Replace accessory belt idler without pulling the whole front?

[Spinnetti]

Did my 2nd TB service, and got all done and heard belt noise.. Disgusted, took it to a shop, and they stung me for a accessory tensioner. $200 for what I could have done for $60 and 5 minutes.. Get it back, noise still there. Pulled the accessory belt, and no noise. Hmm. Checked the idler and it felt kinda crunchy and assume thats it. (no roughness or play in the AC or PS)... Anyway, I have it up in the air, but two questions:

1. What's the easiest way to replace it? I REALLY don't want to put it in "service position" again.
2. What's the size of the bolt? is that a Torx T40? I couldn't really get in there, but everything I had was too small. I'm tempted to cut away a bit of the fan housing where it blocks me from putting in the torx...

TIA..

[mdk]

I just did mine, and I did have to put it in the service position. I don't think there's any way around it. I believe the bolt is a 12mm triple square, but I cheated and used a 9mm allen because it fits in the same and was easier to find. Car sounded unbelievably better afterwards.

[Spinnetti]

I just did mine, and I did have to put it in the service position. I don't think there's any way around it. I believe the bolt is a 12mm triple square, but I cheated and used a 9mm allen because it fits in the same and was easier to find. Car sounded unbelievably better afterwards.

Arrg. I was hoping I wasn't going to have to do that. Such a PITA.

[ECS Tuning-Audi]

You may not need to fully remove the front end. For things like that you can just loosen the bolts that hold the front end on and let it hang forward a bit. This should give you plenty of clearance to remove and install the tensioner.

I've replaced a timing belt on my B5 with out completely removing the whole front end like this.

Jason

[MmmBoost]

You can get the front in service position in 30 minutes. Maybe 45-60 if it's your first time. No need to drain coolant....just spill some washer fluid

[Ritz]

You must be a contortionist. I don't know how anyone can get their hands in there to deal with the TB without having the front clip physically pulled at least 6-8 inches forward. I generally just swing the entire mess off to the side so I can sit on a small stool in front of the engine and do the job in relative comfort. Sure, you've got to disconnect the radiator (and the transmission cooling lines if you've got an auto), but then everything is right there in front of you with plenty of room to operate.

You may not need to fully remove the front end. For things like that you can just loosen the bolts that hold the front end on and let it hang forward a bit. This should give you plenty of clearance to remove and install the tensioner.

I've replaced a timing belt on my B5 with out completely removing the whole front end like this.

Jason

[ECS Tuning-Audi]

You must be a contortionist. I don't know how anyone can get their hands in there to deal with the TB without having the front clip physically pulled at least 6-8 inches forward. I generally just swing the entire mess off to the side so I can sit on a small stool in front of the engine and do the job in relative comfort. Sure, you've got to disconnect the radiator (and the transmission cooling lines if you've got an auto), but then everything is right there in front of you with plenty of room to operate.

A good friend of mine is an Audi tech and he showed me this way. It's how he gets t-belt jobs done in a few hours rather than half a day!

No need to disconnect the coolant lines or any of that jazz. It was just hanging forward and I had plenty of room to work.

Jason

[Ritz]

Hmmm...I'll have to try that next time.

Best,

A good friend of mine is an Audi tech and he showed me this way. It's how he gets t-belt jobs done in a few hours rather than half a day!

No need to disconnect the coolant lines or any of that jazz. It was just hanging forward and I had plenty of room to work.

Jason

[zz2h33]

I second that, i've done my TB on my 3.0 without putting the car into full service position. Remove lower/upper bumpers, remove the bolts holding the crash bar things to the core support. remove upper core support bolts (2 on each side). tilt the entire assembly forward, snub mount can even be popped out to get more access. I can probably do that in about 15 minutes. I'm not sure clearance difference between 3.0 and 1.8s but its pretty damn tight with the V6 and i didnt have a problem.

[Rausch]

No need to even put it in the service position. I just did mine. I bought a cheap 12mm triple square and cut down the bit as short as possible and used an opened end wrench on it. It is still a tight fit up against the fan but only took 5 minutes.

[rollerton]

Obviously you don't have to go this far, but loosen it up mostly and slide/ tilt it forward several inches. Don't drain coolant or anything, shouldn't be hard at all. You seriously should have it done in under an hour.

[walky_talky20]

A good friend of mine is an Audi tech and he showed me this way. It's how he gets t-belt jobs done in a few hours rather than half a day!

No need to disconnect the coolant lines or any of that jazz. It was just hanging forward and I had plenty of room to work.

Jason

x2. This is how it's done.

[Spinnetti]

You may not need to fully remove the front end. For things like that you can just loosen the bolts that hold the front end on and let it hang forward a bit. This should give you plenty of clearance to remove and install the tensioner.

I've replaced a timing belt on my B5 with out completely removing the whole front end like this.

Jason

Yeah, its just that I JUST had the whole mess off for the TB job. I hate doing a job twice, and I have a FMIC, and Oetty front end, its not as simple!

BTW, Torx 40 or what is the size of the bolt again?

Thanks.

[Spinnetti]

No need to even put it in the service position. I just did mine. I bought a cheap 12mm triple square and cut down the bit as short as possible and used an opened end wrench on it. It is still a tight fit up against the fan but only took 5 minutes.

Ah, that's what I was thinking... where do you get the triple square? HF have that sort of thing?

[Rausch]

They should. I bought mine from car quest.

[ECS Tuning-Audi]

Yeah, its just that I JUST had the whole mess off for the TB job. I hate doing a job twice, and I have a FMIC, and Oetty front end, its not as simple!

BTW, Torx 40 or what is the size of the bolt again?

Thanks.

I believe its T45 or T40 can't remember off the top of my head exactly.

Jason

[Spinnetti]

Cools.. Thanks for all the feedback.. Turns out I forgot I already had a triple square set.. I'll chop one off and see if I can do it without pulling the nose. Ready to have my DD back! Then its on to figuring out why my B5 stumbles and hesitates and throws lean codes....