Doing a conversion to an alternator is pretty darn easy. First you will have to make sure you have a fuel pump AND fuel pump push rod equipped for an alternator-equipped Type 1 engine. Do not get a NAPA style pump...they vapor lock due to poor design so simply put...don't use them.
First off, here is the spec. sheet for different length fuel pump push rods. http://incolor.inebraska.com/elassley_bie/misc/pumprod.jpgFor alternator style fuel pumps, it measures 99.5mm long and the generator version is 107.5mm long. Do not try to force an alternator style fuel pump on a generator push rod. You'll brake the internals of the pump easily and ruin it. This is the good style alternator fuel pump: http://www.germansupply.com/home/image.php?productid=16235 Usually I've seen them called the Brosol brand from Brazil. I'm seeing more and more of this style fuel pump for alternator equipped engines and seems to be okay: http://www.justaircooled.co.uk/images/T/beetle%20parts%20fuel%20pump.jpg You do not want this style of fuel pump (look at the one mounted on the engine): http://1.bp.blogspot.com/__j7WfkWr-8U/SYDfk8Vzm6I/AAAAAAAABnE/a1dgZq4wWYQ/s320/vox3.jpg It's easy to tell because the tubes come out of the top of the cannister. This are NOT good fuel pumps. The one in the guy's hand is a serviceable fuel pump with replaceable parts. I've never owned or put a kit in one so I have no idea on how good they are or if you can even get kits for them. Also, here is a chromed style fuel pump you do not want to use: http://www.chircoestore.com/catalog/images/129240.jpg This is the taller fuel pump for generator equipped type 1 engines: http://farm4.static.flickr.com/3569/3359690232_6674cc7192.jpg In a pinch, you can make a generator style fuel pump work with and alternator but you have to take a ball peen hammer and dent in the domed cover where it contacts the alternator. It's a tight squeeze but it will work. I've done it before and driven quite a few miles on it until I changed over to an alternator style fuel pump. Now, let's get back to alternators. There the largest post will usually be your hot wire. Then you'll have a smaller wire that is your idiot light that indicates when you're not making power. I remember in the past, it being said if you indicator light is burned out, you won't charge. Not sure if that's just for generators but it's a good time to test the bulb out anyway. Internally regulated is always best if possible because you run one wire to the battery and one to your idiot light and you're done. If you're using a used alternator, open up the brush pack and verify the length of the carbon brush that transmits power. The one in my bus was completely worn out and you can't get these as a service kit. I modified a brush from a 1960's electrolux vacuum cleaner, ground it to get, and then resoldered it into the brush holder. Still charges 10 years later. :) You'll also need an alternator stand because the generator ones sit higher. Also, if you choose to do this replacement in the car, you'll need to remove your strap that holds the generator on. You can use your old strap to hold the alternator to the new stand. You'll need a 36mm socket to loosen the fan from the back of the generator and dexterous fingers to work between the fan shroud and the firewall of the beetle. When you remove the nut on the back of the fan (you'll be leaving the fan in the shroud, be very, very careful to not pull out the generator unless you have a finger pressing hard on the end of the shaft and follow it on out as you remove it. You might even want to use a screwdriver or punch...something to hold the washers, hub, and fan in place until you can put the alternator back in place. There will even be a key in the generator shaft you don't want to lose and move over to the alternator. I hope this helps you out. Don't forget to check out www.vintagebus.com for color wiring diagrams and just sit down, think about it, and trace them out. If you find any externally regulated setups for dirt cheap, they are okay to run but you'll need to pay close attention as to what wires run where. Erin NQ _______________________________________________ vintagvw site list [email protected] http://lists.sjsu.edu/mailman/listinfo/vintagvw
