My new TB tensioner does not match old one

0die

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Nov 29, 2012
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corpus christi, tx
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1996 Passat wagon B4V


trying to the the TB on my 96 Passat and the new tensioner that arrived looks nothing like the old one. It won't even fit over the mounting stud. what gives?
 

Ski in NC

Top Post Dawg
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Jul 7, 2008
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Wilmington, NC USA
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2001 Jetta ALH 5sp stock
One on the left looks like spring loaded TDI tensioner. One on right looks like manually adjusted tensioner used for IDI engines (??). Where did you source the parts?
 

Herm TDI

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The tensioner on the left:
028-109-243-F Applicable to the AHU / 1Z TDI
///////////////////////////////////////////////////////
The tensioner of the right:
026-109-243-L Applicable to the 2.0 & 1.8 gassers
 
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0die

Veteran Member
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corpus christi, tx
TDI
1996 Passat wagon B4V
I got the new tensioner from AZ AutoHaus...they always been good to me.

the old tensioner is what was on the car...there are paint marks on the sprockets so someone has done the TB before...

the "correct" tensioner will not fit over the stud...the stud is too wide...
 

Herm TDI

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They swapped these parts because they were (most likely) rushed to get the job done and did not have the correct parts on hand at the time.
Stud Information:
N 014-408-3 Stud (1.0x8x62)
 
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0die

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corpus christi, tx
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1996 Passat wagon B4V
Bingo...that's my guess...not on the rush but on that is was swapped out...

I was thinking maybe go to the dealer and see if they can order the stud...

uh-oh...usually the stud is the same diameter on both ends...in my experience...

that 1.0x8 is the same as the crank pully bolts which fit the tensioner...but what about the end that goes in the head?
 

Herm TDI

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Bingo...that's my guess...not on the rush but on that is was swapped out...

I was thinking maybe go to the dealer and see if they can order the stud...

uh-oh...usually the stud is the same diameter on both ends...in my experience...

that 1.0x8 is the same as the crank pully bolts which fit the tensioner...but what about the end that goes in the head?

The Stud screws into the cylinder head. The tensioner is held in place by a nut.
N-900-744-01 Self Locking Nut (M8)

Go to a local delaership and order the stud & the nut.
 

Herm TDI

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The stud has two different diameter ends. The larger diameter screws into the cylinder head and the smaller end of the stud takes the nut that secures the tensioner.
 

0die

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corpus christi, tx
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1996 Passat wagon B4V
cool! mystery solved...assuming the local V Dub place can get the stud. :)

I still don't get it though...if they didn't have the time to get the right tensioner...how did they have the time to change out the stud? And even get the stud? seriously stupid people I guess...
 

Herm TDI

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Location
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..... seriously stupid people I guess...
You just experieanced an epiphany.
To experience a sudden and striking realization.
This has been a sustaining thread through out the life of this forum.
Owners who have encountered exactly the same situation that you're having right now.
All because of seriously stupid people and we do not see an end to this problem any time soon.
 

IndigoBlueWagon

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I helped a customer recently who has a Passat with an AAZ engine and the PO had used an IDI tensioner. Apparently this was common practice as the IDI tensioner was significantly less expensive. Had to swap out the stud to use the correct tensioner as well.
 

0die

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1996 Passat wagon B4V
like time is cheaper than just using the right tensioner? the one I ordered was like $20...I can't see swapping out the stud for a cheaper tensioner....if it was like a $50 difference maybe...and what's the cost of the stud?

Now I can see if an older tensioner is NLA then do something like that...
 

dieselvet

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Location
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MB GLK 250 4M BT
The unsuspecting client gets charged a fixed price for the belt and tensioner change. They get an IDI tensioner with the stud changed. I bought my 2002 Jetta with this setup. They had used ordinary threaded rod cut to length as the tensioner stud. The PO had paid $950 CDN for the work a few months before(at a so-called Volks specialist). I had to redo it again.
 

0die

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Location
corpus christi, tx
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1996 Passat wagon B4V
wow, on a $950 bill I would not expect any kinda monkey biz....now if it was a rock bottom price quote I can see a shop being dishonest...well, never trust anything you don't do yourself
 

KLXD

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like time is cheaper than just using the right tensioner? the one I ordered was like $20...I can't see swapping out the stud for a cheaper tensioner....if it was like a $50 difference maybe...and what's the cost of the stud?

Now I can see if an older tensioner is NLA then do something like that...
Where'd you get it. I don't see any markings on it. Usually the back side has P/N and Mfgr on it.

For $20 I'm thinking you've gotten a Chinese part. This isn't a part to save 40 bucks on.
 

0die

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Location
corpus christi, tx
TDI
1996 Passat wagon B4V
went to the VW dealer to get the right tensioner stud....VW shows a split year for 96 Passat TDI...early is the old 10mm stud and old style tensioner...later VINs use the 8mm stud and auto tensioner....

I didn't have my VIN handy so I gotta go back tomorrow and have them decode it...but I'm guessing it's the early one. build date is 3/96. Or where can I find the engine code?

If so...is it possible to retrofit the newer style tensioner? Judging from the dealer schematics...both studs seem to be 10mm in the head...only the tensioner end is either 8 or 10mm....but they are also different lenghts? one tensioner does appear a bit wider where the bolt goes through.
 

IndigoBlueWagon

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I think they're mistaken. I think you want 028 109 243F. There's some confusion in ETKA (VW's parts catalog) about AAZ (non-TDI) and 1Z engines in '95 and '96, even though the AAZ was never sold in the US. I'd suggest you get a kit with the tensioner shown above and the correct stud and install that. As an aside, the earlier tensioners are pretty hard to come by. Did the dealer say one was available? That may make your decision for you.
 

0die

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corpus christi, tx
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1996 Passat wagon B4V
I ordered the 028 109 243F tensioner. That is what I want to use...but the car had the 068 109 243F tensioner and 10mm stud currently installed.

I need to figure out if I have the AZZ engine or was maybe the engine replaced? Or possibly a Canadian Passat, if that even exists.

The ETKA schematic and parts list also notes a different cover plate, i assume to accomodate for the spring tang thing on the newer style tensioner...there is an intentation on the backing plate that seems to correspond with the tensioner tab..

The tensioner in the ETKA schematic looks different than either of the two I've seen...it shows a long tab or ear in the 5 o'clock position that looks to fit over another shaft or stud?
 

IndigoBlueWagon

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Not sure about the timing belt cover. I seriously doubt you have an AAZ, as I think the last year for those was 1995, and there were none sold here, at least not new. And ETKA diagrams are generic: don't go by what you see. It's often different than the actual part.
 

GoFaster

Moderator at Large
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Jun 16, 1999
Location
Brampton, Ontario, Canada
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2006 Jetta TDI
Why not just buy a new eccentric tensioner (same as the one you have, just to get new bearings) and use that? The only thing "wrong" with the eccentric non-spring-loaded tensioner is that you have to set the tension on the belt ... there's no spring with a pointer indicating when you have it right.

Millions of VW diesels were built with the eccentric tensioner (and the corresponding need for the installer to use common sense when installing them). There is an argument that there are more ways to wrongly install the spring-loaded tensioner than the old style.
 

jetta 97

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I ordered the 028 109 243F tensioner. That is what I want to use...but the car had the 068 109 243F tensioner and 10mm stud currently installed.

I need to figure out if I have the AZZ engine or was maybe the engine replaced? Or possibly a Canadian Passat, if that even exists.

The ETKA schematic and parts list also notes a different cover plate, i assume to accomodate for the spring tang thing on the newer style tensioner...there is an intentation on the backing plate that seems to correspond with the tensioner tab..

The tensioner in the ETKA schematic looks different than either of the two I've seen...it shows a long tab or ear in the 5 o'clock position that looks to fit over another shaft or stud?
Not sure about the timing belt cover. I seriously doubt you have an AAZ, as I think the last year for those was 1995, and there were none sold here, at least not new. And ETKA diagrams are generic: don't go by what you see. It's often different than the actual part.
It is 1Z look injectors, few pictures before tensioner.
 
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