TheSamba.com :: View topic - Alternator pulley does not align with crankshaft pulley

Sat Jun 10, 2017 12:28 pm

Hey everyone,

My alternator pulley does not line up with my crankshaft pulley. It sits about .5" further out than the crank pulley. Pictures are attached. Also, the alternator does not sit completely flush with the alternator stand. I've talked to a lot of people, about differnentbaxking plates spacers etc and haven't been able to come up with a solution. Help! I'm at the end of my rope.

Sat Jun 10, 2017 1:07 pm

Backing plate looks okay to me.

The alternator doesn't fully sit in the alternator stand cradle...right? Can the shroud go down any more, or is it as low as it can possibly go?

The way you have it now the belt is too short and sits way too low in the pulley.

Sat Jun 10, 2017 1:17 pm

junk aftermarket alt stand, get an OE one or clearance that one or the alt to fit.

Sat Jun 10, 2017 2:02 pm

Shroud can't go down anymore and appears to be sitting properly. Also, when I take the backing plate off the alternator and push it flush against the stand, the pulleys seem to line up correctly. So it's almost as if the alternator itself is too long

Sat Jun 10, 2017 2:59 pm

60ragtop wrote: junk aftermarket alt stand, get an OE one or clearance that one or the alt to fit.

Agreed this is what happens when a bunch of aftermarket stuff is used, I know you didn't ask but for a self locking nut to work the stud needs to protrude through the nut. The alternator strap is backwards and clocked wrong.

Sat Jun 10, 2017 3:04 pm

I did some checking on Bosch website and that alternator is for various BMW's, Opel, Volvo car's and is not listed for any VW's . As you have allready found out the alternator is too long. Don't know where you got it from but take it back and get correct one.The correct part number is 00-9444-1 55amp.
Robert

Sat Jun 10, 2017 3:07 pm

I'd like to see that alt bolted up to anything other than a VW and see how it fits :wink: It sure looks like a VW alt to me.

Sat Jun 10, 2017 3:19 pm

Do as I did Rick, go onto Bosch website and check it yourself. A lot of alternators look the same. Looking at the engine the fan housing seems straight so is seated correctly but if it was pushed back any futher not only would the fan housing would be out of line and retaining strap would be over the plastic brush housing. It's the wrong alternator !
Robert

Sat Jun 10, 2017 3:29 pm

I bought an alternator kit from jbugs, so I would think the alternsotrnis correct. I even bought a second alternator, that specifically said for 73 superbeetle, that didn't fit either. Where can I find a shorter alternator?

Sat Jun 10, 2017 3:40 pm

Get back onto jbugs and give them the correct part number. It looks like they may have had incorrect alternators supplied to them.Won't be the first time this has happened and won't be last time.
Robert

Sat Jun 10, 2017 4:50 pm

It may be lens parallax, or just the angle, but it looks like your upper pulley halves are not seated properly in your first photo.

See how low the belt is riding? That may or may not be correct, based on the length of the belt. But see how the pulley halves are not parallel? That looks wrong.

To install pulley halves with a new belt, or on a new engine, we must ensure that the pulley halves are fully seated against each other, not pinching the belt, so the belt tension is consistent throughout the rotation of the crankshaft pulley and generator pulley. Begin by using all your shims between the pulley halves, and tightening down the generator nut. The belt should be loose. Remove one shim, and tighten again. Repeat this process until the belt is at proper tension. This ensures you're not getting a "false tension" reading on the belt as your pulley halves come together out of alignment.

Robbie

Sat Jun 10, 2017 5:49 pm

The pulley in the last photo, well it does not seem that it has been turned. This happens while installing the belt turn the engine over with out starting. When properly installed I bet it all lines up.

Sat Jun 10, 2017 6:07 pm

Any chance the fan belt is to short? Try putting a straight edge on there without the belt just to see how things look.
DWP

Sun Jun 11, 2017 2:12 am

c705ncp wrote: I did some checking on Bosch website and that alternator is for various BMW's, Opels, Volvo car's and is not listed for any VW's . As you have allready found out the alternator is too long. Don't know where you got it from but take it back and get correct one.The correct part number is 00-9444-1 55amp.
Robert

you have to look it up in the mexican bosch catalog as it is intended for that market. On that catalog you see that part number 0986mn0400 is just for VW aircooled application. Besides, no bmw or volvo or any watercooled car that i know of drive a cooling fan through the alt shaft...

edit: to elaborate more re your second post, it is true that most alternators look the same but one intended for an aircooled VW engine with upright cooling (such as this one) looks nothing like the others.

Sun Jun 11, 2017 2:49 pm

hey everyone. So i think i got the pulley's a bit more aligned. I did a couple of things:

1. switched crank pulleys to a smaller "power pulley". this allows the belt to ride higher on the alternator pulley and lets those pulleys be parallel, unlike in first picture

2. added a spacer behind the crank pulley.

so, the alternator still does not sit flush against the pulley stand, but the pulleys seem much more aligned...do you think the belt is straight enough to try and start the engine?

Sun Jun 11, 2017 2:54 pm

Looks good let her rip

Mon Jun 12, 2017 12:54 am

I see from the first pic that your belt is of the correct size for an alternator. given this and the fact you saw an improvement by switching the crank pulley, the question is, was your first pulley of the same size as a stock one, and, more importantly, do you have the alt pulley shimmed correctly?

Mon Jun 12, 2017 6:43 am

Power pulley will let engine run warmer also. The stock diameter lower pulley lets the fan turn 1.6 times faster as it should.

Mon Jun 12, 2017 7:17 am

I was using the stock pulley with an alternator in the first pic, but it seems like the belt isn't long enough. When I switched to the smaller power pulley, it looks like the belt sits correctly in the alternator pulleys.

I would prefer to use the stick pulley, but I can't seem to find the right belt for it.

Mon Jun 12, 2017 8:07 am

Homelessghost00 wrote: I was using the stock pulley with an alternator in the first pic, but it seems like the belt isn't long enough.

I would prefer to use the stock pulley, but I can't seem to find the right belt for it.

Take the belt that is too short with you to NAPA or CarQuest or other parts store, and buy a belt slightly longer like 1/2-inch/25mm. Maybe buy a second one a tad longer than that, and return the one that does not fit.