Alternator problem: I'm stuck and stupid

[fry]

I need help. I had a problem with the alternator of my van. It has had some modifications (It would take to long to explain but I can't just replace it) on it before I got it and now it's failed I need to find out what it should look like. I think it is a 1.9TD AAZ engine (there is no engine code) with a ribbed, approx 1 inch wide alternator belt. Is it possible I could visit a club member in the Yorkshire area (I live in Wilsden, West Yorkshire) to see their engine get my head straight on what I need to do to sort it out.

In hope, fry
PM me, many thanks

[Red Westie]

As yours is modified...wouldn't it be easier just to get your alternater re-conditioned..there are a few independants out there that with either give you a direct replacement or even take your unit and re-con that one.
Martin

[kevtherev]

yes I agree with red westie.
Have you looked for a part no on the Alternator

[fry]

Thanks guys but the problem is not the alternator. I know the previous owner changed the engine from a 1.6TD to a 1.9TD but I think they used the 1.6TD alternator mounting bracket and alternator. If I am right the 1.6TD had a v belt pulley but the 1.9TD has a 1 inch wide grooved belt. So the garage that put the engine in welded a grooved belt pulley on the end of the old pulley. When I found out the alternator had failed I ground the pulley off to change the alternator. When I welded the pulley back on for the new alternator, I tried my best but it wasn't properly centred and the new alternator failed. (Yes I am stupid for even buying the van, but it has been a hell of a first project) With this I investigated further and I think the the 1.9TD engine has a different mounting bracket, alternator and pulley but I am not sure and don't want to fork out any more money until I am sure, hence my need to see a good engine.

[Grumpy Midget]

The AAZ engine was originaly fitted with a Valeo 90 amp Alternator Ribbed belt setup, you can revert back to the 1.6 td (JX) setup, but you will have to source 65 amp Alternator plus change Crank pulley, Water pump pulley and Alternator pulley, plus the Alternator mounting bracket, which can be easily couced from any breaker on here ( Give CJ Syncro spares a shout) think his name is Simon. Or Contact Marcus Merc doctor, -------

[Grumpy Midget]

Thanks guys but the problem is not the alternator. I know the previous owner changed the engine from a 1.6TD to a 1.9TD but I think they used the 1.6TD alternator mounting bracket and alternator. If I am right the 1.6TD had a v belt pulley but the 1.9TD has a 1 inch wide grooved belt. So the garage that put the engine in welded a grooved belt pulley on the end of the old pulley. When I found out the alternator had failed I ground the pulley off to change the alternator. When I welded the pulley back on for the new alternator, I tried my best but it wasn't properly centred and the new alternator failed. (Yes I am stupid for even buying the van, but it has been a hell of a first project) With this I investigated further and I think the the 1.9TD engine has a different mounting bracket, alternator and pulley but I am not sure and don't want to fork out any more money until I am sure, hence my need to see a good engine.

Hey fry just re-read your post again I had the original setup on my conversion with the ribbed belt but not the "cock" uP welding of the ribbed pulley, as said in previous post I had a Valeo 90amp alternator stock fitment, then read a comment on here by Andy Simpson (VW Mechanic) of the AAZ Crank pulley syndrome early Mk 3 Golfs Crank failure, I know my engine conversion is a 1Y but it is the same engine as the AAZ yours is Turbo. mine isnt.
If you can e-mail me some piccys of your system from the crank pulley upwards showing belt setup etc I will talk you through and advise what you need to put it back to the 1.6JX standard belt setup. E-Mail is in my sig. Jeff.

[ringo]

Please post a photo and we can take a look.

I'll be interested to see the alternator mount, the alternator and the crank pulley wheel...

Ringo

[fry]

Thanks for the info. I have done some further investigation and taken some pics. I have got the engine No. AAZ 398 481 and the mounting bracket has the part no (sorry if this is wrong) GGG(or 666) -40 068 9 0(or 9) 31450. I don't have a part no. for the alternator as it was a refurbished unit. First time sending pics and not sure. Hopefully the pics are ok.

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