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Old 07-08-2013, 08:44 PM   #1
cb7tuner
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Vortech idler pulleys seizing and belts breaking

Well after having this happen to me yesterday, I noticed another member posted today of the same issue. Maybe more will pop up soon as well...
this happened to me yesterday, belt shredded and my idler pulley on the compressor assembly looks melted in the center and off balanced seeming to be due to a bad bearing in the pulley and the lip is chewed off (4500 miles on my kit, never tracked, never abused). I contacted vortech about this today and I was told I needed to send the bad parts to them for them to be looked at and determine the cause first. I'm not going to do that since this is my daily and that would leave my car down for at least a week since I'm in Georgia. Not to mention shipping charges as well, and no guarantee that I would even be given replacement parts. When I easily fixed the problem myself for $35 in one day. The idler is a dayco 3" smooth pulley with lip part # 89003, cost me $17 and a new replacement belt. Not a big deal but definatley not something I expected from a $5k kit. Pics... And more later of the pulley after I removed it since my phones acting weird


Lip of the plastic pulley I found melted off in the bay

Shredded belt


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Old 07-08-2013, 08:46 PM   #2
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Other thread that the problem is mentioned from post#5 down
http://www.ft86club.com/forums/showthread.php?t=40985
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Old 07-08-2013, 10:04 PM   #3
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That kit uses the stock tensioner, right?
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Old 07-08-2013, 10:05 PM   #4
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Were you hearing noise before this happened?
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Old 07-08-2013, 10:08 PM   #5
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Nope, happened all of a sudden. No sounds or vibrations or differnece in drivability. To be honest I wouldn't have noticed if I didnt smell the faint smell of plastic burning when I got home and parked my car in the garage. I figured I ran over a plastic bag or something on my exhaust. When I popped my hood I was shocked at what I saw
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Old 07-08-2013, 10:16 PM   #6
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http://forums.vwvortex.com/showthrea...ley-to-do-this

http://forums.corral.net/forums/gt-s...n-problem.html

http://www.cherokeesrt8.com/forums/a...p/t-45345.html


In the SRT8 forum they mention the Dayco 89003 as a replacement....

Perhaps they just got a batch of crap pulleys?

Looks like I've got something to do this weekend... change that pulley before it seizes.
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Old 07-08-2013, 10:27 PM   #7
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Garage
I heard a noise that sounded like when someone rat tails someone with a wet towel. Heard it a second time but very faint this time. I looked at my dash and noticed the battery light came on. I pulled over to the side of the road and looked under the hood. To my surprise the belt was severed in half.
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Were you hearing noise before this happened?
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Old 07-08-2013, 10:39 PM   #8
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I think I found the issue. At lesst my issue that is tied to this will post up video in a bit.
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Old 07-08-2013, 10:51 PM   #9
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I think I found the issue. At lesst my issue that is tied to this will post up video in a bit.
Did that noise turn out to be the idler pulley?
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Old 07-08-2013, 10:56 PM   #10
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Awesome
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Old 07-08-2013, 11:03 PM   #11
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this is why i wait on FI kits... lol
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Old 07-09-2013, 01:30 AM   #12
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I need to talk to Brian so they can send me new pulley and intake tube.

Here you guys go this is what I found to be my issue. I also through together a 5 minute video of the process:

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Old 07-09-2013, 01:50 AM   #13
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Dezoris, Thank you for your videos. I had watched your install videos earlier tonight and now this video. You not only do very nice production in your videos, but your honesty is refreshing. I have no intentions of installing one of these, but if I ever did you really gave me an honest assessment of what it entails. Having done many similar installs over the years on different vehicles, we often forget that it is not all sunshine and lolipops. Yes, sometimes we have a wonderful install and ownership experience, but that is certainly the exception and not the rule. Thanks again and good luck to you.
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Old 07-09-2013, 01:59 AM   #14
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Dezoris, Thank you for your videos. I had watched your install videos earlier tonight and now this video. You not only do very nice production in your videos, but your honesty is refreshing. I have no intentions of installing one of these, but if I ever did you really gave me an honest assessment of what it entails. Having done many similar installs over the years on different vehicles, we often forget that it is not all sunshine and lolipops. Yes, sometimes we have a wonderful install and ownership experience, but that is certainly the exception and not the rule. Thanks again and good luck to you.

Thanks I really appreciate that! After staying away from modding for a long time, this car has certainly been a mix of both good and bad.

One thing is for sure if I can get through the bugs of I may start enjoying driving it more.
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Old 07-09-2013, 02:01 AM   #15
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@Brian@Vortech perhaps you might want to chime in on this
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Old 07-09-2013, 02:26 AM   #16
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This was the noise I started hearing which maybe bearing noise from that pulley at this point.


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Old 07-09-2013, 02:31 AM   #17
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Same here.

So many headaches with this kit already

Whats the return policy on this anyways, cannot find it on the vortech page



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Old 07-09-2013, 05:13 AM   #18
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@Brian@Vortech perhaps you might want to chime in on this
I've PM'd him and I think he's aware of the situation, he's mostly involved in their social media and marketing so there's not much he can do himself. But I was asked to talk to a tech and that's where it went south for me. I explained what I found and what had happened, and the techs replys were very defensive and seemed to act as if it was my fault. I was asked to send my parts back to Vortech to be looked at to determine what would be done after that. But come to find out another member here that had the same failure as me contacted Vortech and with no questions asked already has another belt and pulley on the way to him. I feel like I've been given the run around and it could have been handled better for me.
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Old 07-09-2013, 06:46 AM   #19
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My pulley is in perfect condition. It has barely brushed my intake pipe. I did feel nervous about that plastic pulley before install because it did wiggle.

I will say this some of these ground down pulleys "could" be installation error. I still have room to position the pipe higher on the the supplied bracket.

Last edited by charged86; 07-09-2013 at 03:35 PM.
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Old 07-09-2013, 06:48 AM   #20
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Thanks I really appreciate that! After staying away from modding for a long time, this car has certainly been a mix of both good and bad.

One thing is for sure if I can get through the bugs of I may start enjoying driving it more.
If you are driving the car during the winter do you have a battle plan for a blower heater for cold starts?
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Old 07-09-2013, 07:13 AM   #21
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My pulley is in perfect condition. It has barely brushed my intake pipe. I did feel nervous about that plastic pulley before install because it did wiggle.

I will say this some of these ground down pulleys "cold" be installation error. I still have room to position the pipe higher on the the supplied bracket.
My pulley has not touched anything, i don't even think the pipe could touch the idler pulley if I wanted it to. It's ground down because the belt has jumped from the idler wiggling (because bearings failed) and caused the belt to ride on the lip of the idler. Then causing the idler to act like a saw hacking up the belt and taking chunks of the lip with it. My pulley hasn't touched anything. Oh and mine was in perfect shape a few days ago as well.....then it happened. No way it could be installation error. The pulley is pre installed on the blower assembly (but every bolt was checked to be tight before installation like the instructions say to do so) and nothing was loose when I removed the bad parts. I'm an A&P licensed aircraft mechanic. I'm very methodical in my installations. Like I've already stated, its really not that big a deal to me because it was a cheap easy fix. I just don't like how the situation was treated in my personal case by vortech and I would like to warn others of potential future problems and where to get replacement parts with part #s
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Old 07-09-2013, 07:34 AM   #22
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Just checked my pulley/pipe clearance. No issues.
When I installed, I lifted the pipe before tightening the couplers/bracket for this exact reason

It looks like less from the picture, but there is a good 8-9mm of clearance between pulley/pipe



No rubbing




Also, all owners should check their pipe for rubbing... it took less than 2 minutes with a flat blade screwdriver and a 10mm wrench to pull the pipe and check.

The pipe DOES contact the hood insulation, but it doesn't really put pressure on the hood/pipe and only touches when fully closed.

I am changing the pulley for a dayco/Duralast pulley. I wonder what the mfr. of the pulley that comes with our system is....
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