Dismantling and assembling cooling blower: VW (ACD, AS)

ACD
Part 1

60 Nm (6.0 mkg)
Spring washer
Spacer washers
Cooling blower wheel
Observe loose blades
Distance to cooling blower cover => fig.
9

Cooling blower wheel hub
THermostat
Adjusting =>fig.
6
Checking => fig.
7

15 Nm (1.5 mkg)
Thermostat bracket

Cooling air control
Cooling air control connecting rod
Oil cooler air evacuation box
Exhaust shell for oil cooler
Cooling blower housing
Modification: Gradually introduced housing with air inlet ring

Part 2

Inner cooling blower cover
Observe installation position => fig.
8

Reinforcement flange
Outer cooling blower cover
Securing strap
Alternator
Front pulley
Spacer washers
Rear belt pulley half
60 Nm (6 mkg)
Cup wheel
45 Nm (4.5 mkg)

Dished spring
V-belt pulley
Modification:

up to now: ø 170 mm with cooling blower ratio of 1.65:1
new: ø 175 mm with cooling blower ratio of 1.85:1

Removing => fig.
4
.
Work ignition point groove in => fig.
5

V-belt
Checking and adjusting tension => fig.
1
-
3

Fig.1
Check V-belt tension

Adjusting value on the scale

V-belt new: 17.0 - 18.0

V-belt old: 16.5 - 17.5

Hang tester in the middle, between the pulleys.
Turn adjustable adapter until its front edge aligns with the marking on the piston.
Read measured value (to do this the tester can also be unhooked) and add the value on the scale (-arrow 2- = 16) to the vernier value (-arrow 1- = 0.5).

Fig.2
Adjust V-belt tension

Unscrew hexagon nut at the belt pulley of the generator.

Fig.3
Adjust V-belt tension

Place spacer washers appropriately to the ribbed belt tension.

The V-belt tension is to adjust by the allocation of more or less spacer washers between the belt pulley halves.
By taking them out the tension increases and by inserting them the tension is reduced.

Place all spacer washers, which are not between the belt pulley halves, between the rear belt pulley half and the nut in order to keep the total sleeve number on the hub.

Fig.4
Removing pulley

Fig.5
Work ignition point groove in

Place template on the pulley. Align square hole with TDC marking -1-.
Mark the corresponding ignition point on the pulley with the template (e. g. 7.5° BTDC) -2-.
Work groove in and lay out white.

Fig.6
Adjust thermostat

Screw thermostat on the connecting rod.
Loosen thermostat support securing nut.
Press the thermostat upwards so that the flaps are in open position.
Move thermostat support, until the thermostat touches the bracket on the upper limit stop.
Check function of control by moving the thermostat to and fro -arrow-.
Secure thermostat on bracket.

Fig.7
Check thermostat

At a water bath temperature of 65 - 70 °C the barometric cell length must be a = approx. 46 mm.

Fig. 8
Installation position of cooling blower cover

Assemble the alternator with air cooler covers so that the cool air inlet slot -arrow- of the inner cover shows to the bottom when installing into the blower housing.

Fig.9
Distance- Cooling blower wheel to the cooling blower cover

1 -
Outer cooling blower cover
2 -
Reinforcement flange
3 -
Spacer washers
4 -
Hub
5 -
Woodruff key
6 -
Special nut
7 -
Alternator shaft
8 -
Spring washer
9 -
Spacer washers
10 -
Cooling blower wheel
11 -
Inner cooling blower cover

Dimension-a- = approx. 1.8 mm

Check cooling blower wheel distance from cooling blower cover.
Install spacer washers between hub and blower wheel according to need.

The other washers are to place between spring washer and blower wheel.

Note:

When assembling the generator and the blower wheel it must be observed that the bent out spring washer edge shows to the special nut.