So now let's check the Alternator \ Serpentine Belt.
It is loose which is why the Power steering has failed and the battery is not charging.
Jack the Van up and also place wooden blocks under the wheels, better safe than sorry.
Remove the Plastic undertray, I have a video on how to do this.
The remains of the Serpentine Belt tensioner are sitting in the Undertray!
So a catastrophic failure of the Belt Tensioner (which was actually caused by a faulty Alternator Clutch Pulley).
Here is the Part Number to order.
Checking the existing belt and this looks ok. We will take it off and replace it anyway.
Serpentine Belt tensioner was here.
We now need to remove the remains of the old Serpentine Belt Tensioner.
The Serpentine belt tensioner is held in with one bolt. This is accessed from the other side and is a nightmare to get to.
Apologies for the filming here but we found it easier to unbolt the Air Conditioning Unit and lower it a bit, to give us more room to access the Bolt holding in the Serpentine belt tensioner.
The bolt holding in the Serpentine belt tensioner is up there. It's hard to get to but can be done with patience and a long spanner. VW may have a special tool to reach this.
I think a garage would drop the engine mount for access but that is a big job.
May as well charge up the battery while we work on it.
Undo the Serpentine bolt I arrowed earlier and remove the old Serpentine Belt tensioner unit.
Time to stop for lunch and a cup of tea.
We got this new one from a local Independent Van Dealer as it was in stock.
Do not remove that locking pin until the unit is installed and the belt is on correctly.
This is the internal thread that the bolt goes through to tighten it onto the engine. Bolt comes through the back.
We bought a new belt. Compare it to the old belt to make sure it is identical in length and width.
So here is the new Serpentine Belt tensioner slotted into place. There is that one bolt holding it in on the other side (it took a long time to tighten it as access is poor).
Do not remove the Pin until the new Belt is on. It is easier this way although you can get a spanner on the tensioner nut shown to move it if you have to.
Best to keep it pushed in from this side until you feel the bolt bite on the thread from the other side.
Remember we unbolted the Air Conditioning unit to give us more room.
This is the routing of the belt (with Air Conditioning Unit). Yes I drew this as found it impossible to find on the Internet.
Serpentine Belt tensioner is now bolted into place tightly.
We have put the new belt on but it is still a bit loose as we haven't released the locking pin yet, which releases the tensioner spring
Remember to bolt back on the Air Conditioning unit.
If you are confident the belt is on correctly then pull out the locking pin.
Locking pin is out and the spring has taken up the tension on the belt.
Just showing you the belt routing
Looking down from the top of the engine.
Let us start the engine and test.
*Warning*. The belt tensioner should not be moving so much at idle speed! This was a fault with the Alternator clutch pulley (which had caused the old tensioner to fail). Get this replaced and do not drive too far!
Check the battery is charging.
Great stuff.
Now let's check the power steering.
Great job. I'm driving forwards slowly and power steering is working.
Remember to bolt the engine undertray back on.
*Remember*. We had a fault with the Alternator clutch pulley (which had caused the old tensioner to fail). Get this replaced and do not drive too far!