1.8T 20v Timing Belt Tensioner Cog Cracked!!!

[rosco]

I am busy stripping down the engine to gain access to the water pump and whilst trying to compress the plunger which acts upon the timing belt tensioner cog I managed to crack the 8mm allen key opening. I was following the haynes manual which said to use an 8mm allen key to compress the plunger. Looking at it now the 8mm allen key socket has a somewhat smaller allen key socket in its base, which i presume allows a vw specific tool to be inserted and therefore supply extra support.
Can anyone help as the 8mm allen key is simply spinning in the opening due to the cracks.

[kenney]

I would say you hadn't put the allen key in far enough.Anyway you will now have to replace the roller,to get it off simply remove the tensioner.

[rosco]

I would say you hadn't put the allen key in far enough.Anyway you will now have to replace the roller,to get it off simply remove the tensioner.

Is this a case of simply removing the 13mm nut from the centre of the roller/tensioner pulley?
And more importantly, will it fly off with the tension from the plunger when i ease it from its threaded bolt?

[kenney]

No the tensioner is the plunger you mention 2 screws fit it to the block,you can then remove the centre bolt of the roller.To refit the plunger,you will have to put it in a vise and press it very slowly til you can put the locking devise in.Or you can simply cut the belt,which will remove any tension on the roller,and you can press back the plunger,when you fit the new roller.