Fitting of alternator

[JRF]

Hi all. I'm currently assmebling the engine and I've run into some problems with my alternator. I have fitted a new waterpump and a new alternator but the they do not allign up as they should. The alternator should have been 2 cm more to the left but I can't see how..? What am I missing here? I have attached a picture...

[Frank]

si quelqu'un peut traduire.
Il me semble que cela vient de la tige de fixation de l'alternateur, sur la photo elle semble droite, or sur l'oett elle est légèrement courbée.j'ai l'impression aussi que la poulie de pompe à eau est moins large sur l'oett
Je vais faire des photos.

[Frank]

to compare :

[Gilloo]

Hi JRF !

Frank said that your top mounting bar should not be straight.

See the pic below (don't mind the red circle, I took the picture from your last post), you can see that the bar is bended :


Frank says also that your waterpump wheel seems wider than the oettinger's one.

EDIT : too fast for me

[Frank]

merci Gilles, tu me sauve de l'effort intellectuel !

[Gilloo]

But even if you set the right bar at the top, how will the alternator move to the left (do you have enough space at the bottom level) ?

[JRF]

Well that is the problem... Even if the top bar isn't straight (mine is straight, why I do not know) I still lack a couple of cm to the left to have the alternator wheel aligning with the others... I tried to fit the old alternator and old waterpump and had the same result... I just don't get this... I must have done something wrong here...

[JRF]

I think I have found the solution to this problem. According to PGG site part# OE 603 001 00 "Poulie d'alternateur" is a special part for the alternator. I guess that someone has changed my alternator at some point and forgotten to switch over the "poulie" from the old alternator to the new one. I have contacted Oettinger France with hopes that they still have this one in stock...

[Jos]

if you don't find the right part, you can fixed a spacer ! very easy to make

[romaingirardlamamy]

Hi JRF
yeah like you said the oettinger alternator pulley is a special one
but bear in mind that you should also have a spacer at the back of the water pump pulley
as if you look on your picture the auxiliary belt come quite close to your timing belt which leave no space to your cam cover
let us know

Romain

[JRF]

So there is an extra spacer in addition to the special pulley on the alternator?

[Gilloo]

Hi JRF,

No, what you should have is :
- the right top bar for the alternator
- a specific pulley for the alternator (if you don't find one, you can easily add a spacer at the back of the pulley to match the original length of the oettinger pulley)
- a specific waterpump pulley (I don't know if the pulley is specific but Frank said that his one looks thinner than yours, so you can also add a spacer at the back of yours)

romaingirardlamamy said that you sould add a spacer to the waterpump pulley, but not that the pulley is specific. Anyway, if you compare your waterpump to the one on Frank's picture, it looks wider, it may be specific also.

[JRF]

There was a spacer behind the waterpumpwheel which I have installed on the new waterpump. The two wheels at the bottom of the engine is now aligned ocrrectly so what I need is the correct pulley or spacer for the alternator and I'm all set.

[JRF]

I just got an email from Oettinger France and it seems the alternator pully is out of stock so I guess I have to go for the space. Could anyone with an Oettinger and with the right pully measure how wide it is so I have a rough idea on how thick the spacer needs to be?

[romaingirardlamamy]

Hi JRF,

No, what you should have is :
- the right top bar for the alternatorthe bar ref is OE60300500and is indeed specific you could get away by bending your one (flat Z shape) if you look on your pics your bar work with an angle it could also work with some self made spacers
- a specific pulley for the alternator (if you don't find one, you can easily add a spacer at the back of the pulley to match the original length of the oettinger pulley)the pulley ref is OE60300100 and if not available space the alternator pulley of 7.5 mm which the amount the crank pulley as been spaced out
- a specific waterpump pulley (I don't know if the pulley is specific but Frank said that his one looks thinner than yours, so you can also add a spacer at the back of yours)the water pump puley ref is 056121031(not an OEttinger ref) and is spaced out with a spacer ref OE10600300

romaingirardlamamy said that you sould add a spacer to the waterpump pulley, but not that the pulley is specific. Anyway, if you compare your waterpump to the one on Frank's picture, it looks wider, it may be specific also.

explain above pulley vw ref +spacer OE ref at the back

here to clear the problem;
you already know that there is a spacer at the back of the water pump pulley and good that you fitted it
just space your alternator pulley of 7.5mm and you should be fine but you might run out of secure fitting on your alternator shaft
let us know how you get on

Romain

[JRF]

Thanks for the help guys. I will try to bend the top bar to the correct angles and I will see if I can find a 7.5mm space for the alternator somewhere or have it made. Will keep you guys posted.