Help Please - Alternator issue

[Andyvandy]

Hopefully some kind soul or souls can help me...

I have a T25 with AAZ 1.9TD engine fitted (by previous owner) from VW Golf
Engine, water pump, power steering pump and alternator pulleys are all 'V' Belt.

I needed a new alternator and could only source it from GSF (90Amp -903VG0160)
Having come to fit the new alternator I have found that the alternator pulley is about half an inch too short and therefore doesn't line up with the engine and water pump pulleys.
VW and else where all show the AAZ with the flat belt system not 'V' belt.

Unfortunately I have sent the old alternator back as there was a hefty surcharge on it and cannot fit the old pulley.

Can anyone suggest a solution?

The only suppliers of alternator pulleys show the flat belt type.

We are moving to France at the end of the month and have to get the van back on the road by then.

Thanks

Andy

[Oldiebut goodie]

Are you saying that the v-belt pulley,even if you had one, still wouldn't line up as the alternator shaft is too short?
You normally have to transfer the old pulley onto the new alternator if keeping the v-belt setup. I suppose you bought an alternator for an AAZ rather than CS/JX which is the problem by the look of it. To keep an AAZ alternator you have to usually run the flat belt system.
When I did my engine swap I had to alter the fitment of the pulley by welding the spacer back to front onto the pulley - can't remember exactly what as it was some time ago and didn't take any pics of what I had to do.
Did the gearbox end swap go OK?

[Andyvandy]

Oldie,

I got an alternator specified for the AAZ engine as fitted in the VW Golf.
It seems logical that a replacement alternator for an AAZ engine should fit without any hassle
One for a JX wouldn't fit (I ordered one by mistake and found that out!)

What I am confused about is flat belt/v belt setup. It seems as though this AAZ engine has had the V belt setup from new. I fitted a new water pump for an AAZ engine and that was V belt, the original alternator for the AAZ is V belt.

The gearbox end swap went well and the box is back in the van along with the engine.
Just waiting to sort this alternator problem out and can then get the van started.


Andy

[Oldiebut goodie]

Just looked at the manual - it depended upon specification as to which belt system was fitted! It doesn't say what the criteria were. My 1Y was flat belt which I put back to v-belt.
I would expect the alternator to fit as supplied as long as it was for the same model and spec for that Golf - there must be differences that have caused the problem. Can't see an obvious solution without trying various parts to see which line up.
Have you looked to see if you can mount the pulley around the other way - they are usually offset to a degree. I was lucky as I had various spare parts that I could offer up to get mine to fit, even so still ended up welding to get it in line.

[Andyvandy]

Oldie,

The pulley needs to be further out by about half an inch, so turning it around wouldn't help.
I don't have any spare bits or welding gear to hand.
My workshop is now packed up in the back of the Luton van for transportation to France!

I am now awaiting a call from the auto electrician in Turriff tomorrow after he has done some research and hopefully found something to fit.

Nearly there after blood, sweat and tears - literally!

Thanks

Andy

[Oldiebut goodie]

If you have the alternator mounting bracket that has 2 lugs and a spacer tube you can reposition to the outside of one lug and the inside of the other but that is no good if you have the type with a solid one piece mounting.( + adjustment of the adjusting bracket if not auto tensioner) Just a last despairing thought.

[Andyvandy]

Oldie,

No room for adjustment
If I had a decent workshop I would consider fitting another pulley (secured by screws) on the front of the existing one (which is alloy), but alas no facilities.
I will have to hope that the auto electrician can come up with something...

Thanks for your support

Andy

[Andyvandy]

Update,

The local garage recommended an auto electrician in Turriff (about 20 miles away)
I popped over to see him late Tuesday afternoon and he said he would do some research.
He got back to me yesterday and said he had found what seemed to be the correct alternator with the pulley protruding further out.
He ordered one in and I went and picked it up today and it fits nicely!

That problem over.

Andy

[Oldiebut goodie]

Phew! - time was running out for getting it fixed and the move.

[Andyvandy]

Oldie,

Tomorrow:
Fill: Oil, antifreeze, water, power steering fluid and prime the fuel system.
Then see if it starts and deal with any more presenting problems...
Replacement brake slave cylinders fitted today after new ones leaked!

Andy