www.tdiclub.com

Economy - Longevity - Performance
The #1 Source of TDI Information on the Web!
Forums Articles Links Meets
Orders TDI Club Cards TDIFest 2015 Gone, but not forgotten VAG-Com List Unit Conversions TDIClub Chat Thank You



Go Back   TDIClub Forums > TDI Model Specific Discussions Areas > VW MKIV-A4 TDIs (VE and PD)

VW MKIV-A4 TDIs (VE and PD) This is a general discussion about A4/MkIV Jetta (99.5-~2005), Golf(99.5-2006), and New Beetle(98-2006). Both VE and PD engines are covered here.

Reply
 
Thread Tools
Old October 26th, 2010, 22:09   #1
smokedvw
Member
 
Join Date: Oct 2005
Location: Victoria, BC Canada
Default Question on Stripped Serpentine Belt Tensioner Bolt...

Today while replacing my alternator I was putting the serpentine belt tensioner back on and stripped the thread which the longer bolt goes into... (the top one in this picture). I am assuming I am going to have to go with a helicoil kit to fix this. The bolt does not seem to come out on the other side to use a nut and it looks like a helicoil is the only way. We pulled out the windshield washer container and figured it might be to difficult to get a small drill in this area and may have to create a manual one with the kit and a socket set.

Is this going to be a problem to not fix this bolt and rely on the other 2 to hold the tensioner? It seems like this bolt takes more of the load for the tensioner.

I was looking for any suggestions from anyone who has had to fix this at this location before.

A hard pipe (I believe AC line) runs at the bottom of where the windshield wiper holder is and because of this its hard to get a drill at a level position with the hole that the bolt goes into. I have 2 small makita drills and the driver looks like it would be just small enough but the smaller drill hits the line and cant get level.


__________________
19" Axis Supermesh
2.25" FK Hi-tech Suspension Kit
Ottinger Grille
smokedvw is offline   Reply With Quote
Old October 26th, 2010, 22:32   #2
Joester
 
Joester's Avatar
 
Join Date: Aug 2009
Location: St. Louis
Fuel Economy: 52/42/28
Default

mine did the exact same thing when i was replacing the alternator. its been running fine on 2 bolts for about 5 months now, i forgot which one of mine stripped though.

I thought about it too, and i think a helicoil would be the only plausible solution.

I figure when it does break ill say "aww shucks" get AAA tot ow me home and Helicoil it. im kinda relying on luck to let it break someplace and some time convenient

EDIT: i think we actually stripped the same bolt. thats the one that part of the bolt shaft is smooth before the threads appear right?

if you do end up helicoiling it tell me how it goes.
__________________
2002 Golf 4dr 5spd TDI ---- Malone stage 4 - Borg Warner BV-39 - PP520 Nozzles - South Bend Stage II Daily Clutch - TacoTaco Intercooler - Bilstein Sport Shocks and Struts on H&R Sport Springs - 17x7 Long Beach Wheels with Bridgestone S0-4 Summers - General Altimax Arctic on Stock 15s for Winter

Last edited by Joester; October 26th, 2010 at 22:37.
Joester is offline   Reply With Quote
Old October 29th, 2010, 07:10   #3
wolfman79
Newbie
 
Join Date: Oct 2008
Location: Columbus/Gambier, Ohio
TDI(s): 2002 Jetta
Default

I just stripped the same bolt while installing my new tensioner! Has anyone checked to see how far the threaded hole extends into the engine block?...maybe a slightly longer bolt could be used to reach good threads?
wolfman79 is offline   Reply With Quote
Old November 1st, 2010, 12:28   #4
Joester
 
Joester's Avatar
 
Join Date: Aug 2009
Location: St. Louis
Fuel Economy: 52/42/28
Default

IIRC the bolt goes all the way through, it actually doesnt go into the engine block i dont think, it goes in an aluminum part mounted to the engine block, but its such a giant part, you might as well just take out the engine to replace the part that bolt goes into.
__________________
2002 Golf 4dr 5spd TDI ---- Malone stage 4 - Borg Warner BV-39 - PP520 Nozzles - South Bend Stage II Daily Clutch - TacoTaco Intercooler - Bilstein Sport Shocks and Struts on H&R Sport Springs - 17x7 Long Beach Wheels with Bridgestone S0-4 Summers - General Altimax Arctic on Stock 15s for Winter
Joester is offline   Reply With Quote
Old November 1st, 2010, 14:33   #5
VW Petrolero
Veteran Member
 
Join Date: Aug 2002
Location: Vancouver.BC
Default

Quote:
Originally Posted by smokedvw View Post
Today while replacing my alternator I was putting the serpentine belt tensioner back on and stripped the thread which the longer bolt goes into... (the top one in this picture). I am assuming I am going to have to go with a helicoil kit to fix this. The bolt does not seem to come out on the other side to use a nut and it looks like a helicoil is the only way. We pulled out the windshield washer container and figured it might be to difficult to get a small drill in this area and may have to create a manual one with the kit and a socket set.

Is this going to be a problem to not fix this bolt and rely on the other 2 to hold the tensioner? It seems like this bolt takes more of the load for the tensioner.

I was looking for any suggestions from anyone who has had to fix this at this location before.

A hard pipe (I believe AC line) runs at the bottom of where the windshield wiper holder is and because of this its hard to get a drill at a level position with the hole that the bolt goes into. I have 2 small makita drills and the driver looks like it would be just small enough but the smaller drill hits the line and cant get level.


Just do the Helicoil repair and you 'll be OK THAT BOLT DOES MOST OF THE WORK IN KEEPING THE TENSIONER IN PLACE.
Later
__________________
Andes Auto is back in Richmond B.C.
(604) 401-2137
TDI Friendly Repairs.TBs & Vag-Com .
VW Petrolero is offline   Reply With Quote
Old November 1st, 2010, 17:47   #6
iantyler
Veteran Member
 
Join Date: Sep 2010
Location: ny
Default

oof very tight squeeze in there. good luck on it!
iantyler is offline   Reply With Quote
Old November 1st, 2010, 18:29   #7
DanG144
Veteran Member
 
Join Date: Aug 2007
Location: Chapin, South Carolina, USA
Default

Ask DidJettarun for some tech tips on this.

He had a stripped bolt, and did two helicoil repairs.

Dan
DanG144 is offline   Reply With Quote
Old February 3rd, 2011, 14:59   #8
mike92105
Member
 
mike92105's Avatar
 
Join Date: Apr 2004
Location: Lemon Grove CA
Fuel Economy: Seems like it used to be better
Default

I just did the same thing,stripped the longest bolt on the tensioner. At first I thought it was a helicoil that the factory put in because it came out looking like a helicoil. I've never done a helicoil so I guess this will be a new skill set for me. I thought about just drilling the hole all the way through as it appears the bracket is just aluminum, but figure I'll try the helicoil first and if that doesn't work I can always drill it all the way through. I'm pretty sure I never put more than 25 ft/llbs on the socket wrench. Still not sure why the factory didn't put more threads in there knowing it was aluminum and therefore not very strong.
mike92105 is offline   Reply With Quote
Old February 4th, 2011, 13:29   #9
DidJettarun
Veteran Member
 
DidJettarun's Avatar
 
Join Date: Nov 2008
Location: South Carolina
Default

Yep the bolt brings out the threads with it and it looks just like a failed helicoil...And yes when I did the repair I used two helicoils...one for the failed bolt and one for the good one that I drilled out by mistake talking to DanG144 while I was working...LOL
__________________
2005.5 Jetta, package 2, RC 1+, DG Bypass Oil Filter,Metalnerd Magnetic Oil Plug
2003 Jetta GLS, Cat Fuel Filter
"When the people fear the Government that is tyranny; when the people fear the camshaft it's a PD
DidJettarun is offline   Reply With Quote
Old February 4th, 2011, 14:39   #10
mike92105
Member
 
mike92105's Avatar
 
Join Date: Apr 2004
Location: Lemon Grove CA
Fuel Economy: Seems like it used to be better
Default

Just finished, the bolt is a 8mm 1.25 pitch 3.25 inch long bolt. When doing a heli-coil you will need a 21/64 drill bit and an angle drill adapter. It was my first heli-coil so I took my time. Needless to say it took me a while, thought I busted out the tang, but on inspection with a mirror it was still there, several attempts later, gonzo! I was a little hesitant to put too much torque on it when I was done, does anybody know what the torque should be on this bolt?
mike92105 is offline   Reply With Quote
Old February 4th, 2011, 14:41   #11
mike92105
Member
 
mike92105's Avatar
 
Join Date: Apr 2004
Location: Lemon Grove CA
Fuel Economy: Seems like it used to be better
Default

The good news is the tensioner does not have to come out. You can drill and heli-coil right through it.
mike92105 is offline   Reply With Quote
Old February 28th, 2011, 17:11   #12
r72gsaol
Veteran Member
 
r72gsaol's Avatar
 
Join Date: Jan 2010
Location: Upstate New York (Have Vag-Com)
Default

Found this bolt missing on my beetle while doing the timing belt.

I just tapped it out to 3/8x16 SAE thread. The tap will go right into the existing hole with a little work and the hole in the tensioner needs to be opened up just a hair to 3/8.

Easy quick 30 minute fix.
__________________
Have a Vag-Com located near Albany NY
r72gsaol is offline   Reply With Quote
Old January 1st, 2015, 18:51   #13
brandonkraemer
Veteran Member
 
brandonkraemer's Avatar
 
Join Date: Dec 2013
Location: Cincinnati, Ohio --> LA, CA
Fuel Economy: 42 mpg
Default

I've never attempted to tap out for a bolt before and I have this same issue on the long bolt for my tensioner. I like the sound of the tap vs. helicoil and doing the work with a wrench. Is there a pictorial on this type of repair or specific advice on necessary tools?
__________________
Mods: SB Stage 2 Daily, Panzer FMJ, Cage
brandonkraemer is offline   Reply With Quote
Old January 2nd, 2015, 07:49   #14
jimbote
 
jimbote's Avatar
 
Join Date: Jul 2006
Location: spiral arm, milky way (aka central NC)
Fuel Economy: golf=38-43mpg...tacoma tdi=29-33mpg
Default

Quote:
Originally Posted by r72gsaol View Post
Found this bolt missing on my beetle while doing the timing belt.

I just tapped it out to 3/8x16 SAE thread. The tap will go right into the existing hole with a little work and the hole in the tensioner needs to be opened up just a hair to 3/8.

Easy quick 30 minute fix.
this ^^.... easiest and quickest method! .... that one long bolt threads into a very thin part of tbe bracket ... it's no wonder it strips so easily
__________________
'You know what? This is a business.' So, now, I just keep my mouth shut and pet my chihuahuas." Mickey Rourkefor sale thread "The junk man cometh' !!!" Let Me Build Your Standalone TDI Swap Harness!!! PM me for details!!
jimbote is online now   Reply With Quote
Old January 2nd, 2015, 14:44   #15
brandonkraemer
Veteran Member
 
brandonkraemer's Avatar
 
Join Date: Dec 2013
Location: Cincinnati, Ohio --> LA, CA
Fuel Economy: 42 mpg
Default

Quote:
Originally Posted by jimbote View Post
this ^^.... easiest and quickest method! .... that one long bolt threads into a very thin part of tbe bracket ... it's no wonder it strips so easily
I just bought a GreatNeck 6pc tap wrench set. It has the 3/8" NC16 tap in the set... it was cheaper than the 3/8" x 16 Helicoil set the guy at AutoZone was recommending. I assume the only difference here is the coils themselves... that the taps are the same?

Does anyone know the bolt length off hand? I picked up a 3/8" -16 X 2.5" one but without starting the job and removing the old one I was guessing.
__________________
Mods: SB Stage 2 Daily, Panzer FMJ, Cage
brandonkraemer is offline   Reply With Quote
Reply


Currently Active Users Viewing This Thread: 1 (0 members and 1 guests)
 
Thread Tools

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off

Forum Jump


All times are GMT -7. The time now is 00:38.


Powered by vBulletin® Version 3.8.5
Copyright ©2000 - 2015, Jelsoft Enterprises Ltd.
Copyright - TDIClub Online LTD - 2014
Contact Us | Privacy Statement | Forum Rules | Disclaimer
TDIClub Online Ltd (TDIClub.com) is not affiliated with the VWoA or VWAG and is supported by contributions from viewers like you.
1996 - 2015, All Rights Reserved
Page generated in 0.15890 seconds with 9 queries
[Output: 123.92 Kb. compressed to 102.59 Kb. by saving 21.33 Kb. (17.21%)]