300tdi AC tensioner pulley

[michael67]

I've gotten my old 300tdi Elite AC back together enough to charge and run it, but I had to swap back to my original AC tenioner pulley, as the new tensioner pulley sits about 1/8" further out. I thought it was close enough, but eventually the belt slips inward and half rides on the tensioner pulley and destroys the belt. Fortunately I had a spare belt and the old tensioner pulley is still good (bad idle pulley though).

Here's a couple photos of the new tensioner, Allmakes brand (ERR7296.Z8):

Here's a couple of the old pulley (installed - sorry):

I don't know what that lip is on the new tensioner pulley (as well as the new idle pulley), but it doesn't interfere. The new pulley seats fine, just not as deep as the original. Was there a design change? I haven't seen any alternate part numbers. Or is this something Elite-specific?

Thanks.

 

[Priapus]

I can’t help but I literally encountered this issue yesterday as well. My old tensioner pulley looks nothing like the new replacement one and does not fit correctly. I’m considering replacing the bearing on the old one instead. Please update if you figure this out.

 

[steinhnj]

I had a similar problem as well on my AC install last weekend. Ended up with a shredded belt after about 300 miles. I didn’t have an original idler pulley, but the pulley supplied with the kit was from Britpart. I also didn’t follow the procedure in the workshop manual by setting the torque, rotating the belt, releasing tension and re-tensioning the belt. I think it is the idler pulley that’s misaligning the belt.

I’ve ordered a Dayco brand idler pulley from LRDircect and plan to install this weekend using the workshop manual procedure. Hopefully this will solve the problem.

 

[michael67]

For mine, the pulley is visibly off. Mine ran for a 20 minutes before shredding, while I was filling the system with Freon.

So we've got Britpart & Allmakes both not aligning properly. Let us know about Dayco.