Date: Sun, 26 Jun 2011 22:59:02 -0700
Reply-To: Scott Daniel - Turbovans <scottdaniel@TURBOVANS.COM>
Sender: Vanagon Mailing List <vanagon@gerry.vanagon.com>
From: Scott Daniel - Turbovans <scottdaniel@TURBOVANS.COM>
Subject: Re: Fitting a Bosch AL33X alternator into a Diesel Vanagon
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it's not very efficient for me to sell them..
but I have made custom brackets that allow bolting any 90 amp common Bosch
alternator right to the stock DV alternator stand.
pulley's have to be swapped over ..
and maybe a spacer added for belt alignment.
and wiring modified of course..
but that's an advantage since the plastic plugs wear out on the 65 amper and
new ones are not avaiable.
oh..and I *never* use the stock two belts-with-shims knuckle ripper system
..
( I like that ...the 'Knucle Ripper' system.
Even with engine out of the van adjusting those totally sucks.
it's pathetically bad engineering, and there is absolutely zero reason for
them building it that way. )
I have run my Single Belt System for thousands of miles on many diesel
vanagons.
I always and only do a Single Belt Conversion for water pump and alternator
drive.
there is so much repair and project work for me though ..
it's totaly ineffecient to promote and pack and ship small conversion parts.
now if someone wants to take that part on ..
I'll be the creative genious ...and they can do the other part and make a
few bucks doing it.
And help the diesel vanagon community ..
and these engines need all the help they can get ! lol.
Scott
www.turbovans.com
----- Original Message -----
From: "Poppie Jagersand" <poppie.jagersand@YAHOO.CA>
To: <vanagon@GERRY.VANAGON.COM>
Sent: Sunday, June 26, 2011 10:09 PM
Subject: Fitting a Bosch AL33X alternator into a Diesel Vanagon
> Some notes for replacing the original 65A Alternator with a generic Bosch
> AL 33X 90A in a Diesel Vanagon.
>
> Recap from earlier posts: My regulator brushes wore short some time ago. I
> was debating whether to just replace the regulator, rebuilt the alternator
> myself (new sliprings and bearings) or buy a rebuilt.
>
> In the end I decided to upgrade to the 90A Bosch AL33X. There's also an
> AL27, which may have the same size. Both of those are supposed to be
> generic replacements (come without pulley) for 025903023EX that is the
> alternator in the newer gas Vanagons, but they are larger than the
> 068903017MX fitted in the Diesel Vanagon.
>
> Fitting the AL 33X required some small changes:
>
> The diametre is significantly larger than the original. I swapped the
> original cast mount for a mount I had found some time ago in another
> Diesel Vanagon. The second mount is wider and has two holes so that the
> belt tensioner can be placed at two different diametres. I still had to
> make a custom piece to mate the alternator with the tensioner.
>
> The flange to pulley distance on the Al33X was a few mm smaller than the
> original so belts didn't line up. Luckily removing one washer from the
> pulley fixed this.
>
> Then I struggled for a while to get the pulley on without wobbling.
> Thought the shaft of the rebuilt alternator might not be straight. However
> the problem turned out to be that the locknut supplied with the AL33X,
> while small enough to fit over the threaded part, it got stuck on the
> shaft beyond the threads. Changed to a larger ID washer and pulley was
> straight.
>
> The belt needs to be slightly longer for easy fitting. Hope it will be
> possible to buy a 10mm or so longer belt. (In the local FLAPS they can
> only seem to locate parts based on vehicle type, not dimensions or
> specs...)
>
> Electric terminals needed changing from the plug style on the 65A to
> individual connectors on the 90A, but that was easy.
>
> Martin (and '82 Westy 1.9TD "Poppie")
