SERPENTINE BELT REPLACEMENT - T5 2010 2.0L TDi 6SPD MAN SWB

[KanaVW]

Hi,

Serpentine belt totally failed on my T5 2010 2.0L TDi. Had rego inspection last week and a small cut and burr of rubber was noticed on the belt. This burr was clipped off with the hope the belt would last. Alas, last night the belt failed on the highway. T5 is now parked up safe near the shops not far away.

I have replaced serpentine belts easily on cars before, but not the T5 2010 van. So, I have a few questions which I really hope someone can help out with.

1) Where can I get a diagram of how the belt goes?
2) Any tips or instructions for putting the belt on? I can see the tensioner, looks tight but doable.
3) What belt should I get, or any recommendations where to buy?
4) Pulled most of the old belt off. The wheels all turn ok and feel ok. Looks like some old rubber will need to be cleaned out from the grooves. Any other tips?

Hope I can do this myself. Might be a useful post for others. Couldn't find another about this, though sorry if its already out there.

Cheers Ken

[wanderingwilson]

KanaVW, first you should go and buy yourself a Lottery Ticket. What usually happens after this belt fails is sections of it get past timing belt guard and under the timing belt where everything goes rapidly downhill and costly from there. They are not easy but doable to a good tool man. Cheers

[KanaVW]

Thanks for the advice.

[winchy]

@KanaVW, does your pulley assignment resemble this? Please disregard if it's different and excuse my naivety as I'm not clued up on the T5. This is a diagram of a Bi Tdi 2.0 Amarok motor, so not sure if it is similar to your engine configuration. Did a few tensioner and belt changes on the Amarok. The tensioner retaining bolt is at the rear ( Amarok)


Sent from my SM-G930F using Tapatalk

[Umai Naa!!]

Nah, that's different to the Transporter one.

[winchy]

Ahh, fair enough.

Sent from my SM-G930F using Tapatalk

[KanaVW]

Thanks winchy. Yes, looks a bit different, but don't have it in front of me.

Some more info. After the comment above about the possibility of the serpentine/acc belt getting past the timing belt cover and into the timing belt causing disastrous failure I decided to have a closer look. Took off the upper cover, and had a very close thorough look with a torch down inside. A looks ok and clear. And it all starts and runs no-problem. So, lucky!

That upper cover is really a flimsy bit of plastic protecting a vital part of the engine. Its now back on properly, but looked like it had not been replaced correctly at some other time as the top and lower parts were mis-aligned allowing a gap, easily done. Re-tensioned the clasps also. There would be 100 ways to make that cover better.

Still after the serpentine belt path diagram.

[Rebuild]

wasn't there a modification or an updated timing belt cover for these 5.1's, to stop those engine failures?
a recall?
did a quick google.Couldn't really find much

edit,
Kana, check the tensioner for any damage/alignment issues

There is an updated cover for the Amaroks
Dead Engine. Multi V belt failure took out timing belt and engine.

[winchy]

The Amarok Bi turbo had a bulletin for the updated lower timing cover, to reduce the chance of serpentine belt ingress into the timing belt area if the serp belt broke/ shredded. No recall though.

Sent from my SM-G930F using Tapatalk

[KanaVW]

Looking on the TDi with the standard turbo, the lower cover looks impenetrable on its own. But, where the lower and upper cover meet there is a possible gap, unless both are carefully mated together which is fiddly with interlocking plastic tabs. It would be easy to imagine a serpentine belt breaking and just catching the lip of the covers then being rapidly speared inside and tangling with the timing belt. Especially if the upper cover was hit with some force. There are some numbers on the upper cover, on a sticker. I wonder if this identifies an updated cover or not? Alternatively, may be some improvisation precautionary...

[LogicprObe]

This is mine 2011/12 2.0 TDI 6sp man

[LogicprObe]

Cost $56 at VW...............only just did it last month when I had to replace the alternator.
(now there's a story of woe..........you wouldn't want to do that job every day!)

[REVHE4D]

When Vw change the belt, the also change the waterpump at the same time, and robustnesskit is installed as well, beefed up rollers and cover are included in the kit. I had mine done at 120000k

Sent from my SM-G955F using Tapatalk

[LogicprObe]

The serpentine belt doesn't do the waterpump.
That's the timing belt.

[KanaVW]

Thank you Logic, winchy, and all. That (Logic) is the way it goes. Looks the same as the other pic also.
And yes it cost $56 Looked like there was some grit and rubber stuck in the grooves that had caused the belt to run off. Cleaned all this up, took an hour, then installed the belt in 10 min. All goes well now. A few things to note for others who might need to know:

1) Belt is 6PK-1555
2) Before replacing serpentine belt, remove the top cover to the timing belt. Check inside. Retention clips if required. Replace cover being careful to very correctly align interlocking tabs securely.
3) Make sure to remove any loose bits of belt.
4) If the timing belt is all ok - runs the water pump, and if there is charge in the battery, vehicle can be driven ok without power steering or head lights. Drove it for about 20min on the highway. (Apparently can be driven over 100km depending on battery level to operate computer/injection etc.)
5) Make sure to clean any dirt or rubber thoroughly from pulley grooves before replacing serpentine belt.
6) Check pulleys spin ok.
7) There is a small hole in the arm of the tensioner pulley. Using a socket/spanner lever back arm fully then insert a small hex key or similar strong pin into this hole which then holds back the sprung tensioner arm/pulley.
Replace serpentine belt. Not difficult with diagram (above) and locking pin in hole. With the right sized belt observing smooth/v-groove placement, there appears to be only one obvious path.
9) Check belt is seated carefully. Check timing belt cover is secure. Go.