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Discussion Starter #1
Hi folks, I recently bought a T4 with no alternator belt so went down my local VW specialist parts place and bought 2 belts as they suggested I need both an alternator belt and a separate power steering belt.

Had a little look today and now I'm scratching my head. Firstly, there's no tensioner as far as I can see. Notveven an arm to carry a tensioner. Secondly, do I need 2 belts or one?

The fact that there's no tensioner suggests somebody went to fix the belts, didn't finish the job and then sold it "as is" I guess. Been stood around for quite a while apparently.

It's an AJA engine 2.4D and any advice would be truly appreciated...
 

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One of these , it should have a spacer behind it to bring it out and inline with the power steering pulley, it bolts to the block with an allen head bolt.
Alternator moves to tension that belt.
 

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Discussion Starter #5
Hmmm...still none the wiser. Seems hard to get consistent advice on my particular engine. Are there really that many variations?

So, I have no belts. That;s the first question. Should I have one belt or two? As far as I can see, just one.

Then there's no tensioner whatsoever. The part that PGSI suggested looks like it would fit, but there's absolutely no way that the alternator moves. It's fixed, bolted and immovable. Looking at youtube videos, I'm seeing something like an L bracket with a pulley attached that acts as tensioner. I don't have that and assume I need it but can't locate that as a part on ebay.

Can anyone point me at the right part?

Secondly, if I get the part just mentioned, is there another tensioner at the bottom? Looks like a part was taken off where I have marked (see the photo attached).
176099
 

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Discussion Starter #6
176100
I

This is what I mean by the upper part. I don't have this at all and can't see where it would attache if I did. Also, can anyone reference the part number so that I can try and track it down if I need it? Is this what people mean when they say "tensioning from the alternator?"
 

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One thing....they are NOT V Belts....they are Poly-V.....totally different kettle if fish!
That's it for me.....I don't know the 2.4D at all (other than every thread I have read).
A poet and didn't know it.... :rolleyes:
 

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Yeh ribbed not v and the part i suggested is for v belts, unfortunatly i dont know what you need for ribbed.
 

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I definitely can't help with first hand knowledge but do these threads help:

 

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Okay, here are the parts you need:

074145278c 78mm idler pulley, held in with an M8x22 bolt and nut
074903308a clamping lever - the tensioning arm that goes through the bracket, held in with an m6x16 socket head bolt
028903315r tensioner on the back of the bracket. You might still have that on there though. held in with 2x m8x22 socket head bolts.

For completeness also get hold of 2x dust caps for the tensioning shaft, 028903310 and blob some grease on the shaft inside as they are only plain bearings in there. It it possible to replace those bearings as they do wear away to nothing eventually.

No idea which length of belt you need sadly as you have AC and I don't. It's sure not 1355mm long anyway, maybe 1694mm?

Good luck with it.
 

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Discussion Starter #14
Okay, here are the parts you need:

074145278c 78mm idler pulley, held in with an M8x22 bolt and nut
074903308a clamping lever - the tensioning arm that goes through the bracket, held in with an m6x16 socket head bolt
028903315r tensioner on the back of the bracket. You might still have that on there though. held in with 2x m8x22 socket head bolts.

For completeness also get hold of 2x dust caps for the tensioning shaft, 028903310 and blob some grease on the shaft inside as they are only plain bearings in there. It it possible to replace those bearings as they do wear away to nothing eventually.

No idea which length of belt you need sadly as you have AC and I don't. It's sure not 1355mm long anyway, maybe 1694mm?

Good luck with it.

This is fantastic, thank you. Just looking at the diagram in this photo, you are describing the parts in the top section. Is the bottom section an alternative set up or for different models or what? My mechanic was suggesting the metal casing around the alternator was more like the middle section diagram which seems to be a different ball game altogether....
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Hmm, that middle bracket I believe is for the 2.5 AET petrol engine. That's got a tensioner in a different place so there's just an idler on there. It seems the standard AJA bracket with the aircon fitting isn't shown, but it's similar enough for ilustration I guess. There's a few things missing from those diagrams and they're a right bugger to figure out sometimes.

Remember the tensioner is the last thing to be pulled by the engine before the belt goes back to the crank pulley, so starting from the bottom of the pulley it'll go crank - P/S - A/C - alternator - tensioner - crank.
 

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Actually, that bracket of yours I don't recognise. Are you able to post a pic of the other side of it? Whilst it might not be definitive, your sump fins don't match my AJA and the bracket holes don't seem to line up with any 2.4d block that I know of, but I can see your glow plug plug & bracket on the front of the block which seems normal...
 

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Discussion Starter #17
Actually, that bracket of yours I don't recognise. Are you able to post a pic of the other side of it? Whilst it might not be definitive, your sump fins don't match my AJA and the bracket holes don't seem to line up with any 2.4d block that I know of, but I can see your glow plug plug & bracket on the front of the block which seems normal...

Trust me to get something non-standard :(

176316


On the photo above, I can't see any way that the alternator can be adjusted. There is a hole next to the upper bolt on the alternator. Something (pully lever?) could theoretically go there? It doesn't go anywhere, just the top of the alternator case
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On this last photo, the hole where there was clearly a pulley of some sort before - can't see what's the other (back) side of it.

Still a complete mystery to me what tensioner I should have on here.
1581168931984.png
 

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Aha, things become clearer, cheers for the pics. You can see that hole is for an idler only - the marks where it's cut into the cover show that. I think I see a glimpse of a tensioner bracket above the crank pulley, which is standard for the 2.5TDIs.

A google image search of 2.5tdi engines gives a nice pic of the layout you have. There should be two idlers, one above the crank pulley and one in that obvious hole, and a tensioner up and rear of the crank pulley. The idlers should just thread into the holes with a bolt. The belt looks to be the one of the longest ones they do.

It's certainly an unusual setup for a 2.4. I wonder if VW were fitting TDI brackets to the 2.4's with AC in the end...?
 

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Discussion Starter #20
Isn't that bizarre? When I asked a local independent VW expert to look it up from the VIN, they came up with the original diagram I posted above but after googling what you suggested, I reckon you're right.

I'm tempted to take it to VW and ask them to sort it but am imagining several hundreds of pounds worth of main dealer costs which is just out of the question right now.
 
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