1.9 L TD Rebuild

[ibmserf]

Hi guys,

Just rebuilt the engine after my crank gear started spinning.  Everything seems to be running fine, except for a few little querks:
1.  The tensioner on the serpentine belt is constantly wobbling back and forth making the tension on the belt tighten then loosen.  Not sure if this will ever be a serious problem, but it is bloody noisey!  Anyone know if this is common?
2.  Sometimes when I let the clutch out (in neutral) there is a rattling sound.  Someone I talked to said it might be the clutch release bearing.
Any suggestions on how to fix these is appreciated...Right now my car is turning heads, but for all the wrong reasons

[houseofdiesel]

You will have to "rebuild" the serpentine belt system-buy a new lever (028-903-308G), tensioner (028-903-315R), two bushings (028-903-310) and two rubbers (028-903-313). You should also replace the alternator pulley with a clutched one off a TDI (028-903-119AA), this really extends the life of these parts. You can source these parts aftermarket if you shop around long enough, saves big $$$.
As for the clutch noise I have not heard of that type of release bearing making noise (tdi trans yes, but not the 020 trans)-could it be something loose in the clutch/flywheel? The release bearing is inside the green cover at the end of the transmission, easy to change/inspect if needed and cheap.
Greg