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Volkswagen EuroVan: 1992-2003 (T4) Replacing serpentine belt


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Last Post: Dec 30, 2017 1:53 AM Last Post By: AlexThaimor
haris

Posts: 12
Registered: 05/22/04
Replacing serpentine belt
Posted: May 22, 2004 7:37 AM
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Help! I managed to remove my old serpentine belt by loosening one of the smooth belt rollers, but now I can't figure out how to loosen the belt tensioner pulley so I can slip the new belt on. This is so frustrating and there's so little room in there. Thanks for the help.
gregoryw

Posts: 285
Registered: 11/16/02
Re: Replacing serpentine belt
Posted: May 22, 2004 9:22 AM   in response to: haris in response to: haris
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Don't mean to put you down, but you went about changing the belt the wrong way. Been there and done that (on other VWs). Anyway, on the EuroVan the bracket that holds the tensioner pulley must be turned. It is spring loaded and requires a special tool. As you may have noted, it is not very accessible. The first time I did it I did not have the special tool. I went to Sears and purchased the largest "channel lock" type pliars that they had. I then used a band clamp with screw drive (like used to secure hoses, but large) to hold the handles together and keep the pliars tight on the bracket. This worked, but is was not easy. The special tool is available at Zelenda Tools (www.zelenda.com) and others. It makes the job easy. Good luck with getting it back together.

Windy Gregory
www.VUupdate.com (EuroVan Update newsletter)
TomB

Posts: 1,416
Registered: 08/06/02
Re: Replacing serpentine belt
Posted: May 22, 2004 11:22 AM   in response to: haris in response to: haris
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Attachment Belt removal.bmp (52.6 KB)
You don't say what year or which engine this is. If it's a 97 or later VR6 engine it is much easier. The "special tool" needed for that is just a long M8 bolt! The tensioner body has a threaded M8 hole towards the front. (illustration from the manual is attached) You screw in the bolt and tighten, and it contacts the spring-loaded arm and gradually releases the tension on the belt. Loosen more than you think you need, as the new belt tends to fit tighter.
I've done this without even pulling the radiator forward for more room. Just need to remove the bottom shroud and remove and replace the belt from their after loosening with the bolt from above. It's a very easy job on these engines.
haris

Posts: 12
Registered: 05/22/04
Re: Replacing serpentine belt
Posted: Jun 1, 2004 6:48 AM   in response to: haris in response to: haris
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Sorry I didn't mention it, but it's a 1993 Eurovan with the in-line 5 Audi 2.5 engine. Well, I borrowed the special tool from my local VW repair shop (what a nice fellow!) and got the belt replaced, but the high-pitched whirring noise (like a swarm of cicadas for those who know the sound) is still there! It is especially noticeable when accelerating, is present even at highway speeds, but momentarily disappears when the engine upshifts in local driving. Any suggestions as to which pulley is the most likely culprit or ways to isolate where the noise is coming from? Thanks for all your help thus far.
haris

Posts: 12
Registered: 05/22/04
Re: Replacing serpentine belt
Posted: Jun 1, 2004 6:51 AM   in response to: gregoryw in response to: gregoryw
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Got it replaced with the special tool borrowed from my local VW dealer, but the high-pitched whirring nosie (like a swarm of cicadas) re-appeared after a couple of hundred miles. It picks up as one accelerates, disappears briefly with the upshift, and is still present on the highway. Any suggestions as to ways to isolate where the noise is coming from and/or the most likely culprit? It seems the belt is plenty snug. Thanks.
TomB

Posts: 1,416
Registered: 08/06/02
Re: Replacing serpentine belt
Posted: Jun 1, 2004 4:01 PM   in response to: haris in response to: haris
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Among the possible sources I'd think the ribbed belt tensioner pulley or the idler pulley as the most likely and also easiest to change - if you can get the special tool again! In the Audi A4 forum is a post commenting on the whining noise that was cured by replacing.
However, potentially more serious would be the timing belt tensioner pulley. I'm hearing of more cases where this siezes and takes out the belt, which in turn bends valves, etc. Not a good thing. When was the timing belt last changed?
Especially with the timing belt I'd replace the tensioner pulley whenever the belt is replaced. This style of belt is used on a lot of VW/Audi engines, and many have gone to recommend replacing the belt and tensioner at 60,000 mile intervals. I don't think they have specified this for the EV yet, but when they are so similar...
I've also had loud whining from alternator bearings, etc. I use a mechanics stethoscope to probe areas (be careful around the belts and pulleys - contact areas close to them) to find where the sound is loudest.
tantalus

Posts: 922
Registered: 06/02/04
Re: Replacing serpentine belt
Posted: Jun 2, 2004 8:21 AM   in response to: TomB in response to: TomB
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Just remember that along with the tensioner pully there is also an idler pully for the timing belt.
corradoman

Posts: 107
Registered: 02/14/04
Re: Replacing serpentine belt
Posted: Jun 13, 2004 5:56 AM   in response to: tantalus in response to: tantalus
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Just another thought fellas the spring loaded tensioner shaft can get gunged up and it sticks giving improper tension when the engine is loaded up.The tensioner can be removed and cleaned and rebuilt saving you$$ getting a new tensioner this really works and have carried out this task several times. If you need any advice on how tro strip the unit let me know. Also when replacing the belt you should use Continental belts as the rubber is softer.
haris

Posts: 12
Registered: 05/22/04
Re: Replacing serpentine belt
Posted: Jun 25, 2004 11:43 PM   in response to: corradoman in response to: corradoman
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How do I remove the belt tensioner? I don't have the manual, and there doesn't seem to be a lot of room to work. Thanks for the reply from beautiful Down Under!
corradoman

Posts: 107
Registered: 02/14/04
Re: Replacing serpentine belt
Posted: Jun 26, 2004 1:35 AM   in response to: haris in response to: haris
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Hello again is your Vw a 5 cylinder? The tensioner layout is different depending on the engine. If 5 cyl you can remove the 4 bolts holding the air con compressor and hang the compressor out of the way. You also remove the power steering pulley which has 3 6mm allen bolts. This then exposes the tensioner arm.Remove the tensioner pulley and the 2 6mm allen bolts on the spring tensioner and 1 5mm allen bolt on the end of the arm. Then remove the tensioner housing .Fit a slave bolt in the arm and knock the arm out of the alloy housing. This you will find will be gunked up. The slave bolt only acts as aid to help knock the arm out without the threads being damaged. Clean the arm and housing . Refit with silver or copper grease and refit in reverse order. If you have a VR6 then all you need is 3 inch long M8 bolt which screws into tensioner and this releases tension.
Good luck hope the message is clear.
buddy6713

Posts: 4
Registered: 07/11/04
Re: Replacing serpentine belt
Posted: Jul 11, 2004 2:22 PM   in response to: corradoman in response to: corradoman
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Hello. Own a 93 GL, 5 cylinder gas and at precisely midnight on a lonesome stretch of Oregon highway in the U.S. my fully loaded (with river rafting gear) car started losing steering and power, alternator idiot light came on, ABS light came on and then the car stopped shortly afterwards. I smelled burning rubber and suspected a belt or two.

After an all night tow 200 miles I am now awake again and read the manual which describes 3 different V belts with 3 different parts numbers: power steering/ac; alternator/something else; and something else.

When I called my parts store they said their computer search only showed a serpentine belt, not three separate belts. That belt was available for $35.

I'm eager to do something now but lack experience on this car (used to be able to do things with my old beetles and vans from the 60s)

When I looked under the hood I think I saw a split and severred v type belt, but it was hard to even see much less touch.

What do you think is going on and if it's a serpentine belt is it something I can really replace?

Tks for your comments.
tantalus

Posts: 922
Registered: 06/02/04
Re: Replacing serpentine belt
Posted: Jul 11, 2004 6:39 PM   in response to: buddy6713 in response to: buddy6713
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As far as I know the only Eurovans imported into the US had the surpentine belt. I'm not sure of EV's sent to Canada. Any chance yours is not a US model?

To replace the surpentine belt you will have to overcome two obsticales:

1. Remove the belly pan. The belt is mostly removed from below.

2. Since your belt is toast and is probably gone you will be saved the trouble of removing it. But to put the new one on you will have to pull the tensioner back. VW has a special tool, I always just a simple 10" adjustable wrench. I first get the new belt looped into this tensioner pully (and what ever else I can get on) and then with the wrench pull the tensioner back. While holding it there use your other two hands to get the belt on all the other pullys

This is one of those jobs that the first time will be hard and take over an hour. But the next time it will be easy and take 10 mins.
blisspacket

Posts: 20
Registered: 07/28/04
Re: Replacing serpentine belt
Posted: Jul 28, 2004 12:50 PM   in response to: haris in response to: haris
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Thanks for your info, hans. I used the pliers and hoseclamp and lever pipe. My belt was OK, but I had that terrible bad bearing noise. Mine came from the a.c. compressor, which didn't work anyway, so it's in the trashcan, and Autozone's Kelly Springfield belt 710K6 fits the shortened spans without the compressor. Twelve bucks and a quiet but warm ride.
lars

Posts: 38
Registered: 03/22/04
Re: Replacing serpentine belt
Posted: Jul 22, 2008 1:46 PM   in response to: blisspacket in response to: blisspacket
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I just replaced the alt. belt on our '92 Eurovan (Canadian) a few weeks ago. I was too cheap to buy a tensioner tool (I think some of the generics will also work, but they cost over $60...when I have more time, I'll make one). In the meantime, I used a ratchet strap to move the tensioner pulley. Basically, I put the belt on the pulleys where it runs on the outside (ie: the pulleys that have grooves in them), then I put the ratchet strap around the belt and those same pulleys, and ratcheted it down really, really tight to the point where it started to pull the tensioner arm inwards. That allowed me to slip the belt over the inner pulleys.

Warning: use a good quality ratchet strap and face protection. It would be a "bad thing" if the strap were to break while your face were a few inches away.

...lars
k4blammo

Posts: 1
Registered: 01/21/09
Re: Replacing serpentine belt
Posted: Jan 22, 2009 12:54 PM   in response to: corradoman in response to: corradoman
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RE: corradoman's post

---> "Just another thought fellas the spring loaded tensioner shaft can get gunged up and it sticks giving improper tension when the engine is loaded up.The tensioner can be removed and cleaned and rebuilt saving you$$ getting a new tensioner this really works and have carried out this task several times. If you need any advice on how tro strip the unit let me know. Also when replacing the belt you should use Continental belts as the rubber is softer. "

I realized you posted this almost 5 years ago, but I would be very much interested in learning the procedure to rebuild the tensioner on my 93 eurovan. I have the special tool to remove tension, and the thing won't even budge with that. I dont know if the thing can be saved at this stage of the game, but if you think that rebuilding it could save it, please let me know!

Message was edited by: k4blammo

JRAMAGE

Posts: 1
Registered: 09/23/16
Re: Replacing serpentine belt
Posted: Sep 23, 2016 7:58 AM   in response to: corradoman in response to: corradoman
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Hello there corrodoman,
I work in a shop in Northwestern Ontario Canada. I've come across a situation with a 93 VW Eurovan 2.5L(gas) 5spd.
Vehicle requires the drive belt tensioner be replaced. I am in the same situation with a 074903315b tensioner. The only tensioner listed is a 044903315C - this tensioner I have received from a VW dealer parts dept. This particular VW parts dept. has not info to help resolve this situation.

So far I have determined that the only solution reported for this issue is cleaning and rebuilding the tensioner. If you could provide info pertaining to this task that would be extremely helpful.
Is there possibly a secret tensioner part # that no one is aware of?

Any help with this situation would be greatly appreciated.

Thanks in advance,

Jason Ramage
Done Rite Tire & Auto
866-622-1148
Jason@donerite.ca
sidd

Posts: 7
Registered: 12/17/17
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Posted: Dec 17, 2017 8:32 AM   in response to: JRAMAGE in response to: JRAMAGE
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AlexThaimor

Posts: 2
Registered: 12/30/17
Re: Replacing serpentine belt
Posted: Dec 30, 2017 1:53 AM   in response to: TomB in response to: TomB
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