Engine - Hard Steering/Gen Lamp ON/Engine Noise
Group 13 number 08-08 dated13 10 03
2018317/3
June 14, 2010
Supercedes Technical Service Bulletin Group 13 number 08-08 dated November 24, 2008 for reasons listed below.
Affected vehicles
Condition
^ Generator warning light is illuminated.
^ Noise from the engine.
^ Increased steering effort is required, but the condition does not result in loss of steering control.
Technical Background
Broken tension spring in belt tensioner (roller without profile).
Production Solution
Change to belt drive with belt tensioner 022 145 299E (roller with profile).
Service
Switch to belt drive with tensioner 022 145 299E (roller with profile).
1. Before removing belt, mark the direction of rotation/running side.
After changing the belt drive, you will need to ensure the belt is in its original position.
2. Install belt tensioner 022 145 299 E with profiled roller (Figure 1, Point 2).
Reuse bolts. Torque to 25 Nm.
3. Replace ribbed belt pulley 021 121 031 D (Figure 1, Point 3) with a smooth disc using water pump wrench V.A.G. 1590.
a. Replace bolts (N 905 442.03), 3x M8x11.
^ Torque to 20 Nm.
b. After tightening the pump by hand, turn twice and check to make sure it is freely rotating.
c. Press the cap on by hand.
d. Ensure all holding clips are seated properly.
4. Install idler pulley 022 145 276 A with smooth roller (Figure 1, Point 4).
Bolt M10 torque to 45 Nm.
Press the cap on.
5. Position the belt as shown (Figure 1, Point 5) and bring service bolt back into engine operating position to tension the belt.
6. Finally, start the engine and ensure the belt drive is running smoothly and there is no noise.
Warranty
Required Parts and Tools
Additional Information
All parts and service references provided in this TSB are subject to change and/or removal. Always check with your Parts Department and service manuals for the latest information.