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Old 07-09-2010, 02:02 AM
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Car: 1999 2.0L 5 speed 133K miles
Default How to replace the belt tensioner for the serpentine belt?

Today, as I was driving on the freeway my serpentine belt on my 1999 Beetle 2.0L 5 speed snapped.
I picked up a new belt and replaced it in about 5 minutes.
While I was replacing the belt, I noticed the roller on the belt tensioner was very stiff. I suspect that was the reason the belt snapped. I'm sure it froze for a moment while I was on the freeway and the rotation of the crank pulley burned right through the belt.
The new belt is doing fine and the tensioner roller was turning but I will not drive it tomorrow. Instead I will pick up a new belt tensioner/roller assembly and install it this weekend.
My question is: How difficult is it to change it? Does anyone have step-by-step instructions or know the link to a thread with this information?
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Old 07-09-2010, 11:38 AM
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I wonder if the serpentine tensioner is the same on the 2000 1.8T; I'll take a look at Cowboy's this weekend. If it is I could do a DIY on it.
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Old 07-09-2010, 12:01 PM
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The tensioner is held onto the motor with 3 bolts. Its a real easy job, i don't remenber if you have to take anything else off first since its been a few years since I did a mk4 timing belt (its gotta come off for that).
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Old 07-09-2010, 03:47 PM
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The pulley for the the tensioner only cost $15, where as the entire assembly is $70. So my question is, is it as easy to just change the pully? Is it just held on by a simple bolt or does it need a special tool or needs to be pressed on?
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Old 07-09-2010, 07:38 PM
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this picture shows that it looks to be held on with a t25 or t30ish looking torx screw? If it's that easy then i would do that instead of buying a whole new assembly.... but it looks like it might be a pain to get off
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Old 07-10-2010, 01:22 AM
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Hey thanks, I just finished changing the pulley on the tensioner. I was extremely easy.
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