Author Topic: Clutched alternator pulley upgrade on AAZ  (Read 22114 times)

February 10, 2010, 02:01:04 am

neimis

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Clutched alternator pulley upgrade on AAZ
« on: February 10, 2010, 02:01:04 am »
I recently upgraded the stock alternator pulley on my AAZ to the “clutched” or “freewheeling” type, and thought that some of the information I learned may be useful to others. I know this has been covered in other posts, but there are some details not previously covered that I learned along the way.

First of all, according to my research, there are two sizes (diameters) of pulleys.

Part # 038 903 119A, or it’s superceded part# 022 903 119C, or various other #’s, is for A4 and later vehicles (1999+). Size is 61.5 mm. O.D. It is too big for the AAZ. If you need one for your A4 TDI, best price I found was on eBay for $42 US (INA brand).

Part# 028 903 119AA is for A3 TDI’s. Size is 55.5 mm. O.D.  This is the one that can be swapped onto an AAZ alternator. Brand I bought was INA, $84.50 + tax at V.M.autohaus here in Vancouver. Best price I found was BusDepot for about $62 US.

There is no correlation between pulley size and amperage rating of the alternator, just depends on what was in your car.

On my Passat, it is very easy to remove the alternator (no air conditioning). Make sure to disconnect the battery first! After the alternator is out, an impact wrench with a 23? 24? mm. socket easily spins off the pulley nut. I didn’t have the correct size metric socket, so I used a 15/16”, it did the job. The pulley itself was stuck on tight, but a bit of twisting and gentle persuasion got it off. I didn’t want to tap or hit the pulley as I thought it might damage the bearings or the shaft.

To install the new pulley, I used the Metalnerd Pulley bit set (Part MN3400) $29 + shipping. I will probably have occasion to use this again, as these clutched pulleys seem to have a limited lifespan, and the bit will be absolutely necessary to remove the pulley in the future. I didn’t worry too much about tightening torque (52 ft-lb.?) as it is essentially self-tightening.

The hardest part of the job was getting the belt off and on. Runs great, can’t say as how I notice a difference, but any insurance to save the crank nose on my recently installed new engine is worth it.

Thanks to Vince and others for previous info and the inspiration to do it!


'92 Passat TD
'01 Golf TDI
'15 Golf TDI

Reply #1February 10, 2010, 07:56:55 am

dieselsmoke

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Re: Clutched alternator pulley upgrade on AAZ
« Reply #1 on: February 10, 2010, 07:56:55 am »
I just did this update as well. Besides saving the crank nose it also stops the belt flop for the serpentine belt. I had a brand new tensioner and roller in mine and the belt was pretty sloppy, as soon as I put in the clutched pulley there is zero flop now and runs much smoother.

Reply #2February 10, 2010, 08:17:59 am

rallydiesel

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Re: Clutched alternator pulley upgrade on AAZ
« Reply #2 on: February 10, 2010, 08:17:59 am »
Good info.
2006 Jetta TDI - gtb1749v, Malone 2, Frank's Titan 2 cam, VR6 clutch....
1991 Jetta TD - sold :(
2001 Golf TDI - Son's
1981 Rabbit - BEW tdi swap project

"ONCE YOU GO CLACK, YOU NEVER GO BACK"

Reply #3February 10, 2010, 08:23:49 am

veector

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Re: Clutched alternator pulley upgrade on AAZ
« Reply #3 on: February 10, 2010, 08:23:49 am »
x2 on good info
1981 Jetta D
1997 Jetta TD

Reply #4February 10, 2010, 10:42:45 am

GEE-BEE

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Re: Clutched alternator pulley upgrade on AAZ
« Reply #4 on: February 10, 2010, 10:42:45 am »
So these are fixed type alt that use the roller /arm tensioner not the plunger/spring alt bracket

Gee-Bee

« Last Edit: April 15, 2010, 11:19:21 pm by GEE-BEE »
1.9 AAZ, CHD 5spd with Peloquin
KO4/KO3 Hybrid turbo
Giles Pump OHC
Complete Techtonics 2'5 S/S DP and Exhaust
Coilovers, MKII Pedal Swap,G60 BRAKES
MK1 JETTA DASH
675MM 16V radiator (MKII) PASSAT DUAL FAN
42K original miles , South African Front End
15x6 Le Casletts 195-45-15

Reply #5February 10, 2010, 11:26:06 am

Vincent Waldon

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Re: Clutched alternator pulley upgrade on AAZ
« Reply #5 on: February 10, 2010, 11:26:06 am »
Great stuff... thanks for posting.

Moving to the FAQ section where more folks will benefit from all your great homework in the future. :D
Vince

Edmonton, Alberta, Canada
2001 silver TDI Jetta Malone Stage 1.5 , 2001 blue TDI Jetta SBIII 216s Malone Stage 3, 1970 Bay Window bus

Gone but not forgotten: 1969/1971 Beetles, 1969/1974 Westies, 1979 Rabbit, 1986 TD Jetta, 1992 gas Jetta, 1994 TD Jetta

Reply #6March 09, 2010, 09:16:52 pm

veedubcanuck

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Re: Clutched alternator pulley upgrade on AAZ
« Reply #6 on: March 09, 2010, 09:16:52 pm »
 In the Mk3 Jetta and Golfs you don't have to even take out the alternator. Just take out the airbox and you have room to get an impact in and do the work with it in the car.
2003 Jetta GLS 1.8T w/ Upsolute software 20k kms (yes 20)
1993 Jetta GL 1.9TD stock 440k kms
1990 Jetta 1.6TD stock 320k kms
1993 Golf GL 1.9TD stock 401k kms
1991 Jetta 1.6TD Stock 587k kms

Reply #7March 25, 2010, 05:19:38 pm

1STGENFARMBOY

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Re: Clutched alternator pulley upgrade on AAZ
« Reply #7 on: March 25, 2010, 05:19:38 pm »
My 03 jetta tdi had the cluched pully factory and i had to change it
with only 63,000 miles on the car, IT FELL APART, my wife drives it most
of the time and hadn't told me it was makin a noise. ::)
03 TDI jetta 5spd bone stock for now.

Reply #8March 31, 2010, 08:04:13 pm

Smokey Eddy

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Re: Clutched alternator pulley upgrade on AAZ
« Reply #8 on: March 31, 2010, 08:04:13 pm »
So does this include a serp set up on a 1.6?
Could i use this part no. on a 1.6 with a serp set up on it?
Ed
Blacked out mk2 AAZ Jetta RIP. You will be are missed.
White 1999.5 ALH Golf 2dr. 2" wider. 2.5" lower.

Reply #9March 31, 2010, 11:26:45 pm

neimis

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Re: Clutched alternator pulley upgrade on AAZ
« Reply #9 on: March 31, 2010, 11:26:45 pm »
Sorry I can't help you, I don't know anything about the 1.6, maybe someone else can chime in. What about measuring the outside diameter of your current pulley? My old one is exactly 55.5 mm
'92 Passat TD
'01 Golf TDI
'15 Golf TDI

Reply #10April 01, 2010, 01:26:40 pm

Smokey Eddy

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Re: Clutched alternator pulley upgrade on AAZ
« Reply #10 on: April 01, 2010, 01:26:40 pm »
That's okay. Thanks for the response. I'm going to try fixing my issue with a new pulley and if things don't improove I'll start looking for a new alternator and THEN if things still don't improove i'll look into a serpentine set up.
Ed
Blacked out mk2 AAZ Jetta RIP. You will be are missed.
White 1999.5 ALH Golf 2dr. 2" wider. 2.5" lower.

Reply #11April 15, 2010, 12:34:04 pm

GEE-BEE

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Re: Clutched alternator pulley upgrade on AAZ
« Reply #11 on: April 15, 2010, 12:34:04 pm »
This alt shop show's different #'s

028-903-119 A / Ebay i.d. 200295885792

17 mm bore

38.5 Long
55 mm O.D.

Uses 6 groove Belt

038-903-119A/Ebay i.d. 200350268420

17 mm Bore

50MM O.D.
34.5 Long

Uses 6 Groove Belt

75.00


I purchased this one , smaller o.d., shorter length, great fit on my 90 amp Bosch installed on a AAZ
uses the washer and thread's on , Includes a Dust end cap also....



GB
« Last Edit: April 15, 2010, 11:39:40 pm by GEE-BEE »
1.9 AAZ, CHD 5spd with Peloquin
KO4/KO3 Hybrid turbo
Giles Pump OHC
Complete Techtonics 2'5 S/S DP and Exhaust
Coilovers, MKII Pedal Swap,G60 BRAKES
MK1 JETTA DASH
675MM 16V radiator (MKII) PASSAT DUAL FAN
42K original miles , South African Front End
15x6 Le Casletts 195-45-15

Reply #12April 15, 2010, 10:48:02 pm

neimis

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Re: Clutched alternator pulley upgrade on AAZ
« Reply #12 on: April 15, 2010, 10:48:02 pm »
Here's where I found the info regarding VW part # and diameter:  http://www.ika-germany.de/PRODUCTS/CATALOGUE/tabid/133/language/en-US/Default.aspx?ProId=3
'92 Passat TD
'01 Golf TDI
'15 Golf TDI

Reply #13April 15, 2010, 11:28:10 pm

GEE-BEE

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    1981 with South African front end ,42 k original
1.9 AAZ, CHD 5spd with Peloquin
KO4/KO3 Hybrid turbo
Giles Pump OHC
Complete Techtonics 2'5 S/S DP and Exhaust
Coilovers, MKII Pedal Swap,G60 BRAKES
MK1 JETTA DASH
675MM 16V radiator (MKII) PASSAT DUAL FAN
42K original miles , South African Front End
15x6 Le Casletts 195-45-15

Reply #14October 23, 2010, 07:45:09 pm

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Re: Clutched alternator pulley upgrade on AAZ
« Reply #14 on: October 23, 2010, 07:45:09 pm »
Did the upgrade this afternoon. Used the 028 903 119AA on my OEM alternator. Seems to fit perfectly with no additional modifications. Took a few pictures for illustrative purposes.

Remove the air filter box.
Loosen the serpentine belt tensioner and remove the belt from the alternator.


I had an old impact wrench that fit. I didn't have a 24mm socket so I used a 15/16 12-point. I was able to just hold the pulley with my hand and the impact wrench zipped it right off. If it's really on there, there are two holes on the alternator where you could insert some bolts to hold it in place (1 and 8 O'clock in picture above)


The old and new pulleys...as well as the special bits you need to install the new one.


The triple square blt goes through the splined tool to hold the alternator shaft. Hold the triple square with a breaker bar and tighten the splined tool with a wrench. Don't know what the torque should be. I just put it on nice and snug.


That's it! Put the belt back on. Make sure everything is lined-up. Replace the air filter. Sleep better knowing you may have extended the life of your engine.


Took about 30 minutes. Hardest part was finessing the air filter assembly out :)

1993 AAZ Jetta ~280k