Setting Timing Belt Tensioner - 1.9 TDI AWX

[daveo138]

I'm in the process of replacing the timing belt on my 2003 (53) 1.9 TDI.

Apart from the motor factors supplying all the wrong parts, it seems that the timing belt tensioner is nothing like the Haynes manual, so I am at a loss as to know the correct way of setting it....that is assuming that when I get the correct part tomorrow, it will be the same as the one I am taking off.

The kit that they supplied looks as though it is for an earlier model, with the hydraulic tensioner.

I will try to attach a photo of the old tensioner. It has a pointer on it, which I am assuming will have something to do with setting the tension.

Any help greatly appreciated

[redmax90]

be carefull what engines are being show in the diagrams in the hayes manual. the pd engines have different tensioners than the older distribution pump engines. However depending on who makes the kit the design of the tensioner may vary. what make of kit did ya buy ?

[passat>sport]

That is the newer tensioner in the pics.
Yes the haynes manual has the one with the hydroulic piston type thingy. (old type) It's the same as the haynes book says but you tension the tensioner clockwise untill the pointer points in the recess.

[Crasher]

Just be thankful you haven’t got the hydraulic tensioner, setting them up to a 4-mm gap drives be potty! I am going to experiment one day, converting a hydraulic tensioner model to the friction tensioner. You do have the proper cam and crank locking tools, don't you?

[passat>sport]

Just be thankful you haven’t got the hydraulic tensioner, setting them up to a 4-mm gap drives be potty! I am going to experiment one day, converting a hydraulic tensioner model to the friction tensioner. You do have the proper cam and crank locking tools, don't you?

I've done it crasher, The car we spoke about has had a 2001 engine fitted, All I did was change the rear cam cover and drill another hole/tap for the guide roller. It was a bit wonky (my drilling) and the belt runs a little toward the engine side of the cam/sprocket. I'm sure you've got better tools to do the job than I have.

[Crasher]

Humm, a bit of a pain in a Golf 4 engine bay.

[passat>sport]

Well yes. I meant guide roller btw not tensioner. I'm sure you knew that.

[daveo138]

Thanks for the replies.

I bought the Laser crankshaft tool and used a 6mm rod for the camshaft.

The timing belt kit was by Gates - pic of wrong tensioner attached.

It also had the wrong idler roller.

The motor factors also supplied me with a tensioner for the air-con belt instead of the one for the auxillary belt, which I ordered.

I'm hoping they'll have the right parts in stock tomorrow.

[passat>sport]

When you tighten the tensioner make sure you counter hold the tensioner while you tighten/torque the nut with your other hand. The pointer moves otherwise. And do it with a cold engine.