serpentine on 1.6l TD?

[jb86]

i have a 91 jetta w/1.6l TD. a/c and power steering. 3 v belts. the alternator belt loosens. just a crappy set up to maintain. i have the engine out - car was painted last week (2000yr indigo metallic blue) and under the hood. i have a new engine machined - bottom end and head. i will assemble it then drop it in. i was hoping to find a way to convert it to a serpentine belt.
the only issues i see are -
the harmonic balancer. on a gas engine car it is stamped steel. on the diesel it is a heavy balancer. the TDI has a similar balancer. would it be approriate to install the harmonic balancer form a tdi or similar engine and it will have the serpentine grooves?
the altenrator from a 93-up (has the serpentine grooves) has some type of clutch to relieve pressure from the belt when it kicks on. would i use an alternator form a 93-up?
any input?
i would get a tensioner from a 93-up
water pump pulley and power steering pulley from 93-up.
jon

[coke]

You can pull the setup from an AAZ. I believe that setup would use serpentine for AC, and Alternator. You can just use the harmonic balancer from that. The "clutched" alternator pulley may or may not be installed, it wasn't from the factory I don't believe but you can get them, and you should. Be a good time to upgrade to the TDI sprocket too, used on the AHU motor I think. Common swap for people here.

Now, there were two or three different setups for serpentine. Water pump, alt, ac, and just ac and alt.  The latter used a v-belt to run the water pump and power steering, but you would likely need the power steering pump and bracketry for it from the AAZ. The early TDIs did this as well. My father's 98 uses a v-belt for the water pump and power steering, and serpentine for the AC and alt.  I do also believe there is a 3rd bolt or a 2nd bolt or something that bolts through the bracket to the water pump housing that you can't use when you swap setups unless you modify your lower IP bracket like libbybapa did.

Should be several write ups here for you to look at to give you some insite.  Now that I think of it, I do believe that the setup that uses 1 belt for AC/Alt/WP may use a counter rotating water pump, which would be difficult to source. I'm not sure, I know it can be done but honestly your easiest option is probably the 1 serp, 1 vbelt, with the vbelt running water pump and power steering pump.

[tdihuntdawg]

there is a wealth of info in the FAQ/TECH TIPS/READ THIS FIRST/ section i am attempt to retrofit 2000 jetta ac system into my AAZ Vanagon

[the caveman]

I would try to remedy the 3-v belt system first. There was a tech bulletin about modifying the alternator bracket so the belt contacts more of the pulley, and so less adjusting needed.I will try to find it but...
 did it to a couple of cars including a pal's . Worked much better.
Using a serpentine belt, while less short term maintenance is needed, it can cause crank pulley failures if not done 100% properly.
I just installed an AAZ into a friend's doka and was going to keep the serp setup, but i'm going to recommend to him to change it back to a v-belt even thought it's only one belt.
For some people it would be better to have to spend 15 minutes to adjust it every few months , then having a big failure later.

 just my 2 cents

[GEE-BEE]

here are the parts:

028105243t dampner 72.50
v-pulley for p/s no part #
8x 45 bolts 4 each for above attachment
water pump serp pulley no part #
6pk1145 serp belt ( a/c)type 13.50
belt for p/s 11.7 x 5.90 $ 7.92
1.9 aaz alternator bracket with tensior arm and roller ( thepartsplace.com) new 189.95
alternator ALO184 120 amp or ALO181X 90amp
clutch pulley, ebay 130229511505 72.50

Iam sure you can find some used stuff from member's here, if your into used part's

GB

[mystery3]

IIRC there was a guy on vortex selling setups from the abf or aab or some euro motor that made it pretty easy. I'd link it but the vortex search function is so poor it might take me an hour to find.

[rdezsofi]

That clutch pulley on the alternator is from the factory, and it's not really optional. It was to fix the issue with the AAZ engine when they first went to the serpentine system....trashed crankshaft sprocket keyway/crankshaft....ruined entire engines. The clutch prevents the drag on deceleration from the alternator, which was tearing up the crankshaft keys. (I guess the serpentine belt grabs pretty good!)

[Bugsy_malone 666]

I have kinda done a serpentine belt conversion on a 1.6TD that I have in my camper (a 72 baywindow camper that I did an engine conversion on) mainly because when I got the engine I didnt have the pulley for the alternator and its a funny length so was hard to get hold of!

Basically I used a mixture of parts for mine, the alternator pulley I really not sure what model of golf it was off of, something like a G60 maybe but it had about a 3/4" offset to it, mounting, meaning I only needed a shim washer behind it to makesure it fitted tight. The water pump pulley I used was from a mk3 golf GTi as they are smooth meaning you dont have to worry to much about belt alignment as long as its on the pulley and when I got to the bottom pulley is where I hit a hurdle as I couldnt find the mk3 golf TDi type which I was also informed causes problems. In the end I managed to get a pulley from a 2000 skoda TDi (the 1.9 from passats/skodas/golfs of that time?) and basically it was a serp belt pulley, it had 4 bolt holes in it and was a plain pressed steel item, I then made a 4mm thick aluminim spacer for the crank and it seemed to work spot on! The belt I then used was from a mk5 golf I beleive.

I'd like to be more helpful with part numbers but I havent really got any to hand, mine was more of an ebay guess work thing, but what it shows is by using spacers etc you can achieve the right alignment!

Now with yours you say you have PAS as well as A/C, I think as mentioned the mk3 golf setups have a dual belt setup with a serp belt that does alt/ac/water pump, then a little single V for the PAS pump, I know my mk3 golf (non AC) has that setup and I also have an AC bracket that has a built in belt tensioner.

Now if I were doing the conversion again myself having read the few things I have I think what I would do is basically hunt down a serp setup from a mk3 then you just get the right amount machined off the bottom pulley (I think its about 1/4") as then you are using just one single setup thats common (unlike mine which is a mishmash and about to get worse!)

Something I am curious about is you mention how you have 3 belts, is the AC on Vs as well? if so that could be a bit of a PITA to either change the clutch pulley on the front or have to change the AC compressor and get the system regased.

So depending on how the PAS and A/C pulleys fit to the main crank(I know with my mk3 you can actually seperate the serp and V pulleys) you may be able to either cobble something together to run serp on the alternator/water pump then stock everything else or change to a complete mk3 setup.

After several thousand miles on my conversion I havent seen any issues and the belts not gone slack, uses a stock bracket!

I am about to convert further, going to look at sticking a 100amp alternator and power steering pump off of something else and make a custom bracket, I may investifate a TDi AC bracket to ease the fitment job with its built in self tensioner!