1.6 TD serpentine conversion?

[Ohiobenz]

Is it possible to convert the 1.6td to serpentine belt?
Not running any power steering or AC. Just a GM alternator,  crank and water pump.
I have the crank pulley off right now.

This is in a Suzuki Samurai.

Thanks.

[Ohiobenz]

I found an old thread, but there were no actual part numbers given for the crank or water pump pulleys. I'll make my own tensioner mount since my alternator sits on the "back"/intake side.
What is the AAZ crank pulley part number?
What is the Corrado water pump pulley part number (if that works)?
Thanks!

[libbydiesel]

The AAZ was notorious for ruining the crank sprocket.  Same crank sprocket as the 1.6 which failed much less frequently.  The difference in failure rate is presumed to be from the added stress of the serpentine belt setup.  I would not recommend added the serp belt to the 1.6TD unless you update to the later Mk3 TDI crank sprocket and get the crankshaft machined to accept it.  I also would not recommend it with a solid alternator pulley.  Get a clutched style.  Also there is one of the serp bracket mounting holes not present on the 1.6 block. 

[fatmobile]

Right the TDI sprocket uses a flat spot to "key" it to the crank.
Instead of the weak "key" which even went out on some 1.6s.

[Ohiobenz]

I've had a history of issues on multiple MK2's with the alternator and PS V belts slipping. Too much tension and then the bearings go...

On this Sammy swapped 1.6TD there is no PS, just the alternator and the water pump.

The alternator tensioner bracket or its' attached bolts have broken 3x or more times. Everything is aligned.

I've built a new bracket now that is so reinforced. It's hard to think it could break again. I went to all grade 8 metric equivalents in hardware, added more bolts to the ACME alternator mount brackets.

If this breaks again after it's back together I'll be lost for solutions. It's almost like there's some destructive resonance...




I broke up the thoughts with spaces for easier reading.  Orc

[fatmobile]

Thanks, that does make it easier for me to read.
 So you have the alternator on the backside like the audi 4000? or quantum?

[srgtlord]

When I had the AAZ Serpentine setup it lasted awhile before the bracket cracked in half. I found out the bracket is NLA nowadays

[Ohiobenz]

Haven't figured out how to post pics from my Android on here yet :-(

The ACME adapter kit for the VW/Samurai has a GM alternator option for the 1.6TD. It mounts the it roughly where the VW PS sits, a little higher.

I'm running a Prius EPS so no hydraulic PS.

[fatmobile]

 So the MK2 bracket with the non-AC upgrade should work right?
 Have you seen that thread.
 Might be in thye FAQs.

[Rock3tman]

If I  recall correctly, I used a MkII alternator bracket from a non a/c, non p/s ABF code engine for this application on a 1983 Jetta 1.6 turbo CY code engine (non a/c, non p/s) with mechanical lifters.  Imported the ABF bracket from Germany, as non a/c was much more common than in North America.   Belt adjustment is provided by a spring between the bracket and the alternator.  I also needed to weld a small tab on the back of the stock injection pump bracket to be able to put a 4th bolt fastening between the alternator and injection pump brackets.

I used a late idi/early tdi crank sprocket, the normal crank serpentine pulley, the normal smooth water pump pulley, and an INA brand, clutched serpentine alternator pulley.   Works great: perfectly smooth belt tracking, great belt tension at all times, a powerful 90A alternator, and increased safety to crank sprocket longevity by the clutched alternator pulley.