Super easy 16v serpentine belt swap

[dswalterwi at gmail.com (Don Walter)]

I have boxes, well almost, of those bolt/stud things that screw bolt into
the water pump then have a stud sticking out.  They are the strangest and I
didn't even know what they were for until we swapped the engine in my used
to be son's scirocco.

On 10/22/07, Mark F. <mk1mark@xxxxxxxxx> wrote:
>
> ** Warning **  - Actual Scirocco content!  Some of you may want to skip
> this...
>
> Hey list,
>
> My recent mini-project has been swapping a 16v engine into my 82
> winter beater.  The donor setup included power steering and A/C,
> neither of which I'm running in the 82.  Since 16v no a/c setups are
> pretty much non-existent I decided to solve the problem with an
> upgrade to a serpentine belt setup.  Some list and vortex searching
> revealed a couple different ways people were doing it.  One involves
> buying an an ABF setup (good deal on this very sweet setup here:
> <http://forums.vwvortex.com/zerothread?id=3494634>), and another
> involved sourcing the pulleys and brackets from ABA and VR6 engines
> and getting the crank pulley machined 6mm to fit.
>
> I was checking out the serp. setup on my 1Z TDI engine and realized
> that the TDI and 16v timing belts were both wide, leading me to
> believe that it should be a straight swap to a 16v.  I happen to have
> a spare TDI alternator bracket, and alternator (thanks Earl!), so I
> pillaged the pulleys from the TDI (have another set lined up already
> to replace them) and set to work.  Here's the result:
>
> <http://i216.photobucket.com/albums/cc187/mk_1_mk/16v_serpentine_setup.jpg
> >
>
> The pulleys line up perfectly!  A direct swap...  The lower plastic
> timing belt cover had to be clearanced a bit with a knife (the crank
> pulley hole needed to be enlarged), and some minor surgery of the
> alternator bracket was required to clear one of the water pump bolts.
> As with the ABA alternator bracket swap only three of the four bolts
> are used to hold it down.  Here's a pic of the bracket, showing where
> I had to grind some aluminum to clear the top right water pump bolt:
>
> <http://i216.photobucket.com/albums/cc187/mk_1_mk/modified_bracket.jpg>
>
> The TDI setup uses a bolt/stud arrangement for the top left water pump
> bolt, but Earl let me down a bit by not providing one.  Unphased, he
> did have an 8mm x 1.25 stud and two nuts, and I was about to recreate
> the TDI stud/bolt when I figured there'd be no harm in setting the
> bracket directly on the water pump and just use a longer bolt to cinch
> it all down.  The bracket sits at a slightly different angle as a
> result (tilted a bit closer towards the engine), but that'll help with
> any possible alternator/radiator clearance issues anyways.  I don't
> believe the slightly off mating surfaces will be a problem, but I
> added some blue loctite to the three bolts for insurance.
>
> Tomorrow I swap fifth gear covers because of this:
>
> <http://i216.photobucket.com/albums/cc187/mk_1_mk/My_freakin_ears.jpg>
>
> ... and then the actual swap begins.  I'm going to run the stock 82
> CIS system and graft in the 16v knock sensing ignition and see if I'll
> be happy with that.  Hopefully it won't run too lean at higher revs.
>
> Later,
>
> Mark.
> 75
> 82 16v engine going in this week
> 82 Caddy - mTDI swap in progress, but on the backburner this month
> 91 Jetta Coupe - off the road for the winter soon
>
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>



-- 
Don Walter - Waukesha, WI
1986 8V Black Scirocco (Daily Driver)
1984 8V Audi 4000s (RIP 2/14/2006)
1986 2.0L 16V TEC 2 Black Scirocco (see progress at
http://www.cardomain.com/memberpage/708939)
1986 2L 16V Toronado Red Scirocco (Ben's Car)
1988 1.8 16V Toronado Red Scirocco (sold on 3/29/04)
1984 1.8 8V Pewter Scirocco (sold years ago)
1971 Karman Ghia (sold)
1969 Karman Ghia (sold)
1969 Beetle (sold)