Former VWDieselParts.com Forum

I have to say, I really wish I had taken the bracket off the car to grind on it. I covered stuff up and blew and sprayed everything after but it wasn't totally effective. Those tiny (even invisible) iron particles went everywhere and then stuck to everything becoming rust (after a couple days). I had to spray ospho (metal prep) all over the areas affected, wipe, scrub, rinse..... and the results are not pretty. Would have been Soooo much easier to just do it off the car (especially since I changed the water pump and had that bracket off!)

Hope the holiday season is being good to you guys!

Now that the positioning is on the right path, I wonder what the right pulley for the job is. I was thinking on having a custom one made, however, id like to know what standart pulley can do the job, since they tend to be way cheaper than having it made. I found a couple of solutions, however no part number or reference yet. I ll leave you with the 2 pics i found hoping for an explanation.

https://store.alternatorparts.com/part- ... ators.aspx - double pulley config
https://www.google.pt/imgres?imgurl=htt ... mrc&uact=8 - single pulley with edge

I used a ford pulley gp688 on a guess from one of Fatmovil's threads - it worked. Pretty cheap on ebay.
It looks just like your double groove 2G pulley, but the the gp688 is 6mm smaller in diameter.

sgnimj96 wrote: ↑Thu Dec 28, 2017 6:58 pm I used a ford pulley gp688 on a guess from one of Fatmovil's threads - it worked. Pretty cheap on ebay.
It looks just like your double groove 2G pulley, but the the gp688 is 6mm smaller in diameter.

No problems with the alternator's short shaft?

and 1 more thing: the shaft really does have a keyway, at least on my alternator

And finally, to remove the bracket, there are 4 screws, right? 2 of them are visible and easyto access, but how did you reach the other 2? did you remove the fuel pump? i cant reach them with any of my tools

I removed them with a quarter inch drive ratchet, long extension, and swivel joint. Without removing the pump. It was tricky, but it can be done.

I've never had any luck on that top right bolt with any standard tool, not to mention it's pretty tight and if don't get a solid grab on you can really screw up and have to remove the IP.
What i do is get a cheap 1/2 wrench , cut it in half, use the box end of the half wrench on the bolt and another box end wrench (or anything that works) to turn it.
Slow but it works.

Easy to make special tool.
I'm going to try that one.
Way easier than removing the injection pump.

That's a place where an "obstruction" wrench (S-shaped or crescent-shaped) may help.

Update: i managed to find a stock non ac pulley for the golf and i have everything lined up almost perfectly!

Next step is the alternator fixation. I found this type of tensioneer which appears to be easier to apply. Any ideas on whether it works and is as reliable as a custom made curved support arm?

https://m.ebay.com/itm/3-8-Chrome-Sreel ... 0408.m2460

I think someone tried a turnbuckle and it's made for pulling not pushing. Trouble ensued.
I took a picture of my 2-piece adjuster setup but forgot to load it onto my computer.
My adjuster bar with the slot is straight and is bolted to one of the lower holes in the alternator bracket.

I read that these were effective in compression on an ebay add but i ll investigate some more. If im wrong, i guess ill still use it, hanging from the old alternator bracket arm, coming from the fuel pump area. It is a way easier fix, instead of the old steel ones that have to be custum fitted

found these pics
http://i1176.photobucket.com/albums/x33 ... 5531498486
http://i1176.photobucket.com/albums/x33 ... 5531514901
he still had to make a small bracket because it's not a straight line to the adjuster hole in the alternator housing.

I guess if you measure correctly, it would work- but only 1 1/2" of adjustment?

Just a thought, I snapped a turnbuckle on a small gate frame for my back yard - and I didn't even tighten it that much. Maybe you can get a beefy one for about the same price.... those 4 cyl diesels can get rough on stuff.

As an afterthought, I should have just bought one of these https://www.ebay.com/itm/Mr-Gasket-9851 ... da&vxp=mtr and maybe saved a lot of time.

It's finally finished. Ended up using the turnbuckle option from the top of the alternator. A small adjustment on the original suppor arm and it fitted perfectly. Already ran a few miles and it doesnt seem to loosen up. I ll post a pic or 2 tonight. Thanks for the help and ideas guys