant

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Can anyone give me some "how to" remove the damper (part 29) for the alt/power steering belt. Looks to me the aircon unit needs to come off?

Also how to change the the pressed bearing (part 23) for the main bracket (part 21)?

Thanks.

John
 
Here's the blown up diagram of said parts.
 

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Really surprised no one knows how to take these parts off???
 
Thanks Ovid, was beginning to give up on the forum! I know there's a few members on here who would of done this many a time.

This helps me with the bush. I've not had any further time to work out what's involved with removing the spring tensioner. Mines removed from the brackets and loose now just not sure yet how to get it out from there. Be good to know what to remove before I start throwing spanners at it this weekend.
 
Little info here on the forum at the moment so just thought I'd post up the solution to removing the spring tensioner for anyone who may need to know.

6 bolts to remove. 3 to drop the the aircon pump out the way, then another 3 to remove the bracket which holds the aircon pump. The bracket just pulls away leaving enough room to drop the tensioner and replace if needed. Worth doing just to give more room to attack the rear mounted bolt to replace the bearing for the spring tensioner bracket.

Hoping to remove the bearing from the front without replacing and snapping the rear bolt to remove as advised by Audi. Will know when I've got the replacement parts to see if it's do able! Will post up my solution when done.
 
Photo showing the aircon holding bracket removed to release the spring tensioner.
 
Photo for the Maestro Chris.

Starting to get to grips with this now but still appreciate your input please.

The old thin " top hat" bushes complete with pin/ seals seem in okay shape and firm enough. I've got a new tensioner bracket and there appears to be no wear in the old bracket internally as I've measured up against the new one. However there's about 3/4mm gap when you place the bracket in position. I'm assuming that the bush in the photo has let go and is incomplete which resulted in the bolt snapping and causing the belts to go.

There does not seem to be a part number for the inner tensioner bracket bush/bearing to replace and I did ask for all the new components as well?? Be nice if I could get a replacement bearing and replace from the front without having to take the power steering pump and oil cooler off to change everything. Would it make sense to change the lot now as I've come this far. Will take your valued experienced advice.

I've dropped the aircon pump and could take the power steering pump off and oil cooler. Is there any bleeding of the oil systems if I do take them off?

Thanks in advance.
2015 04 07 203631 800x600


2015 04 07 203631 800x600
 

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Another Photo
 

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You might just want a new inner bush and use new bolts and seals to make sure it's fine. Also buy a new bracket if you can, they do wear internally as they rub against the teflon coated top hat sleeves...When it's all rebuilt rock the assembly in and out to make sure there is no excessive play in the machined bearing/bush of the PAS/AC braket... When the bracket is in good nick the belt runs true, when it's worn the belt drives on the edge of the pulley cutting a groove into the plastic cowling...it soon jumps off the guides and wraps itself round the crankshaft pulley !
 
Thanks Chris.
Makes sense now it's nearly stripped to replace everything. Struggling to find the inner bracket bush I was sent all the listed items to replace but not the bracket bush as this must of been part of the bracket listing at one time but does not come with it anymore .The bush appears not to be listed on it's own?

I take it there are no problems with removing and reinstalling the power steering pump and oil cooler? Will I need gaskets or will some gasket sealant do the job?
 
audi upgrades
Just for reference and for anyone else having to do this job. I fully understand this job and what it entails now. The bearing that works the axis for the bracket tensioner is part of the main bracket housing and not a separate part. My bearing tolerance for the bracket tensioner is too far gone so I will have to buy the expensive larger bracket as well as the pin,top hat bushes and washers! Could of been worse I suppose the belts could of damaged the cambelt when they let go and ******** my top end.
 
John, from the pictures you provided it looks like the bracket might be in good nick, certainly the teflon bush looks ok, however the pivoting cast bracket that holds the tensioner roller do also wear where it rubs at the contact point with the PAS bracket. I would pay close attention to that and replace if ANY wear found- 1mm of play throws the belt a few good mm off the pulleys as it does not run true !

It's pity I don't have a picture of a worn bracket to show you, i have replaced many but did not take pictures at all... Hope it works well for you !
 
adamss24 said:
John, from the pictures you provided it looks like the bracket might be in good nick, certainly the teflon bush looks ok, however the pivoting cast bracket that holds the tensioner roller do also wear where it rubs at the contact point with the PAS bracket. I would pay close attention to that and replace if ANY wear found- 1mm of play throws the belt a few good mm off the pulleys as it does not run true !

It's pity I don't have a picture of a worn bracket to show you, i have replaced many but did not take pictures at all... Hope it works well for you !
Click to expand...

Hope your right here Chris cause it will save me £175 for the bracket delivered. Got a better photo here . The teflon bush has some damage at the bottom but more concerning to me is there is 3mm in slop (bush od 27mm inner tensioner 30mm) when you mate up the new tensioner bracket. It really does rattle about!

My conclusion was that there was so much wear on the teflon bush that it caused the retaining bolt to snap on the tensioner bracket..If that's normal tolerance then I'll just fit up.

I also have no movement in the main retaining pin and have good top hat bushes.
 

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The tensioner bracket is well larger than the bush it fits over it ! I would just rebuild the whole assembly with a new pvoting bracket, 2 new teflon washers and new inner bush + 2x new bolts ! The bracket looks fine to me going by the way the bush looks like ! If you pay attention at the bush (look at 9 o'clock) there should be no wear on the circular side of it ! If there is any wear on the sides then start with a new PAS bracket !
 
Thanks again Chris. I'll take your advice every time as I bet you've done 100 plus of these over the years. Just so surprising that the tensioner bracket has such a loose fitting to the bush on the PAS bracket. No doubt the bracket will tightened up when bolted up, just doesn't give me much confidence on the strength of the set up. Real crap design and such an awkward set up to replace?

I will check the bush again but suspect your very much right, it doesn't look like a bush with any normal obvious wear. Got all the other new parts so will rebuild tomorrow. Will put the pas bracket money towards pepping up the Allroad with a nice new slick turbo! :joyous:
 
Rebuilt the assembly today with all the new parts required. I took off the PAS bracket to do the job. Have read on here some one was able to do this job with out removing the bracket, beats me how it can be done that way. Not too bad a job to remove PAS bracket and then it's a breeze to replace the new parts when the bracket is secure in a vice. Got to be just as quick to do it that way too.

When I had the bracket in the vice I could detect a very slight bit off play with the pin in the small bushes, so as Chris recommends a must do job when your over the 150 thou mark. Will be doing this job on my Allroad near the 150 thou mark, this time there'll be no head scratching and I'll just tear down and replace within a fraction of the time.

I'll be replacing the spring tensioner. Managed to buy on fleabay a new alt belt, spring tensioner and idler pulley all for £43 so may as well replace the lot.

I did mention that I thought there was some lower damage on my PAS bracket bush on the photo this is just the top hatch bush which has that split in the facing end. No uneven wear on the bush either. Easy when you clean it down and dissemble and see what your working with!
 
audi upgrades
Hi,
Just doing the same job now to my 2.5 tdi.
Is the play in the tensioner bracket and bush normal??
Seems very sloppy!
In mine the bolt that holds this joint had sheared off!
 
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