[Itsamoto]

Itsamoto, thanks! That's extremely helpful! Based on these pictures, it looks like I don't even have to fab a special spacer for this bracket, probably can get away with using simple spacers on mounting bolts.... Looks very encouraging, I'll start looking into high-output alternators scene again.

Thanks again!
-albertr

No problem -- can't wait to see what your solution turns out to be.

[Itsamoto]

In attempting to find at least a clutch pulley, or better yet a Litens OAD pulley for my alternator -- I pulled the standard pulley to take some measurements. This may also be useful to those who want to follow suit or overdrive their alternator with a smaller pulley. Some of the dims are critical to ensure that everything lines up.

AKF Standard Alternator Pulley


And as a silver lining -- when I looked up the part number from Lucille's rebuilt alternator, it turns out it is 150A! I was wonder why that fusible link was already 175A. 

Bosch 150A alternator


For those who like to hunt the scrapyard -- a quick cross reference says this model is available off of 04-06 Touaregs with the 3.2 VR6

Also of interest -- even though the pulley is a 7 groove, Lucille was running just a 6 groove belt. 

[albertr]

Itsamoto, great information! Can you also check the dimensions of BDF clutch pulley if you get a chance? I'm curious to know if it has the same OD (65 mm) or smaller?
Also, how many spline teeth the clutch pulley has?

-albertr

[Itsamoto]

Itsamoto, great information! Can you also check the dimensions of BDF clutch pulley if you get a chance? I'm curious to know if it has the same OD (65 mm) or smaller?
Also, how many spline teeth the clutch pulley has?

-albertr

I made a quick measure, but its not as accurate because the pulley is still on the alternator. The BDF's pulley is ~61mm OD, and ~41mm Length, with 6 groove. Theoretically it might work with use of spacer to bump it further out.

The other important factor for sizing a clutch pulley, is going to be the thread of the alternator's output shaft. So far the Bosch models I have have the same 16x1.5 thread.

I've been talking to Ritchie at IAT-USA.com -- and he's closing on a suitable clutch pulley replacement for the stock solid pulley found on the eurovan. I'll update when I find out more. 

[albertr]

Great, thanks! Keep us updated on your pulley quest.

-albertr

[Itsamoto]

One thing that I came upon that I wanted to pass along here for VR6 vans. I noticed that with all three of the 24v engines I had on hand, that the thermostat housing is real weak point. Every engine exhibited signs of coolant leak -- the engines always dirty and grimy right below the housing.



In looking at the housings closely, all of them exhibit signs of leaking or breaking down. Lucille was also sporting a metal impeller water pump -- which I believe was not stock, and thereby she's probably on here second thermostat housing as well!

Thermostat Housings

Housing from a BDF -- plastic flange is warping and beginning to separate. It's not visible in this picture, but there is gap there where coolant could swap out through.


Second BDF housing -- flange has separated and broken off.


Lucille's housing with dried-up coolant on the gasket.

These plastic components become very brittle over time -- makes the Eurowise cast housing pretty desirable.



Although these are for 12v, they will mount to the 24v fine -- the known issue is that their extended inlet and outlets mean that they can interfere with MK4 shift linkage. A builder on Vortex is planning on using this on his R32 build -- welding up some AN fittings as well.

As this is for 12v, it also has a 3rd sensor position, meaning it's possible to move the coolant temperature sensor from the rear coolant outlet line to the front/side outlet and clean up the engine bay a bit more.

[albertr]

Here is mine after 146K miles....



-albertr

[Itsamoto]

Yes, these just don't last. One of those ones from the BDF was at ~80k miles! 

I read Eurowise is working on a cast version for 24v as well -- but I don't think its as big an issue for EV fitment -- we have tons of coolant hose on that side of the engine that can be cleaned up much better as well.

[Itsamoto]

I managed overcome a big hurdle with the engine conversion -- removing the crank pulley. To remove the pulley, you need a 27mm socket (for the bolt) and a 46mm counter holding wrench. After researching and reading how painful it is to do with the engine out, I was really worried that this might be the show stopper for converting to the AXK ancillary components. Getting stuck with BDF pulleys wouldn't have been all that terrible - but still a compromise to the plan.

Rather than buy the special VW tool (3406) -- I searched for a 46mm offset wrench. They aren't cheap or easy to find around here. Cross searching though, it was interesting to find out that the Haldex/4-motion AWD filter wrench is 46mm -- a near perfect substitute for the DIY'er. Luck smiled on me again, and I managed to find a used one locally for $30 CDN.

Haldex Filter Wrench


The only modification needed, was to grind out enough clearance for the 27mm socket.

Wrench with Socket


I was still a little skeptical if this would work with the engine on a stand. I tested out the amount of "effort" that would be needed to loosen the bolt on my garbage BDF -- and it wasn't too bad actually. Socket w/Breaker bar + 4' cheater bar, Haldex wrench + 4' cheater bar = bolt off! 

With the "good" engines - I carefully made sure that the loosening forcers were as balanced as possible -- no sense in tipping over the engine at this point.

Loosening the crank pulley

Good BDF

As per the norm with Lucille's engine block - lots of paint peeling and rust on the block. After closely looking at the cooling system layout -- I'm convinced its inadequately plumbed - I have more on that to share later.

Lucille's AXK w/ crank pulley removed


For those keeping score, this sealing plate/ crank cover is actually different between the BDF and AXK -- different part numbers : 021 103 153 vs 021 103 0153 A. The difference (as I can tell) is just to the prying tab locations.

[albertr]

It's great to hear that you are making a nice progress!

Is that the wrench you were using?
https://vw.snapon.com/SpecialToolsDetail.aspx?itemId=7690003

-albertr

[Itsamoto]

It's great to hear that you are making a nice progress!

Is that the wrench you were using?
https://vw.snapon.com/SpecialToolsDetail.aspx?itemId=7690003

-albertr

Yes that is it -- a Haldex filter wrench. I'm surprised how cheap it is  (although just about everything is cheaper stateside)-- I've seen them going for $60-80.

[albertr]

In attempting to find at least a clutch pulley, or better yet a Litens OAD pulley for my alternator -- I pulled the standard pulley to take some measurements. This may also be useful to those who want to follow suit or overdrive their alternator with a smaller pulley. Some of the dims are critical to ensure that everything lines up.

AKF Standard Alternator Pulley

I was looking into alternator pulley tonight and I think the following one might be a close match size-wise:


It's known under the following part numbers:

Valeo 595258
         440127
         440128
DB     271 155 02 15
         271 154 14 02
         271 154 15 02
INA    F-557311.01

Used on the following DB cars:

C 160 Sportcoupe Kompressor
C 180 Kompressor,-Kombi,-Sportcoupe
C 200 Kompressor,-Kombi
C 200 CGI Kompressor,-Kombi
C 230 Kompressor,-Kombi
C 250 CGI,-Kombi
CLC 160, 180, 200 Kompressor
CLK 200 Kompressor,-Cabriolet
CLK 200 CGI,-Cabriolet
E 200 CGI,-Kombi
E 250 CGI,-Kombi
SLK 200 Kompressor Cabriolet

It's has a smaller O.D. @ 55.7mm vs. 61 mm of stock AXK pulley, but I think 55.7mm still would work with stock belt.
Also this pulley is darn expensive - more than a $100!

-albertr

[albertr]

There's also a similar pulley with even smaller O.D. of 50mm - INA F-239808 aka

Valeo   593960
MB       642 150 03 60
           642 150 06 60
Jeep     05175811AA
and other names...

It's used on the following cars:

Chrysler 300C 3.0 CRD
Jeep Commander 3.0 CRD
Grand Cherokee III 3.0 CRD
MB C 320/350 CDI
CLK 320 CDI
CLS 320/350 CDI
E 280/300/320/350 CDI
G 320/350
GLK 320/350 CDI
GL 320/350CDI
ML 280/300/350 CDI
R 350
Sprinter 218,219,318,319
419,518,519
Viano 3.0
Vito 120/122



Most likely will not work with stock serpentine belt without some spacers to take away belt slack.

-albertr

[Itsamoto]

It's has a smaller O.D. @ 55.7mm vs. 61 mm of stock AXK pulley, but I think 55.7mm still would work with stock belt.
Also this pulley is darn expensive - more than a $100!

-albertr

Awesome Albertr -- thanks for searching. This first pulley could be the ticket -- and its also the correct thread for the Bosch alternators @ M16x1.5.

From talking to the supplier, he mentioned to me that one of the critical measures is the distance to first groove -- which is measured from the back side of the pulley. So on the van's pulley -- I crudely measured 18mm to the start of the groove, while the INA pulley is 19.4mm to the valley of the groove.

Theoretically, if the distance to first groove matched, you could run an 8, 9 or 10 groove pulley -- because your belt would be aligned and run straight onto the pulley without any sort of lateral stress fro misalignment.

At $100 it is expensive, but these things save alternators!

UPDATE: Supplier says these are about $39 each.

[albertr]

Guys, does anyone knows how to find out the O.D. of the following crankshaft pulley - VAG P/N 03H105243Q ?
It's used on 2011 - 2013 Touareg with 3.6L V6 (which looks to be VR6 on steroids). I'm trying to see if I can get its 220Amps alternator implanted into EuroVan and need to calculate pulley's ratio.

-albertr