AAZ serpentine belt issues..

[Torchd]

Hey guys!

I've got issues with AAZ serpentine belt... the belt keeps bouncing around the idler(roller) like mad at idling speed. I had original vw tensioner first and I thought that was fault so I replaced it. I got a febi one and that fixed the problem for like a day but it was a different design and starting producing this irritating noise from its spring.

So i got another tensioner which is a vw design but unknown brand, fitted it and the belt was smooth for half a day and then starting bouncing again. And it produces this extremely irritating noise that i just cant stand.

Would any one know whats wrong with it? How can it be  fixed?

Cheerrs

[bert]

hi,i stopped my belt bounce by fitting a alternator clutch pulley,my belt is now quiet 
Bert

[Torchd]

Thanks for the reply bert.

Would you know what sort of clutch pulley would fit on the aaz alternator?
Part number?

[Vincent Waldon]

http://www.vwdiesel.net/forum/index.php?topic=11008.0

http://www.vwdiesel.net/forum/index.php?topic=15010.0

and a few more... "alt AND pulley" are good search terms.

It's a good upgrade... all that belt bouncing is the system torquing and un-torquing the belt, all the while  putting strain on an already weak crankshaft sprocket key and keyway.

[blackdogvan]

Torchd you should take a road trip to Libby's place for a crank nose upgrade. 

[Vincent Waldon]

Now *that* would be a road trip!!

[Torchd]

Torchd you should take a road trip to Libby's place for a crank nose upgrade. 

My crank pulley is as straight as it can get!!! and Im pretty sure there is no damage on the nose.

http://www.vwdiesel.net/forum/index.php?topic=11008.0

http://www.vwdiesel.net/forum/index.php?topic=15010.0

and a few more... "alt AND pulley" are good search terms.

It's a good upgrade... all that belt bouncing is the system torquing and un-torquing the belt, all the while  putting strain on an already weak crankshaft sprocket key and keyway.

Thanks vince..  found all the info.
I just have a question... cant I fit a pulley from a Mercedes since Merc parts are easily available here as oppose to VW parts that do not exist, I will have to source it from abroad. Or can I install a complete alternator from a Merc? They look pretty similar.

Now *that* would be a road trip!!

Its more like a world tour... Im in Pakistan!

[blackdogvan]

What??? He could stop in & have a visit with oldschoolrich on the way!

[Torchd]

I just received my freewheel pulley from Bosch for roughly US$ 50.

What size bolt and what thread do I need to install it?

Thanks!

[Torchd]

So I do not need to drill and tap and install that bolt?? Like in this picture?

Why did Vince do it then?
http://www.flickr.com/photos/26223372@N06/4507845404/#
http://www.flickr.com/photos/26223372@N06/4507207357/#

[Torchd]

Thanks man!

http://www.vwdiesel.net/forum/index.php?topic=15010.0

If you read second post by Vince...  you will see "and the old style alternator shaft won't take the new locking sleeve... I drilled and tapped the end of the old shaft to take an extra bolt instead".

You reckon this is why Vince did it that way?

[Torchd]

And can I do it without the special tool?

I am in Pakistan and I waited to months for my Bosch dealer to get me this pulley.

What if i just hand tighten it and install it.. wouldn't the ratcheting action it up?

[Vincent Waldon]

I'm not sure why Vince did it that way, but I will say that IMO it is not necessary.  Belt and suspenders?     It's a fashion I wear frequently...

Wasn't sure the belt was tight, so backed it up with suspenders. 

On an alternator designed for this pulley the shaft is machined to accept a torx or triple-square bit at the center... this gives you something to hold the shaft still with while you tighten down the pulley using the splined tool.

In this case I was retrofitting an alternator with no center hole.  The only way I could think of holding the shaft steady was to lock it using the internal fan blades. I didn't want to bend the fan so I took it easy on the torque and then backed it up with a locking bolt... M10x1 iirc.

These days every alternator I've seen has the centre hole, even the AAZ replacements, so there's likely little call to be drilling out the shaft... and if you use locktite you can probably argue it's not required in the first place.  I'm an engineer and we tend to be into redundancy.  I'm an engineer and we tend to be into redundancy. 

[GEE-BEE]

038-903 119 AA: USES 6 GROVE BELT

BELT # 6PK1045 ( NON-A/C) 10.65 FROM AUTOHAUSAZ.COM

BELT #6PK1145 ( A/C)TYPE 12.60



028-903-119 A: USES A  6 GROOVE BELT

I hope this Help's

GB

[Torchd]

Thanks Vince for the clarification. I have two alternators, valeo and bosch one has the torx shaft and the other with triple square so I guess I won't need to drill it out!

But I have made a mess... both of my alternators are 90 amps and my car has aircon. After reading out Vince post I also ordered the 028 6 grove pulley.. but my alternators are 90 amps which I just checked now..

So is there any way I can make this work on a 90 amp alternator? or if I find a 120 amp alternator will I be able to fit that into my car and use the same belt rest of the pulleys?

Thanks!