AC and PS v-belt configs

[oblique]

Hey folks
Is anyone running AC with a manual rack? I want to convert my factory AC/PS 90 1.6TD Jetta to manual steering...just had an 86 Westy rack rebuilt but cannot find the v-belt diagrams. I could've sworn I've seen parts diagrams with all the different accessory combinations but cannot find anything...ideally I track down all the pulleys I need for a factory setup. Currently have the dual 'idler' style water pump pulley.

Also have a buddy who wants to ADD PS onto a non-AC 1.6TD 88 Jetta. Already have a good rack, pump, lines, etc. Also wants a clean setup. Whats the best route to go?

[fatmobile]

 There is a 1/2" belt that will go from the crank> waterpump> alternator.
In fact I think it's the same one as the stock AC setup.

 When I use the MK2 AC alternator bracket and alternator on the MK1 non-AC setup I rotate the alternator down as far as it will go.
 Then I see where it touches and grind some away, from both the bracket and alternator, so it will rotate even farther down.
 This keeps the belt shorter, makes it so you can reuse the stock belt.
 It also requires the ford double alternator pully.
 I swear someone on here has a picture of it as their avatar.

Oh and there is one more trick.
 The adjuster bar. I use 2 pieces.
 Rotating the alternator down, put the adjuster bolt hole on the far side of the alternator.
 I don't know how many old alternator adjuster brackets you have.
 I used a short MK2 gasser bracket, it has a hole near the end. I bolted it to the holes using a (head bolt?) washer as a spacer.
Basically move the adjuster hole to down underneath the alternator.
 Then I bolt a curved and slotted brace to the lower bracket hole.

I thought the info was in the FAQs but couldn't find it.
 Thought I would have a picture somewhere too but I'll have to take one.

[oblique]

thanks for the reply but its hard to visualize.

I found this on cabby-info.com..the later styles seem very similar to what the 1.6td looks like.

the full setup (including dual waterpump pulley w idler):


here we keep AC but remove PS...the compressor does not appear to change location and neither does the Alt...we just move Water Pump to single pulley.


removing AC but keeping PS the Alt DOES seem to shift downward slightly:


Its finding the required brackets and hardware that I want to know.

[fatmobile]

If you put the alternator where the AC is in the top 2 and use the same blue belt.
If you have a picture of the alternator, you'll see 2 holes on the opposite side of the pivot bolt.
I'll try to get a picture but it won't be until next week.

[oblique]

Ok I think I've got it as you described - Belt 1 between Crank, WP and ALT and Belt 2 Crank and PS but how do I tension the alt? With AC it would be the bar to the head bracket - there are free holes in the steel bracket - do I stick a toothed ALT tensioner in there?

[fatmobile]

Your alternator is different than the ones I work with.
 Kind of looks like it's for a non-AC MK2.
 That lower bolt hole is right there where an adjuster backet can get to it.
Usually those 2 holes are way on the other side of the alternator.
 So now you just need a curved bracket with a hole in one end, to mount to the lower alternator bracket hole.
 And a long slot in that bracket to slide the alternator bolt on.

 And if you can grind on the alternator and bracket a little near the top where it's touching,
you can bring the alternator down far enough to use the old AC belt.
Shorter the belt the better I think.

 Seems like I sometimes have a problem with that top alternator pivot bolt trying to come loose.
 So I use a longer bolt and put a nut on it too. Double-nut it.

 And I'm thinking belt 2 goes around the crank, waterpump and power steering.
 There should be another pully on the waterpump maybe.

Doesn't look like the double-pully ford pully on the alternator so it might not line up with the crank and waterpump pullys.