A/C & P/S delete & Serpentine Belt Thread

[Peter Jones]

I thought I'd kick off a new thread to capture this info. There's a few little gems of wisdom dotted around the forums but it's hard to join all the dots at the moment.

Here's my first contribution. What we're going to do here is in preparation to to put a 2.0L (2E motor) bottom end into a MK1.

Most MK3s , the source of this motor, have power steering and air conditioning pumps, neither of which are usually required in a Mk 1. To do this they run a ribbed belt called the serpentine belt and a V belt. Both belts are driven off the Crankshaft. The serpentine belt drives the Alternator and the A/C compressor. The V Belt drives the Water Pump and the power steering pump.



Now, to put a MK3 motor into a MK1 you could just use all the MK1 v belt pulleys and alternator. (The water pump may have to be changed too.). The advantage of keeping a serpentine belt setup are many.

• Easy to Change Belt
• 90 Amp alternator (instead of 35 or 50)
• Automatic tensioner
• More robust mounting mechanism for alternator
• Etc

So let's get started.

Remove these bits.



We're going to need one of these to drive the water pump. It's a water pump pulley off a VR6 Mk 3 Golf. I got this one from GAP http://www.germanautoparts.com/Volks.../Cooling/162/4



First of all I'm looking for alignment of this pulley to the existing belt. As you can see in the next few shots it works out to bee a little too far inset. I'm going to need to make a spacer.

[Peter Jones]

May as well remove the power steering pump and compressor at this point.

Off with the belt



and off with the a/c and p/s



Now, back to that spacer, by the looks of things only about 2 - 3mm is required. Rather than get too complicated here I decided the easiest way to make the sapcer was the cut the centre out of the no longer required p/s pulley. This pulley has the same bolt pattern as the water pump and the same sized locating hole in the centre.

(Professionals feel free to be horrified at my choice of tooling here)



and dressing the edge with a more apropriate tool.



Another test fit. Note here I'm also trying to work out how long the new belt has to be. More on that later.



Offset looking good now. Could be about 1mm further offset to be perfectly central, but now the belt is squarely on the flat of the new pulley.

[Peter Jones]

Time to go belt shopping!

I cut the old belt and marked it at the extremes of the adjuster range to work out the minimum and maximum lengths it could be.



Armed with this I stopped in at Autobarn (It was on my way when running some other errands) and thouroughly confused a 16 year old girl behind the counter. OK perhaps not the best place to ask.

Repco was a few doors down the road and were a lot more switched on.

Here's the missing part of the equation.



Just so there's no doubt.



6PK is the same profile as the original belt. The other part of the code is the length in mm. The original is 6PK1153 and the new one is 6PK1035, 118mm shorter.

Working backwards from this, this belt is to suit the new Mini and the Lexus es300 should anyone need another way to reference the part number.

GAP is showing this part 6K x 1033 http://www.germanautoparts.com/beta/...2/9310/5785607 which should do the trick, and for only US$14.24 rather than the AU$41 repco charged me.
Their verison is 2mm shorter, which will work fine. It's a contitech part too, which is the same as OEM Golf.

And here it is all fitted up.





Hope this helps.

Pete

[Mrk_Mickey]

Even for someone like me with little knowledge in this field I understood everything Nice write-up Pete!

[jayjay]

wow... that's really clever. nice work!

i just used a really crappy old A/C compressor as a tensioner.. so that's where all my power's going..?

[DVR68U]

nice write up pete, its a shame it cant be worked to have more belt area on the waterpump, if that gets wet i think its gunna slip pretty bad. lets hope not tho.
cheers brenton

[mollins]

nice one pete... just did a serp setup on my mk1 engine too.. did it differently to you, but ill post up here when its finished to add to the knowledge base!

love your work!

mike

[GoLfMan]

you used a drill as a boring bar!!!! horrified doesnt even cover it

nice work mate

[Peter Jones]

you used a drill as a boring bar!!!! horrified doesnt even cover it

nice work mate

The drill bit wasn't used for this job, it was there from something I did previously, it was the tool I was reffering to That one has a triangular tip which isn't so good for parting off. I changed to a parting off tool after this photo.

Maybe you should bring me up to speed on the basics one day.

Pete

[Golf Loon]

Nice write up Pete. I have the same setup in the Caddy and your accurate belt measuring could have saved me 3 trips to Bursons!

[Peter Jones]

Nice write up Pete. I have the same setup in the Caddy and your accurate belt measuring could have saved me 3 trips to Bursons!

Exactly why I'd thought I'd addit to the group wisdom. Is your belt the same part number?

Pete

[twin eng, twin turbs]

Nice work Pete! Great to see some mods like this so well documented. I to have done the conversion but took the easy way and bought a set of three alloy pulleys off ebay motors USA for $65 plus shipping. You need a carbide inserted face grooving tool for sure!

[Peter Jones]

Nice work Pete! Great to see some mods like this so well documented. I to have done the conversion but took the easy way and bought a set of three alloy pulleys off ebay motors USA for $65 plus shipping. You need a carbide inserted face grooving tool for sure!

I see what you mean, a quick search came up with these couple of items.

http://cgi.ebay.com/ebaymotors/VW-Golf-Jetta-1-8T-Pulley-Kit-2-0L-99-5-03-Volkswagen_W0QQcmdZViewItemQQcategoryZ38656QQihZ009QQitemZ190246291601QQrdZ1QQsspagenameZWDVW#ebayphotohosting

Addicted2Racing
This auction is for a BRAND NEW LIGHT WEIGHT BILLET ALUMINUM 3 PIECE PULLEY KIT (Exact weight 1.3lbs). Perfect Replacement for Factory Crank, Power Steering, Alternator Pulley. Fits Volkswagen Golf/Jetta 1.8T Turbo DOHC 20V & 2.0L SOHC 8V 99.5-03.

• Strong light weight billet T6061 aluminum
• Grade A+ quality
• Weighs less then 1 lbs per pulley, total exact weight is 1.3 lbs
• Revs faster and accelerate your car faster
• 3x pulleys included
• Direct Bolt on, Installation Instructions and Belt Size available (please seek professionals if you need help)
• Will need to replace old belt

And this little Gem which would simply replace the a/c compressor in a stock setup.

http://cgi.ebay.com/ebaymotors/NEW-A-C-Bypass-Delete-Pulley-For-VW-Passat-Golf-Jetta_W0QQcmdZViewItemQQcategoryZ33543QQihZ024QQitemZ370079199856QQrdZ1QQsspagenameZWDVW#ebayphotohosting

There's a range of underdrive pulleys too, but I'd only run those in constant high RPM applications like a dedicated race car. Would need to put some thought into water pump rpm and cavitation issues.

Pete

[twin eng, twin turbs]

Thats the pulleys Pete! Great buy dont you think, they are very nicely machined and a perfect fit.

[Peter Jones]

Thats the pulleys Pete! Great buy dont you think, they are very nicely machined and a perfect fit.

Yeah, very nice, I might have to grab a set for my next project!

I like that the water pump pulley is ribbed and the lower weight must be a good thing.

Pete