T4 TDI Woes

[tdi]

i know on a mazda van i used to have, mazda specs were "belt every 100k and tensioner only if needed". i found out the hard way that the tensioner must be changed at 100k regardless if its ok or not. luckily no damage for me though, just broken down. i wonder if a similar thing could have happened here. perhaps this "bearing'' should be changed at 120 or 60 (whatever specs say) regardless of its condition?
if a failed bearing caused it to snap, regardless of valve or cam condition this culprit bearing could still be found. but whether they want to find it may be a different story as it may show liability.

checked the invoice when the new belt was fitted and the cam belt tensioner roller was also replaced.

[jets]

With this sort of thing, I imagine after its failed it would be hard to diagnose the actual cause of failure

There are a couple of bearings in there. Inside the tensioner & the waterpump. If they haven't thrown them away it would be easy to see if bearing failure was the cause of belt failure. The tensioner housing can also break & is sometimes caused by trying to turn the tensioner the wrong way at installation.
Re sunny's comment about the tension in the tensioner it's only a matter of lining up the pointers at installation, turning the crank a couple of turns & checking that they are still in line. You can also check this setting some time later to see if all is well.
I have also read where a failed harmonic balancer can bring the whole house down.
Another guy had the crankshaft bolt break, the harmonic balance pulley went rolling down the road. I suspect someone didn't know or care that it is a stretch bolt, one use only. There are plenty of people that don't use the proper tools & use a rattle gun[she'll be right mate]
It's also possible to remove the top guard & have a look at the condition of the belt although I have been told that sometimes they just break & there are no evidence beforehand of what's about to happen.

[Sunny43.5]

Still interested to know what part failed that caused the belt to break .

[jets]

Me too.

[Seano]

I'd work on the assumption that it was the water pump since that is what seems to be the killer based on comments on the interweb over the years. I'll even wager it was the original pump. Current recommendations for the 2.5 TDi are belts (there are two on my ACV engine) and tensioners every 60K and water pump every 120K.

Mine are getting done on Tuesday.

Parts wise I was quoted about $120 ex GST for the pump and $330 ex GST for the timing belt kit...both from the dealer. Bursons gave me a similar price (a bit cheaper for the pump). Throw in coolant and about 7.5 hours labor and the dealer bill is looking at $1,400...

[jets]

I was in collecting some parts that I had ordered & decided to ask at the service desk what the current change period for cambelt change for a T4 with 2.5TDI engine is. I was told by two guys there, 100.000km or 7 years. I went away thinking, that can't be right so I called another dealer who told me 105,000km or 7 years. I wonder what numbers we would get if some of you try your local dealership.

[Transporter]

Infortunately, to get the Timing belt interval right; would be to email VW head office and get the answer form them.

[gldgti]

Parts wise I was quoted about $120 ex GST for the pump and $330 ex GST for the timing belt kit...both from the dealer. Bursons gave me a similar price (a bit cheaper for the pump). Throw in coolant and about 7.5 hours labor and the dealer bill is looking at $1,400...

My dad's just done the timing belt on his T4 caravelle 2.5TDI - all the bits cost him about $400 from tooley imports. I wouldnt use bursons for the timing belt parts, unless i knew the brand was german. last belt from bursons I got was a dayco (ribbed belt, snapped).

Did the whole job himself but it took him a weekend and he had to make several tools.

[Transporter]

My dad's just done the timing belt on his T4 caravelle 2.5TDI - all the bits cost him about $400 from tooley imports. I wouldnt use bursons for the timing belt parts, unless i knew the brand was german. last belt from bursons I got was a dayco (ribbed belt, snapped).

Did the whole job himself but it took him a weekend and he had to make several tools.

Yes, the Bursons are still selling Dayco only. The original t/belts are from Continental and appear much stronger than Dayco.

Yeah, I've replaced the water pump in my T5 in 8 hours, when making the tools to do it fast next time.

[gecko2k]

I have found a lot of good information regarding belt change on T4s. I am fairly busy atm, I will try to post i up on the weekend!

[jfoldbar]

Infortunately, to get the Timing belt interval right; would be to email VW head office and get the answer form them.

ive tried this with other issues. head office will not deal with public and will suggest that you contact dealer for technical information

[jets]

During the conversation I had with one of the dealers I spoke to they couldn't get much info out of head office as well.

[Transporter]

The current Autodata says
For 2.5TDI
Up to 1999 check the timing belt every 30,000km and replace t/b incl. tensioner at 120,000km
From 2000 check t/b at 60,000km and replace t/b incl. tensioner at 120,000km

Regardless of time.

I would use the Autodata information if I couldn't get the answer from VW head office.

[Sunny43.5]

Maybe we should rename VW,s Australian branch as VW "Dead "office . because like dead people they will never answer you . I had some dealings with them some time back and their response was gobsmacking , I asked about sealed for life via an email and a lady rang me with the information that she did not know what it meant , so I asked if she could ask the technical department . The next repsonse was no I cant they wont talk to the customer care persons who are supposed to pass on information to the customer , I then asked were they in a different building "no" they are in the same building I asked were they on a different floor "no" they were on the same floor , apparently these technical boffins must lock themselves in another room and not communicate with any one . I hung up what a waste of time .

[Transporter]

You could also check the erwin site. The info from there could be closer to be the truth than talking to someone in the VW dead office.
Oh, take that back, I mean the VW head office.

https://erwin.volkswagen.de/erwin/showHome.do