question on crankshaft pulleys

[JBG3]

Hi, New member here.  Glad to have joined a diesel specific VW forum vs lowering and stance discussions.    

I am trying to identify what I need to do as far as resolving a line up problem with my accessory and crank pulleys.  I have a 1986 Jetta that I swapped a 1.6 NA out of a 1985 jetta into.  I had previously driven the 1985 jetta for a little under a year until its rust problems became unsafe, and didn't really do anything major, so I never noticed, but now that I switched engines into a new less rusty body, and also replaced the alternator, I notice that the crank pulley is about 1/2 inch further out than the water pump and alt pulleys, which line up with each other.  

The engine is a non A/C 1.6.  My question is can I replace the crank pulley, or space out the accessory pulleys, and basically identifying what part I need to get them to line up properly.  

thanks!

Here is a pic of the reference issue, its about 1 3rd of the joint on my finger off-

[R.O.R-2.0]

one of your pullies is not off that car.. is it about 5mm out of line? the difference between gasser and diesel pulley offset is 5mm..

i would say that your water pump pulley is off an EARLY engine, like a 1.5D maybe, or early 1.6..

i had just the opposite issue of yours.. mine was cured with a small aluminum spacer..

[JBG3]

Im going to try and space out the water pump pulley, and do the same with the alternator to match it up I think. 

I have available a non A/C crank pulley from a 81 caddy, and a A/C crank pulley from an 85 golf.  Think any of those might work?  I have to pull them off spare engines and compare I guess. 

[vanbcguy]

Best bet is to get an entire set off an engine, if you have a spare around.  The pulleys in your pictures look pretty rusty anyhow, meaning they will eat belts faster than a cleaner set. 

If there's a full set on another engine that's looking nicer I wouldn't hesitate to swap them all together.

[R.O.R-2.0]

Yea, like was mentioned, i would pull atleast the crank and water pump pulleys off another car, as well as the alt pulley if you have it also..

[JBG3]

well, since I started this post, I have another 1.6 motor from an 81 rabbit I was going to grab all three pulleys from, and it has the exact same spacing problem!  Must be more common problem than I thought that people would throw any all pulley on there. 

[R.O.R-2.0]

well, since I started this post, I have another 1.6 motor from an 81 rabbit I was going to grab all three pulleys from, and it has the exact same spacing problem!  Must be more common problem than I thought that people would throw any all pulley on there. 

same spacing problem? like crank is too far out, and wp is too far in?

[JBG3]

same problem like the WP and alternator are too far in.  Heres a pic (sorry for these kind of unclear pics).

On the 81 motor, the WP is pushed in 1/8th of an inch, and the alternator is even further, a little over 1/4 inch in from the crank pulley.  Not a single one of them line up!   

I will just proceed with my original plan to space out the pulleys on my jetta to match the crank. 

[Quantum TD]

I've seen this on most non-ac cars. The WP pulley sticks out notably in relation to the alt and crank. Not a real issue unless you're running multiple belts, but probably not great for the life of the belt.

[belchfire]

The wp is closer to the crank & so is a little more critical. I had to put a 1/8" spacer behind it to get mine to line up. Alt is further out and is a little more forgiving.

[JBG3]

So I have not yet dealt with this problem, and I think its having an impact on a more pressing problem, and its time to fix both.

Over the last two weeks I've put something like 1500 miles on this car on business trips.  I'm getting between 40 and 45mpg, so I'm psyched about this little car, already saved me over 100 bucks in fuel.
However, I keep having a problem with the alternator loosening up.  This has happened almost every time I fill up, approx every 500 miles.  Is there an upgrade to the lack of a tensioner on this car?  I have a slot with a bolt and nut on the back side.  It has a lockwasher on it, but its not doing the job. 

As I type this, I'm stuck on the side of the road waiting to cool down so I can make it to an auto parts store, lost the belt this time. 

[srgtlord]

I guarentee it loosened up due to a worn out alternator bushing.

[JBG3]

I guarentee it loosened up due to a worn out alternator bushing.

its a fresh reman alternator though, only been on the car for 2000 miles.  It seems to be sliding on the lower mount bracket, ill post a pic when I figure a way to get this car up to my workspace and fix it

[srgtlord]

I should have been more specific, the alternator bolt hole wears egg-shaped, which causes the alternator to wiggle on the bolt, and causes the alternator bolt hole to wear egg shaped, thus ruining the alternator bolt hole and causing a headache.

[smutts]

Just to be a worry guts, but the crankshaft isn't loose? Knackered thrust bearing wise?