Eurovan 2.8 VR6 Tensioner Pulley Assemblies

[dbeeby]

Hello folks,

Can anyone verify what Gemini (Google AI) is telling me incorrect information about the Tensioner Pulley Assembly versions (021145299A v 021145299C) for an '03 Eurovan:

[Tom Clark]

It appears 021145299A is for the 2.8 in the EuroVans, while the 021145299C is for the other VW models with a 2.8

Compare, and contrast:

https://parts.vw.com/p/48013196/021145299A.html

https://parts.vw.com/p/48013206/021145299C.html
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2003 MV Weekender

[Technoblau]

[qval]

I'm 99% sure you need a pulley with ribs and "taller than those ribs" edges. I'm also 99% sure that the belt tensioner is the same from 97-2003. SD Europarts sells both the whole tensioner and the pulley by itself, though those are kinda expensive.

But don't trust any generative AI without confirming elsewhere. They lie more often than not.
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2000 MV weekender, 270k miles

[qval]

Sometimes at AutoZone I have them try a1997 eurovan instead of 2000 because they should have the same parts but connectors are often oval instead of rectangular. Maybe they'll have a tensioner listed for a 97 or 99, or 2000 that looks right on their screen.
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2000 MV weekender, 270k miles

[tdibiker]

If your tensioner is still functioning, but your pulley is going bad or has broken, the one Europarts-SD sells is the Gates 36320 (edited). It can also be purchased locally. It's a bit bigger in diameter, but it's steel and works and fits well.
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95 EVC 217k
03 EVMV 367k
04 Vista 89k
00 Jetta TDI 384k
07 Touareg V10 TDI 83k
97 F250 WVO 411k
00 996 Conv 180k
....and others

[dbeeby]

[tdibiker]

[dbeeby]

[Tom Clark]

Sorry if this is a dumb question, but why not buy a Four Seasons 45032? Widely available at a reasonable price. Why would Rialta owners *not* be buying the original size/type?
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2003 MV Weekender

[dbeeby]

[dbeeby]

@tdibiker, I just couldn't bring myself to installing the Gates 36320 and a new belt.

At the autoparts store the guy went through all of the pulley boxes and we found a 62mm pulley, but it only had five grooves. But the size difference between the 62mm and 76mm pulleys was too much for me to feel comfortable installing the larger part and putting a bunch of strain on the accessories and their bearings.

I'll keep the Eurovan off the road until the right parts arrive, but thanks for all of your advice folks!

[bikes!]

I had the Four Seasons 45032 on my 2002 weekender for a few years. Worked fine, until the plastic pulley started getting loose from the bearings causing a really annoying rattle at idle.
Replaced it summer of 2024 with ACDelco Gold 36320, which has an aluminium pulley and similar sealed bearings. I did not measure the diameter, but it is a bit larger than the 45032. But not so much larger that the stock belt wouldn't fit.
It's been running well for over a year. I checked it a few months ago when I had the van apart to replace the valve cover gasket. No play, no odd wear.
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VWs past: 66 Kombi, 76 Westfalia Camper, 17 GTI; present: 02 Eurovan MVW, 17 Alltrack SEL & 19 Golf R

[tdibiker]

Well, I'm not sure about the Four Seasons 45032, but I would assume the fact that it's also a plastic pulley is the reason for the Rialta group suggesting the Gates, which is steel. One of my plastic ones exploded with age, so I'm all for not having plastic.

I didn't measure mine to get the specific differences, but I'm fairly confident that it wasn't a 14mm difference. It was only slightly larger and it fit on the unloaded tensioner without interference. I just pulled a tape across the old one and it was 68mm across the outside edge. I didn't feel that the extra range that I had to rotate the tensioner to get the belt on was adding any extra tension as it seems to be a fairly constant tension across its range.

I've installed it on my 2003 EV and my 2004 Vista (03 EV cab) without any concerns.

Good luck on getting rolling again!
_________________
95 EVC 217k
03 EVMV 367k
04 Vista 89k
00 Jetta TDI 384k
07 Touareg V10 TDI 83k
97 F250 WVO 411k
00 996 Conv 180k
....and others

[qval]

Also, I think you're worrying too much about 14mm. That's the diameter and the radius is 7mm. The pulley arm is probably 80mm-100mm long (or more), so you're only adding maybe 5-10% more tension into the belt. Your spring had probably lost that much by sitting under strain for 22+years
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2000 MV weekender, 270k miles

[Abscate]

[dbeeby]

Hey @Abscate, @qval, @tdibiker, and @bikes!,

These are all really good points. I was really on the fence about it and I understand (now) that the difference in size (62mm vs 76mm) and quality (plastic vs steel) probably shouldn't have put me off the Gates 36320/Litens 900467A.

I'll update as soon as I get the van back on the road. Thanks again to everyone for their great advice.

[tdibiker]

Hey dbeeby,

I hope you get it back rolling soon! The amazing thing is how much great information there is on the forum and a few of the others. I've developed so much trust in the Rialta group and this group that I don't even question most things. That's why I wasn't even aware of the other pulley options. Still planning to measure mine but didn't do it today.

Cheers!
Kent
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95 EVC 217k
03 EVMV 367k
04 Vista 89k
00 Jetta TDI 384k
07 Touareg V10 TDI 83k
97 F250 WVO 411k
00 996 Conv 180k
....and others

[Abscate]

Btw we abhore URO parts on our Volvo forum for anything except engine plastic. I’m not sure I would trust anything mechanical. Rubber is certainly out.
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[dbeeby]

Update: the Four Seasons 45032 pulley and a new Continental belt put the van back on the road this weekend.

But I have a warning for other members who do this repair:
DO NOT OVER-TORQUE THE PULLEY BOLT TO LOOSEN THE BELT TO PUT IT ON!

Basically the pulley bolt is reverse threaded -- when you "loosen" it you're "tightening" it. I put on the new pulley and re-installed the tensioner pulley assembly, but when I went to put the belt on I "loosened" the pulley bolt (so it was actually tightening it) to the point where the bolt started to turn again... basically, I had stripped out the threads on the pulley bolt hole.

Instead of using the pulley bolt, insert one of the mounting bolts (M8x1.25x80mm) from above to relieve the tension on the pulley.

I'm hoping this can help other members avoid having to spend $150 on a new tensioner pulley assembly.