Pully help! I need photos!

[addautomotive]

I'm ditching the A/C on my'96 AAZ jetta... the compressor sounds like it's a gravel crusher, and the condersor leaks. So it's out, and it's never allowed back in.

I deicided to do this while I was replacing the tensioner, tensioner arm, cooling hoses and PS pump.

Anyway, the local VW shop told me when they do it, they swap out the Accessory belt & water pump pulley. The idea is, the water pump pulley is run by the accessory belt, instead of the small V belt with the PS pump.

Unfortunately, the water pump pulley the gave me doesn't seem right... It aboout 1mm from the crank pulley, and rubs against the lower timing belt cover. Plus, I don't see any conceivable way to get a belt on it.

Does anyone have a picture of their AAZ No-AC setup? I need to figure this one out ASAP.

[addautomotive]

FWIW, I came up with this thread, which describes teh same thing I'm doing. I just need to see the pulley, and I need to confirm teh part # in case I need to get it new.

http://vwdiesel.net/phpBB/viewtopic.php?t=5543&highlight=aaz+belt

It mentiones these part #s:
028121031K (pully)
028903137BB (belt)

But it doesn't say whether these are VW part or aftermarket. Gave no results in Altrom

[jimfoo]

I'm ditching the A/C on my jetta... the compressor sounds like it's a gravem crusher, and the condersor leaks. So it's out, and it's never allowed back in.
tely, the water pump pulley the gave me doesn't seem right... It aboout 1mm from the crank pulley, and rubs against the lower timing belt cover. Plus, I don't see any conceivable way to get a belt on it.

Does anyone have a picture of their AAZ No-AC setup? I need to figure this one out ASAP.

My pulley is very close to the crank pulley. I always thought the belt went from crank to WP pulley, to PS pulley, not between the crank and WP pulleys. If you still want a pic, I can get one in a little while as my engine is still sitting on the stand in the garage. I'll even check for a number on it. Mine doesn't rub anything though.

[addautomotive]

Is yours a 1.9?
I'd slap my nanny down for a picture!

[jimfoo]

Now that I looked at mine, you must be using a serpentine belt pulley? There is no way in hell mine could ever rub. I didn't see any numbers on the wp pulley, just on the crank pulley.

[addautomotive]

Hmmm, that look like the V belt pulley I just took off!

The steup I'm going to has the WP run off the serpentine belt.

I'll have to get the details on that land Rover conversion!

[burn_your_money]

I'll bring my camera to the shop and see how the WP is driven. I think it's v-belt though because of the PS garbage

[jimfoo]

It's all here. Lots of pics, so slow loading on dial up. http://www.66rover.com/VW%20TD/VW%20TD.html

[addautomotive]

great! Now I'm going to be up till 2 am looking at Land Rovers!

FWIW, I'm pretty sure I have the wrong pulley. This one is 11.5 cm across.

[burn_your_money]

I just looked at my car (forgot my camera  :oops: ) and it has the same setup as above, sorry

[addautomotive]

I need help from any AAZ gurus out there

I was at the local VW shop this morning, and all the water pump pulleys on the non-ac golfs were the same size as mine ~11.5cm.

They think I need to change out my crank pulley too.

Can anyone confirm that there is a smaller waterpump surpentine pulley?

I am without my car in teh meantime, and my wife HATES the Samurai. I mean HATES it!

[addautomotive]

OK, did some searching on Vortex, and came up with some info.

Some of them are running diesel crank pulleys with teh A/C delete WP pulleys. Here is what they say:

http://forums.vwvortex.com/zerothread?id=1674618&postid=28065820

This is a direct bolt on... only issue is that the water pump pulley sits very close, very very close and if you dont have a new or tight pump and it has some wobble you may have rubbing (but the good news is that both this crank pulley and the water pump pulley both have room to be shaved down for safety if desired).

And further down the page:

There really is not an issue with the diesel pulley and VR6 water pump pulley. They do not touch, there is probably only 1 mm clearance but they dont rub. I was just pointing it out for safety reasons. That is personally alittle too close for me. And as I said eithet the flat water pump pulley could be turned down, or the outer belt guides of the crank pulley can be turned down a few mm to give a little more room. Fitting the belt in either case is not a problem.

[CalgaryMcLean]

Is the AAZ setup the same as the early TDIs?  This might help (page 12-13)

http://f1.grp.yahoofs.com/v1/YAwRRvDXe6JIwhZzcYhesQR2fCTkfkBOFSiJNCpx_ybEEUQkjuphFBjgkDcVoLqKSxhxjLX4Nrkzm_M3Rintz-kvLAGbsm-hstrdcA/useful%20documents/vw_diesel_pulleys_de.pdf

Scroll down this page and there is a pic of an AHU with AC removed:

http://forums.tdiclub.com/showthread.php?t=167583&page=4

Water pump pulley is 028 121 031E

Kevin

[addautomotive]

Thanks kevin!

That confirms that I shoudl be able to use the pulley I have... I probably just need to do some tweaking

[addautomotive]

What fun

Picked up some parts on the way home from work. Have been in the garage all evening, and have found that:

1) The tensioner arm I got has the wrong offset
2) The accesory belt is too short
3) The water pump belt is too long

Also, a note for anyone else who wants to do an A/C delete on a 1.9 AAZ:
This is not 100% bolt on. The lower timing belt cover has to be trimmed to clear the a/c delete pulley. Also, the water pump pulley is 1mm from the crank pulley. If your water pump is wobbly, it will not work.