Timing belt component, notched belt, broken. Cause?

Hello!

Write a letter for a friend.

Hardware: 1.9TDI AWX, A4 8E Limousine, Baujahr 2001, 90.000km, FEC-Getriebe

Problem: When performing a standard timing belt replacement at 90,000 km, the timing belt tensioner belt must also be replaced.

It was observed that the span element and the lever attached to it were broken.
The two parts are screwed together, and exactly there, both the lever and the clamping element broke.

Thankfully, nothing else happened, and there were no unusual noises or observations during the engine run either.

The question regarding prevention is now, how such a thing can occur? The belts and the remaining rollers had normal wear and tear, everything was within the normal range. I carefully examined the parts.

Can we simply conclude that this is due to a simple material defect?

Thank you for your opinions!

Are you referring to this spring-like device with the tension roller located to the left and below the viscous coupling, or the tensioning element on the belt for the air conditioning compressor?

If the first cause is material fatigue or using the wrong material/inappropriate manufacturing technology, then consider this. We have already made this mistake twice. Once on a VP37 Tdi and once on a PD.

Oh, sorry, there are two... I meant the one below the flywheel, to the right of the crankshaft pulley.

The other strap only supplies the climate control compressor, and its tensioning mechanism was perfectly intact.

Okay, then see above. I think the part for the climate control compressor was also made of aluminum die-casting.

Did your bearing cost around €80 from a bearing supplier? I think the price is a bit too high. And most importantly, the change is fun!

I have no idea what it cost, but my spare parts are still working. *tap on wood*

After aluminum die casting, it felt good, yes.

80€? He paid 1400€ for his ZR replacement, which should have cost 430€. But what has come to light is no longer a matter of celebration.

Therefore, the investigation of the causes.

So, you mean purely material defects?

Think ahead. Otherwise, it would be dumb luck. Take a look at the fracture. Maybe you can see something in the crack. In our cases, it was wonderful to see and suggested the possibility of vibrational failure.

What else was broken? If I may be curious? The famous Audi quality is no longer what it used to be.

WaPu, engine cover bottom, tire alignment (due to extreme wear on the inside), oil water cooler leaking, gearbox side seal leaking (engine oil in gearbox housing), handbrake cables deteriorated (action)...

I don't remember everything anymore.

And...let Audi know that, unlike the B5, it's possible to adjust the camber and track at the rear on the B6.
They still don't know this comprehensively....

Oh no! This is probably a Monday car. Adjusting the steering at the steering wheel is very sophisticated. A true masterpiece of German engineering. Very comfortable and the maintenance is simply unbeatable.

Simmering, on the gearbox side? Oh no! That's going to be a lot of work!

In my 1Z, the bearing of the tension roller broke about 3 weeks ago.
There were only 4 balls left. It's great when you've just completed a 50km commute and still have 15km left to go...
Riemen had obviously jumped down, so no further driving.
The role has only been in use for <25tkm.

Cost: 76,- Euro in a free workshop, including installation.

Hi,

But now we're talking about apples and pears, right? However, there are subtle differences between a 038 and a 028 engine. It is well-known and sufficiently discussed here that the 1z specifically tends to develop insulation faults towards the bearing.

My take on it:
So, the Spanner in the AWX engine sometimes break, to my knowledge, the Spanner damper is to blame. I have already replaced several, where the 'eye' was worn out, i.e., where it is screwed onto the Spanner roller. There is a plastic bushing installed there, which probably lasts only around 90,000 km. This also happens if the free-running function of the generator is defective.
hello
edz