Author Topic: Generator To Alternator Swap (Read 3047 times)

jim martin · « **on:** May 18, 2005, 08:19:31 PM »

got some time this afternoon and got my engine back together.yeah!!
i'm converting my generator to a alternator and i have a bad problem with belt alignment. basicaly i will need to push the alternator assembley in a fair amount.
but , the first thing i noticed was that there is a 2 mm plus gap at the base of the alternator to the backing plate.it just looks like it should be tighter but if i remember there was a small gap on my generator as well .since i don't know if it should be like this i talked to geoff and he let me know that if i'm using a fan backing plate assembley from a early beetle that this may be a problem.now that i think of it i wounder if i would need a differant fan mounting hub as well?

anyone who has a alternator on there car can you take a look at these photos and tell me whether this gap is correct or should it be flush .??
also geoff let me know that i may need to space out my crank pulley and there is a spacer to do that if needed.again take a look and let me know what you think.

Hansk · « **Reply #1 on:** May 18, 2005, 11:01:09 PM »

I just looked at two alt 's that I have. One an old original style and one is a newer conversion style like yours. They both have a space of about 2mm where your showing. I assume there is a step . These two line up nice though . I would think that if your gen lined up ok and you used all the same back plates, hubs and pulleys etc. , the alt should line up too. Mine did. BTW , the outside edge of my pulley is very close the the front cover of the alt , about 1mm or less. Anyway, sorry I can't be much more help.

kirin · « **Reply #2 on:** May 19, 2005, 12:11:27 AM »

Hey Jim,
Just as to what Hans said my alternator pulley with my new conversion alternator was really really close to the alternator. 1 mm gap as well. Also the pulley on mine was an extremly tight fit(Had to heat it up to get it on...)

Tom H. · « **Reply #3 on:** May 19, 2005, 05:23:10 AM »

Is that an aftermarket alt stand?

jim martin · « **Reply #4 on:** May 19, 2005, 06:49:08 AM »

Quote

Is that an aftermarket alt stand?

yes tom aftermarket stand,i have a original as well .tried it for fun with the same results.
well if others have the same gap then it looks like its time to shim the lower pulley

Geoff · « **Reply #5 on:** May 19, 2005, 10:41:10 AM »

Jim it looks like you have the correct backing plate on there, some are flatter than others. How far away is the upper pulley from the alt? The new pulley may be sitting too far out? If this is the problem (Lanny just went thru this) you may need to run the spacer on the crank to align everything. You may want to try your new lower CE pulley and see if that works.

As for the shims you asked about, We should have them Wed next week.
G.

Bruce · « **Reply #6 on:** May 19, 2005, 08:03:19 PM »

Jim, I had a look at my setup and there's no gap on mine. The end of the alt is hard up against the backing plate. There is a slight chamfer on the end of the alternator though. Aren't you just measuring this chamfer?

The position of your alternator depends on the cylinder covers, fan shroud, backing plate, alternator and pulley.
My engine has all stock genuine VW parts, from the cylinder covers through the fan shroud, backing plate, alternator, top pulley, and bottom pulley. If you want to check out any stock parts, I have extras of most of these parts.

jim martin · « **Reply #7 on:** May 20, 2005, 10:08:25 PM »

thanks bruce, i new if anyone had some insight it would be you.have located what i need at a friend house and all is good now.
looking forward to talking to you soon.