Went to get g-box oil (1.8T AGU) when coming back no power steering. Aux belt had fallen off.

After removing the tensioner, originally thoght it had failed, bought a new tensioner & belt (had to go to an Audi dealer). replaced, started engine & noise from engine. stopped engine immediately. Removed the tensioner & the tensioner wheel was contacting the cam belt cover. Hmm? Old and new tensioner had same damage on the inside edge of the tensioners wheel. Now the last paople to remove this tensioner were the local Skoda dealer when they did the cam belt last year.

I noticed when removing the aux. belt tensioner that one of the three bolts where not fully torqued. After much thought, I then noticed that where the tensioner bolts to the engine the top two bolts also secure a bracket. This results in the tensioner being pulled at an angle towards the cam belt cover. I installed a washer of the same thickness as the bracket on the lower third securing point. Put everything back together, bingo works perfect.

Now I suspect that this lower third bolt was not fully torqued as when it was (by the dealer) it was pulling the tensioner in allowing it to make contact with the cam belt cover. Looks like there should be a shim (washer) on that third mounting bolt to ensure all three points are level.

I will be contacting the offending dealer to discuss this. If anyone has had the aux. belt tensioner off, maybe you could confirm the above.

The only persons that worked on this car (apart from me) and I have never removed this tensioner up to now was the suspect dealer.

:thumbdwn: :confused:

There shouldnt be any washers behind any of the three tensioner bolts.

They however should all be tight..lol.

Is the lower cover clipped in properly, it is possible that it isnt and is sticking out and rubbing on the tensioner.

Cover looks to be secure, Checked this out as I thought as you did that this would be the most likely cause of the tensioner contact the cam belt cover. The mystery thickens. PS Does the belt need to rotate in one direction, that is can it be fitted the wrong way round.

Regards

Adoks

Cover looks secure, does belt need to be fitted to rotate in a specific direction?

Regards

Adoks

Nope belt will work either way around but obviously must be routed correctly.

Update after further consideration, as you said no shim (washer) required on, so I removed it. If when re-installing the tensioner you tighten the top two bolts, then remove the tensioner pin to apply tension. The tensioner wheel will not be aligned with the belt, you can then tighten the bottom bolt until tensioner wheel is aligned with the belt. Start engine, re-check tensioner wheel to belt aligment (running central)

Used thread lock on bolts to ensure they do not loosen, particularly important on the bottom bolt as it can not be fully tightened.

If you continue to tighten the bottom bolt the tensioner wheel will contact the cam belt cover. Looks like this third bolt is to allow adjustment of the tensioner wheel. It also looks like that the mechanic who replaced the aux belt before made the same mistake as me, resulting in the tensioner wheel running in contact with the cam belt cover (you can see the marks of this) from time to time. With hindsight there was a noise on occasion (which I thought was the cold start emmisions pump).

Anyway seems OK now, but not so good for a 32000 mile carefully maintained car. My wifes Fiat seems more reliable & in some areas better engineered, although I may reverse this view the next time her car breaks down.

Regards

Adoks