3.0 TDI ASB crank pulley and belt snapped

[Olympus593]

Hi all..
as the title says the crankshaft pulley on my 2008 A4 B7 3.0 tdi (233) Engine code ASB has separated itself and snapped the belt at same time. The remainder of the crank pulley I managed to remove without taking anything off at the front,just the bottom engine tray had to come off. A new pulley and belt have now arrived but before I attempt at getting either the pulley or belt on there’s a fair amount of rubber from old belt on some of the other pulleys especially one in particular an idler pulley so I intend to heat up the rubber to remove first as is now rock hard.. questions I have for you all is..

should all the pulleys move freely as they are I.e no belt on them as the air con pulley is pretty solid and won’t spin by hand whereas all the others do?
I’d rather know for sure this is normal before I attempt at putting new belt on..

And am I right in assuming that the tensioner is at present de-tensioned with no belt on? And is it a case of prising it closed so to speak with something when putting new belt on? I’ll be trying to feed belt down through bonnet to route the belt. I’ve done a fair few things to this car myself like front mount inter cooler and turbo down pipe (awkward) but this seems pretty straight forward providing I have the space to work with.. just hoping someone out there knows the answer to the air con pulley before tomorrow as I’m refitting it all in morning fingers crossed.. thanks peeps!!

 

[OliNix]

Yes air con pulley should move freely. All should be spinable by hand.

No, with no belt on the tensioner is in the max tension position. You have to wind the old onto it, hook on the belt and let it go. This is then tensioned.

 

[OliNix]

 

[Olympus593]

Yes air con pulley should move freely. All should be spinable by hand.

No, with no belt on the tensioner is in the max tension position. You have to wind the old onto it, hook on the belt and let it go. This is then tensioned.

Thank you very much olinix so new air con pulley or whole compressor you think? I did think it was odd as all others spin freely but air con won’t. Thank you for replying

 

[Olympus593]

Yes air con pulley should move freely. All should be spinable by hand.

No, with no belt on the tensioner is in the max tension position. You have to wind the old onto it, hook on the belt and let it go. This is then tensioned.

Air acon compressor would be a front end all off i take just had a look? also the air con pulley is spotless compared to all the others as in no belt debris at all? Surly that one not turning would have the most rubber left behind on it no? But either way it won’t turn solid. Gutted really as tomorrow I thought I already had my work cut out for me down crank pulley and fitting the belt..

 

[Olympus593]

Yes air con pulley should move freely. All should be spinable by hand.

No, with no belt on the tensioner is in the max tension position. You have to wind the old onto it, hook on the belt and let it go. This is then tensioned.

Could it also be the pulley clutch and not the compressor?

 

[OliNix]

Could it also be the pulley clutch and not the compressor?

I wouldn’t think the clutch, this would just cause it to be always on or always off. You could try turning the ignition on and then turning on the econ switch, which should disengage the clutch. I’m not sure if it does it with the engine off though, I have never tried.

You can drop the front to the service position to get much better access. YouTube has lots of videos how to do this. In short, remove front bumper, undo 6 bolts holding on the front radiator and crash structure and pivot forward. Can be done in about 30 mins, less if you know how.

 

[OliNix]

This is the Audi service document for replacing the poly v belt

 

[Olympus593]

I wouldn’t think the clutch, this would just cause it to be always on or always off. You could try turning the ignition on and then turning on the econ switch, which should disengage the clutch. I’m not sure if it does it with the engine off though, I have never tried.

You can drop the front to the service position to get much better access. YouTube has lots of videos how to do this. In short, remove front bumper, undo 6 bolts holding on the front radiator and crash structure and pivot forward. Can be done in about 30 mins, less if you know how.

Thanks again olinix will be attempting all this today apart from disconnecting air con compressor.. had the front bumper off loads of times but never had to touch radiator and crash bar.. I managed to see the part number for the air con compressor last night looks like an old number and been replaced with a later number and not a lot online about my specific one (8EO260805CD) denso.. but first I will try what you mentioned before about see about disengaging the pulley clutch.. just one thing I don’t understand and that’s the actual air con pulley is the cleanest one of all of them.. and no rubber belt debris at all if that was not not moving with a belt moving round it at speed wouldn’t that have the most on it? Just curious that’s all. That one being stuck still would that alone cause the crank pulley to fail and belt to snap? I do remember the mobile guy who regased it few months ago say something about my car was the last one he was doing using that particular (old type) gas and from that day onwards he was having to use a newer type not that it was an issue for me just saying. Thanks again olinix will let you know how I get on.

 

[piglet14]

What is the interval on the aux belt?

 

[Olympus593]

Not sure mate but it was my air con compressor pulley that seized and snapped the belt as for the crankshaft pulley well that must of been on way out anyway and that went also.. only got 100k on engine

 

[OliNix]

You manage to get it all done?

The new air con gas is r134a. It’s an EU regulation to be not as toxic to the environment. Came in prob Jan last year though, maybe regs are different for aftermarket than to OEMs

 

[Olympus593]

You manage to get it all done?

The new air con gas is r134a. It’s an EU regulation to be not as toxic to the environment. Came in prob Jan last year though, maybe regs are different for aftermarket than to OEMs

Hi olinix
I payed a local mobile guy who I have used in past he seemed to have all the gear,degassed in morning into large bottles I then fitted the compressor then he returned in afternoon and pressure tested then regassed it.. so far so good couldn’t tell you if it was the newer type gas he used.. but I yes I managed to do it all myself I’m not a mechanic by any means And won’t lie it was frustrating at some points with accessibility took whole front end off past the service position.. didn’t realise one of the 8 bolts holding the crank pulley on is ever so slightly offset from the other 7 could of easily messed that one up but took a fag break had a brew and sat back and looked at it face on to see the problem.. why would Audi do that? Like I say I’m not a mechanic I’m a fuel delivery driver nothing more

 

[Olympus593]

You manage to get it all done?

The new air con gas is r134a. It’s an EU regulation to be not as toxic to the environment. Came in prob Jan last year though, maybe regs are different for aftermarket than to OEMs

Hi olinix.. I’m thinking when I had all the front end off recently for the crankshaft pulley maybe I should have done the timing belt too? I had access to it there and then.. though my service book doesn’t mention my engine on the tooth’s belt change interval.. it’s an 09 ASB with 115k on the clock.. get it done ASAP wouldn’t you say?

 

[b6ben]

Hi olinix.. I’m thinking when I had all the front end off recently for the crankshaft pulley maybe I should have done the timing belt too? I had access to it there and then.. though my service book doesn’t mention my engine on the tooth’s belt change interval.. it’s an 09 ASB with 115k on the clock.. get it done ASAP wouldn’t you say?

The timing for these engines is done with chains that are one the back of the engine, no servicing needed on them but people have had chain tensioners go and have replaced them. The only toothed belt on the front of the engine is for the fuel pump I think.


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[Olympus593]

The timing for these engines is done with chains that are one the back of the engine, no servicing needed on them but people have had chain tensioners go and have replaced them. The only toothed belt on the front of the engine is for the fuel pump I think.


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Yep your totally correct and that one b6ben currently looking into exactly what belts my car has and I’m getting mixed up with the high pressure fuel pump toothed belt at the front which from what I’m reading is a belt that isn’t hardly stressed at all and can’t find nothing on an interval change.. car is a 09 A4 B7 3.0 TDI ASB with 115k miles. I’m contemplating changing it for a potential sale of the car soon and just don’t want any comebacks in a few months time saying cars stopped because of it. My Audi service book doesn’t mention it.. I know it’s a pain to get to as I see it recently when front was off doing air con pump, aux belt, crankshaft pulley and an idler pulley but just didn’t think of it. Also would you happen to know if my water pump is a metal impeller or plastic? From what images I’m seeing it’s a metal one and no history of them failing.. thank you

 

[b6ben]

Yep your totally correct and that one b6ben currently looking into exactly what belts my car has and I’m getting mixed up with the high pressure fuel pump toothed belt at the front which from what I’m reading is a belt that isn’t hardly stressed at all and can’t find nothing on an interval change.. car is a 09 A4 B7 3.0 TDI ASB with 115k miles. I’m contemplating changing it for a potential sale of the car soon and just don’t want any comebacks in a few months time saying cars stopped because of it. My Audi service book doesn’t mention it.. I know it’s a pain to get to as I see it recently when front was off doing air con pump, aux belt, crankshaft pulley and an idler pulley but just didn’t think of it. Also would you happen to know if my water pump is a metal impeller or plastic? From what images I’m seeing it’s a metal one and no history of them failing.. thank you

I wouldn’t worry about the toothed belt personally, I’m actually about to do the aux belt on my ASB engine and I’m just going to change the crank pulley and and see if any of the rollers or tensioner needs doing. I’m not gonna touch the water pump or toothed belt. The main reason other Audi engines have the water pumps replaced so often is that they are ran on the timing belt and are under a lot of tension their whole lives so it’s best to change them frequently as if they fail it effects the timing of the engine and that isn’t good at all. For us with the 3.0tdi the water pump is just ran on the aux belt and isn’t under nearly as much tension, also if it fails it isn’t catastrophic. I’m very much a believer in preventative maintenance but sometimes you have to go with the old saying “if it ain’t broke don’t fix it”

It might be worth calling a Audi dealership to see if any of the belts have a service schedule, that’s if you haven’t already done that.

Ben.


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[Olympus593]

I wouldn’t worry about the toothed belt personally, I’m actually about to do the aux belt on my ASB engine and I’m just going to change the crank pulley and and see if any of the rollers or tensioner needs doing. I’m not gonna touch the water pump or toothed belt. The main reason other Audi engines have the water pumps replaced so often is that they are ran on the timing belt and are under a lot of tension their whole lives so it’s best to change them frequently as if they fail it effects the timing of the engine and that isn’t good at all. For us with the 3.0tdi the water pump is just ran on the aux belt and isn’t under nearly as much tension, also if it fails it isn’t catastrophic. I’m very much a believer in preventative maintenance but sometimes you have to go with the old saying “if it ain’t broke don’t fix it”

It might be worth calling a Audi dealership to see if any of the belts have a service schedule, that’s if you haven’t already done that.

Ben.


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Thanks very much Ben..
I did ring my local Audi and they said the toothed belt isn’t an absolute necessity but can be done for good measure and peace of mind. As per earlier posts from few weeks back I did the aux belt an idler pulley crankshaft pulley but I believe the air con compressor was the cause as it’s pulley was the only one that didn’t spin freely. I didn’t enjoy doing it at all laying under my car in the rain but hey it had to be done.. I went into doing it kind of blind so when I married the 8 bolts of the crank pulley up one of those 8 is slightly offset so will only go on one way. I did notice after I had a close look at why it wouldn’t fit then went in perfectly but hey I didn’t know that at the time. I do like the ASB Though a year into owning it needed a whole new gearbox as kept going into neutral other than that great engine.. thanks again Ben.

 

[DaveW1946]

The timing for these engines is done with chains that are one the back of the engine, no servicing needed on them but people have had chain tensioners go and have replaced them. The only toothed belt on the front of the engine is for the fuel pump I think.


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Lawyers in Australia and the USA are examining claims against Audi that several of their cars have been fitted with defective timing chains and tensioners, resulting in early engine failure and unsafe vehicles. Is anything being pursued in the UK about this issue?

Vehicles affected are so far: 2008 - 2012 A3, A4, A5, Q3, Q5, TT

My granddaughter’s A3 timing chain slipped and wrecked the engine at 88,000 miles.

 

[b6ben]

Lawyers in Australia and the USA are examining claims against Audi that several of their cars have been fitted with defective timing chains and tensioners, resulting in early engine failure and unsafe vehicles. Is anything being pursued in the UK about this issue?

Vehicles affected are so far: 2008 - 2012 A3, A4, A5, Q3, Q5, TT

My granddaughter’s A3 timing chain slipped and wrecked the engine at 88,000 miles.

They are completely different models of engine to the car this post is about, you will be better starting a new thread in the relevant place to have more chance of a member helping you with this.


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[DaveW1946]

They are completely different models of engine to the car this post is about, you will be better starting a new thread in the relevant place to have more chance of a member helping you with this.


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Noted with thanks, B6ben, I’m new to these forums and just beginning to find myself around them.

 

[piglet14]

How old was the A3 when the belt went?
Isn't there a xx,000 miles or 10 years whichever comes soonest caveat on cambelts​

 

[b6ben]

How old was the A3 when the belt went?
Isn't there a xx,000 miles or 10 years whichever comes soonest caveat on cambelts​

I’m guessing he is talking about the 1.4tsi engine that has a timing chain, belts have completely different service schedules.


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[piglet14]

Apologies, didn't read it properly.

 

[DaveW1946]

My granddaughter’s affected car is an Audi A3 Sport 197 TFSi 2008 1984cc and it’s vin identifies the engine brand, size and type as ZZZ8P.

 

[Olympus593]

My granddaughter’s affected car is an Audi A3 Sport 197 TFSi 2008 1984cc and it’s vin identifies the engine brand, size and type as ZZZ8P.

I really wouldn’t know anything about that engine I’m afraid. When I posted this it was in relation to my A4 B7 3.0 TDI ASB.. also it was my auxiliary belt,crank pulley etc that failed due to the air con compressor pulley seized not the timing chain.

 

[DaveW1946]

Noted with thanks Olympus 593.