Timing belt tensioner problem

[gbrownlee]

The cylinder head gasket on my Golf GT TDI required replacment and a friend of mine who is a mechanic offered to help me out. We bought a head gasket, inlet manifold gasket, exhaust manifold gasket, head bolts, a water pump, auxillary belt, timing belt and I had the cylinder head pressure tested and skimmed.

We are now at the stage of rebuilding and were attempting to fit the timing belt last night. However, the tensioner doesn't appear to have any movement at all.

After some googling, I have found that a tool should have been used to lock the tensioner before removing the belt?

As we have not done this, is anyone aware of how to rectify this or is there a fault with the tensioner?

Any input with this problem would be greatly appreciated. I will post a full explanation of the cylinder head gasket diagnosis as it may be of interest.

Many thanks,

Graham

[Col]

The tensioner itself, once a basic setting has been achieved (i.e. 4mm clearance), is regulated by a hydraulic plunger.

It is this pluger you need to set in the service position with a small steel forked peg.

The peg comes with a new hydraulic tensioner by the way.

I'd suggest that if you've left the tensioner plunger 'out' the it is probably best practice to replace it. About £70 from VW.... ouch.

The tensioner arrangement is a bit of a piglet !!

Good luck.

[gbrownlee]

BigCol,

Thats exactly what we were looking at. There is a small steel plunger as you say, and unfortunately it is all the way out. Somethings we failed to notice while taking the belt off - Ignorance can be costly.

Thanks for your reply

[Col]

Best advice is to get a new one unfortunately.... it will come with the locking peg btw.

[gbrownlee]

Thanks for your advice on this, I went to Euro Car parts and got a new 'belt tensioner dampner' for £45. We took the old one off the car and managed to contract the plunger in a vice. A tiny 6mm spanner worked as a retaining fork and we managed to refit the original. I am glad I bought a replacement just incase it all went pear shaped but the original is working fine. Thanks for your help on this BigCol,

Graham