2010 Overrunning Alternator Pulleys
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- Gervais Booth
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1 2010 Overrunning Pulleys
2 THE CASE FOR INA OVERRUNNING ALTERNATOR PULLEYS Ignition and compression within an engine results in acceleration and deceleration of the crankshaft. These rotational variances are then transferred to the engine s auxiliary components via the belt drive system. Unacceptable noise, strong belt vibration and early belt wear are the result. Individual accessories affect the drive system to varying degrees. The alternator has the greatest moment of inertia and therefore the biggest infl uence on noise, vibration and harshness. To disengage the alternator and remove it s effects on the drive system, INA has developed the overrunning clutch belt pulley. This belt pulley is assembled on the alternator shaft and is integrated within the belt drive. These units are mainly used: in diesel engines in direct injection gas engines in V-engines with cylinder row shut-down at reduced idle speed in automatic transmissions with high shifting impulse with increased noise requirements at idle speed (use of a Dual-Mass Flywheel) for alternators with high moment of inertia INA overrunning clutch belt pulleys: disengage the alternator from the rotational irregularities of the crankshaft. reduce the noise of belt vibrations. reduce the force levels in the belt drive at idle speeds, during engine startup and shut-down. improve the noise behavior in the belt drive. increase the durability of the belt. reduce the tensioner forces and shorten the tensioner paths, resulting in increased durability of the belt tensioner. increase the average alternator speed in the idle speed range. are economically manufactured in a modular construction system, which includes the standard disengagement unit. prevent possible whistling noises (slipping) of the belt during up-shifting under full load. cannot come free from the alternator shaft during operation, unlike rigid belt pulleys. are designed so that no changes in the alternator shaft are necessary. are supplied with a protective cover which protects it against dirt and spray. The visible surface of the belt pulley has an anti-corrosion layer.
3 Overrunning Pulleys Table of Contents Interchange... 2 Interchange... 2 OAP Interchange... 5 Buyers Guide... 7 Design Functional Test Damage Symptoms Notes Schaeffl er Group USA Inc. All rights reserved. Printed in U.S.A.
4 ALTERNATOR INTERCHANGE ALTERNATOR INTERCHANGE INA INA BMW (Bosch) BMW (Valeo) Bosch Bosch
5 ALTERNATOR INTERCHANGE INA INA Bosch GB GB GB Denso TN Fiat (Valeo) Ford 98VW EA YM CA Ford (Bosch) VW ABA VW10300EA VW BA VW CA GM GM (Valeo) Hyundai (Nippon Denso) Kia (Melco) 0K29T Kia (Poong Sung) 0K K A K B Mazda K AT K B K C K D Mazda (Melco) BPE BPE FS Mercedes (Bosch) Mercedes (Bosch) Mercedes (Delphi) Mitsubishi (Valeo) A004TF A4TF S S Nissan (Bosch) QBB Nissan (Hitachi) W VC Nissan (Valeo QAL Porsche (Bosch) B PSA (Valeo) 57054F H J A ER GC Renault (Bosch) Renault (Valeo) Saab Steyr
6 ALTERNATOR INTERCHANGE INA INA VAG (Bosch) A B A B H G S E F P J B N Q S G H J K L B E D B AB B B B P B Q C D G H A L S T Q K VAG (Hitachi) G VAG (Valeo) A D E T D E R A S Valeo E A14VI SG12B SG12B SG12B SG12B SG12B SG12B SG12B Volvo Volvo (Bosch) Volvo (Denso) Volvo (Valeo)
7 OAP INTERCHANGE OAP INTERCHANGE INA INA BMW F Bosch AA 7V F F GD F00M F00M F00M F00M F00M F00M F00M F00M F00M F00M F00M F00M F00M F00M F00M F00M F00M F00M F00M F00M F00M F00M F00M F00M F00M F00M F00M Delphi F F Delphi Denso Ford 1S7U-10A352-DB XW4U-10A352-AA YM2E-10N356-AA Hitachi GD GD GD GD GD Hyundai Isuzu Kia OK W Mazda GY GY A GY02-18-W37Z K W LF Mercedes F F Mitsubishi 1800A Nippon Denso
8 OAP INTERCHANGE INA INA Nissan W W20A Porsche F PSA Renault Saab VAG H J B AC AM S T F A L M P T C B B B E Valeo K Visteon VP2M5U-10A352-AA VP5L8U-10A352-AA VP6S4U-10A352-AA XW4U-10325AA F Volvo F VW AA
9 Lester # Outer Diameter Length Bosch VW AA References BUYERS GUIDE BUYERS GUIDE Bosch A A A A Ford (Bosch) A 97VW10300EA 120A VAG (Bosch) G 120A J 90A 6K A VW Golf III 1.9 D, TD, GTD, TDI, -Cabrio Golf IV 1.9 TDI Passat / -Variant 1.9 TDI, 2.9 VR6 Syncro Ford Galaxy 1.9 TDI Lester # Outer Diameter Length
10 BUYERS GUIDE Lester # Outer Diameter Length Bosch Mercedes Valeo References Bosch A A A A A A Mercedes (Bosch) A, 115A A A Mercedes All Models C 200 TD, 220 TD, 250 TD E 200 D, 220 D, 250 D, TD, 290 D, 300 D, TD G 300 DT, S 300 TD Lester # Outer Diameter Length Grooves5 Bosch VAG T References Bosch A A VAG (Bosch) S 90A A F 120A Q 70A VW Passat/ -Variant 1.9 TDI, -Syncro 8
11 Lester # Outer Diameter Length Grooves5 Bosch F00M VAG B AC M Valeo References BUYERS GUIDE Bosch A A A A A Ford (Bosch) 95VW ABA 120A VAG (Bosch) B 120A N 150A Q 140A S 120A A VAG (Valeo) A 120A D 120A E 120A T 90A D 90A E 120A R 140A A 120A A 120A Valeo SG12B A Audi A4 / A6 1.6, 1.8, 1.9 TD, 1.9 TDI VW Golf IV Variant, Passat 1.6, 1.8, 2.0, 1.9 TDI Ford Galaxy 1.9 TDI Lester # Outer Diameter Length Grooves5 References Bosch A VAG (Bosch) D 120A Bosch VAG C Audi A6 1.8, 1.8 T, 1.8 T Quattro 9
12 BUYERS GUIDE Lester # Outer Diameter Length Grooves5 References Bosch A VAG (Bosch) 06B B 120A Manufacturer Bosch VAG Manufacturer No. F00M P Audi A4, A6 1.8 T, 1.8 T Quattro VW Passat 1.8, 1.8 T Lester # Outer Diameter Length Grooves5 Bosch VAG S References Bosch A A A A A VAG (Bosch) A 90A B 70A P 90A VW All Models1.7 SDI 10
13 Lester # Outer Diameter Length Bosch VAG References BUYERS GUIDE Bosch A A A A A Ford (Bosch) 98VW BA 90A VAG (Bosch) G 70A H 90A J 120A A 120A Audi A3 1.9 TDi VW Golf IV 1.9 SDI, 1.9 TDI 2.3 V5 New Beetle 1.9 TDI Lester # Outer Diameter Length Bosch F00M F00M F00M Hitachi GD VAG AM A T Valeo References Audi A2 1.4 TDI A3 1.9 TDI, 1.9 TDI Quattro TT 1.8 T, 1.8 T Quattro VW Golf IV 1.9 SDI, 1.9 TDI New Beetle 1.9 TDI, 2.0 Ford Galaxy All Bosch A A A A A A A A A A A A A Ford 98VW EA 120A YM CA 150A Ford (Bosch) 98VW CA 90A VAG (Bosch) A 150A H 120A E 120A K 70A L 90A A B 70A E 90A VAG (Hitachi) G 120A VAG (Valeo) S 120A 11
14 BUYERS GUIDE Lester # Outer Diameter Length Bosch GD5 036 Mercedes References Bosch GB A GB A GB A Mercedes (Bosch) A Steyr A Mercedes G-Class All Lester # Outer Diameter Length Bosch F00M VAG L B References Bosch A A A A VAG (Bosch) C 90A D 120A G 90A H 120A VW Passat 2.3 VR5, -syncro Golf IV, New Beetle 2.3 V5 12
15 Lester # BUYERS GUIDE Outer Diameter Length Bosch F00M Mercedes Mercedes C-Class, E-Class 2.0, 2.2 T References Bosch A A A A A A A Mercedes (Bosch) A A A A A A A A A A Lester # Outer Diameter Length References Mercedes (Delphi) A A A Bosch AA 7V0 Delphi Mercedes Mercedes C-Class, E-Class 2.0, 2.2, 2.7 T 13
16 BUYERS GUIDE Lester # Outer Diameter Length Ford XW4U-10A352-AA YM2E-10N356-AA Mazda GY K W11 References Mazda K AT 90A K B 90A K C 90A K D 90A Ford Probe II 2.5 V6 Mazda 626 IV Hatchback All Lester # Outer Diameter Length Denso Volvo References Denso TN A Volvo (Denso) A A A A Volvo C 70, S 40, S 60, S 70, 2.0 T, 2.4 T, 2.5 T S 80, V 40, V 70 14
17 Lester # Outer Diameter Length Bosch F00M Porsche References BUYERS GUIDE Bosch A A Porsche (Bosch) A A Porsche Boxter 986, Carrera , 3.4 GT Lester # Outer Diameter Length References Bosch A Bosch F00M Volvo Chrysler Voyager 2.5 TD 15
18 BUYERS GUIDE Lester # Outer Diameter Length Volvo References Volvo (Valeo) A A A A A A A A A Volvo S 40, V DI, 1.9 DCI Lester # Outer Diameter Length Valeo References GM (Valeo) A A Mitsubishi (Valeo) S A Renault (Valeo) A A Valeo E 125A SG12B A SG12B A SG12B A Volvo (Valeo) A A Nissan All ModelsAll 16
19 Lester # BUYERS GUIDE Outer Diameter Length Denso Jaguar S-Type All Lester # Outer Diameter Length Delphi GM All ModelsV6 LX5 17
20 BUYERS GUIDE Lester # N/A Outer Diameter Length Grooves5 References Kia (Poong Sung) 0K A 0K A 85A 0K B 85A Manufacturer Kia Manufacturer No. OK W11 Kia All Models2.9 TDI Lester # Outer Diameter Length Manufacturer Mazda Manufacturer No. GY A GY02-18-W37Z References Kia (Melco) 0K29T A Mazda (Melco) BPE A BPE A FS A Mazda MPV II, B-Series 2.5 V6 MX IV 1.8,
21 Lester # Outer Diameter Length References BUYERS GUIDE Bosch A GM A Saab A Isuzu Saab Saab , TiD Lester # Outer Diameter Length PSA Valeo References Fiat (Valeo) A Mitsubishi (Valeo) A004TF A A4TF A PSA (Valeo) 57054F 150A 57055H 150A 57055J 150A 5705GC 150A Valeo A A14VI35 150A Peugeot All Models All 19
22 BUYERS GUIDE Lester # Outer Diameter Length Bosch F00M VAG 06B B Valeo References Bosch A A A VAG (Bosch) 06B AB 140A 06B P 120A 06B Q 150A Audi A4 1.6, 1.8, -T, Cabriolet, 1.8 T Quattro, 2.0 A6 2.0, 2.0 FSI Lester # Outer Diameter Length Grooves7 Bosch F00M Mercedes References Bosch A A A A Mercedes (Bosch) A A Mercedes C, CLK Engine Code M271-20
23 Lester # BUYERS GUIDE Outer Diameter Length Lester # Outer Diameter Length Hitachi GD GD Nissan Altima 2.5 GDI 21
24 BUYERS GUIDE Lester # Outer Diameter Length References Hyundai (Nippon Denso) A Nippon Denso Hyundai Elantra, Santa Fe 2.0 D, Engine Code D4EA Kia Cerato, Sportage All Lester # Outer Diameter Length Grooves5 Valeo Volvo References GM (Valeo) A Mitsubishi (Valeo) S A Nissan (Valeo QAL 120A Valeo A A A SG12B A SG12B A SG12B A Volvo A Volvo (Valeo) A A Volvo 2 T, S 40, V 40 Engine Code D419 22
25 Lester # Outer Diameter Length Manufacturer Bosch Manufacturer No. F00M F00M Mercedes Valeo References BUYERS GUIDE Bosch A A A A A A A A A Mercedes (Bosch) A A A A A Mercedes Sprinter 2-T, Engine Code 0M , 0M , 0M , 0M Sprinter 3-T, Sprinter 4-T Lester # Outer Diameter Length Bosch F00M F00M F00M VAG H E Volvo References Bosch A A A VAG (Bosch) L 150A S 150A T 120A A Volvo (Bosch) A A A A VW Transporter 2.5 TDI Volvo S 60, S 70, S 80, V 70, XC 70 Engine Code D5244T 23
26 BUYERS GUIDE Lester # N/A Outer Diameter Length Grooves7 References Nissan (Hitachi) W201 90A VC201 90A Hitachi GD Nissan W W20A Nissan Terrano 2.7 ZD Lester # Outer Diameter Length Grooves8 References Bosch A Mercedes (Bosch) A Mercedes Mercedes All ModelsEngine Code 0M904, 0M906, 0M924 24
27 Lester # Outer Diameter Length Manufacturer Bosch Manufacturer No. F00M F00M F00M F00M Volvo Volvo C 70, S 60, V 70, S , 2.3 T, 2.4 T5 Turbo, XC D5 XC T, D5 References BUYERS GUIDE Bosch A A A A A Volvo (Bosch) A A A A A A A A A A A A A A A Lester # N/A Outer Diameter Length Valeo References Fiat (Valeo) A PSA (Valeo) 5705A1 150A 5705ER 150A Valeo A Suzuki Vitara 2.0 TDI 25
28 BUYERS GUIDE Lester # Outer Diameter Length Manufacturer Ford Manufacturer No. 1S7U-10A352-DB Ford All Models All Lester # Outer Diameter Length BMW Bosch F00M F00M References BMW (Bosch) A A Bosch A A 26 BMW 316i, 316i Touring, 316Ci Coupe, 316ti Compact, 318i, 318i Touring, 318Ci Cabrio, 318Ci Coupe, 318ti Compact All
29 Lester # Outer Diameter Length Bosch Delphi Mercedes Valeo References BUYERS GUIDE Bosch A A A A A Mercedes (Bosch) A A A A A Hyundai Sorrento 2.5, 2.9 Mercedes Vito 108 D 2.3, 110 TD 2.3, V230 TD Lester # Outer Diameter Length Grooves8 References Bosch A Mercedes (Bosch) A Bosch Mercedes Mercedes All ModelsEngine Code 0M904, 0M907 27
30 BUYERS GUIDE Lester # Outer Diameter Length Grooves7 Valeo K Hyundai All Models All Lester # Outer Diameter Length Grooves7 Bosch F00M Delphi Hitachi GD VAG J References Bosch A Porsche (Bosch) B 150A A VAG (Bosch) B 150A Porsche Cayenne 3.2 VW Touareg 3.2,
31 Lester # Outer Diameter Length Manufacturer Bosch Manufacturer No. F00M F00M Mercedes References BUYERS GUIDE Bosch A A Mercedes (Bosch) A A Mercedes E-Class W211, S Lester # Outer Diameter Length Manufacturer Mazda Manufacturer No. LF Mazda All Models All 29
32 BUYERS GUIDE Lester # Outer Diameter Length Grooves5 Kia Kia All Models All Lester # Outer Diameter Length Grooves8 References Porsche (Bosch) A A Manufacturer Bosch Manufacturer No. F00M
33 Lester # BUYERS GUIDE Outer Diameter Length Manufacturer Visteon Manufacturer No. VP2M5U-10A352-AA VP6S4U-10A352-AA Lester # Outer Diameter Length Manufacturer Bosch Manufacturer No. F00M Buick Regal 3.5 V6 31
34 BUYERS GUIDE Lester # Outer Diameter Length Hyundai Nippon Denso Hyundai All Models All Lester # Inner Diameter Outer Diameter Length Renault References Nissan (Bosch) QBB 150A Renault (Bosch) A A A A Renault All Models All 32
35 Lester # Outer Diameter Length BMW Valeo References BUYERS GUIDE BMW (Valeo) A A A A A A A A A A BMW All ModelsN42, N52 Engine, Valeo Lester # Outer Diameter Length Manufacturer Visteon Manufacturer No. VP5L8U-10A352-AA 33
36 BUYERS GUIDE Lester # N/A Outer Diameter N/A N/A Length N/A N/A GroovesN/A Valeo Lester # N/A Outer Diameter N/A N/A Length N/A N/A GroovesN/A Valeo
37 Lester # N/A BUYERS GUIDE Outer Diameter Length GroovesN/A Mercedes Valeo Lester # N/A Outer Diameter N/A N/A Length N/A N/A GroovesN/A Manufacturer Mitsubishi Manufacturer No. 1800A061 35
38 BUYERS GUIDE Lester # N/A Outer Diameter N/A N/A Length N/A N/A GroovesN/A 36
39 DESIGN DESIGN An overrunning clutch belt pulley consists of: 1) Belt pulley 2) Overrunning clutch unit 3) Integrated radial support bearings 4) Inner sleeve with ramp profile 5) Inner ring 6) Serration 7) Elastomer gasket 8) Contact plate with lip gasket 9) Plastic cover Axial belt guide forces are absorbed within the overrunning clutch unit. The axial clearance means the belt track is self -adjusting. This signifi cantly improves the noise behaviour of the belt running in the profile, as the belt is not positively driven on the alternator driving wheel. The mounting hole for the overrunning clutch belt pulley is designed so that no changes in the shaft of the alternator are necessary. The inner ring is secured on the shaft by a fi ne thread. The serration is used to transfer the tightening torque. A protection cover over the front protects the unit against dirt and spray. The visible surface of the belt pulley has an anti-corrosion layer Belt pulley 2. Overrunning clutch unit 3. Integrated radial support bearing 4. Inner sleeve with ramp profile 5. Inner ring 6. Serration 7. Elastomer gasket 8. Contact plate with lip seal 9. Plastic cover 37
40 FUNCTIONAL TEST FUNCTIONAL TEST Overrunning alternator pulley / Overrunning clutch belt pulley Checking the function of an overrunning alternator pulley/overrunning clutch belt pulley is difficult to assess while installed. It is recommended that you remove the OAP from the alternator before testing it. 1. Secure the inner ring (Fig. 1 and 2) 2. Turn the outer ring in the drive direction of the alternator. If working correctly, the outer ring will not turn. 3. Turn the outer ring against the drive direction of the alternator and hold the inner ring at the same time. The outer ring should turn with slight resistance. Fig. 1: Securing the inner ring Important: If either of these functionality tests fail, the overrunning clutch belt pulley must be replaced. Fig. 2: Securing the inner ring! Operation is only permitted while protection cover is in place! 38
41 DAMAGE SYMPTOMS DAMAGE SYMPTOMS Damage symptoms 1 Profile peaks very worn (Fig. 3) Causes: Tension in the drive is too low. The belt slips over the overrunning clutch. The overrunning alternator pulley does not work. Fig. 3: Worn profi le peaks Damage symptoms 2 Guide edge abraded (Fig. 4) Causes: Misalignment between the rolls of the assemblies (installation error) Belt fitted incorrectly Fig. 4: Guide edge abraded 39
42 NOTES 40
43 Innovation - Global Research and Development Facilities - Advanced Engineering and Manufacturing Capabilities - A Leader in Automotive, Industrial and Aerospace Technology Quality - ISO Certified - Backed by a Team of Quality Control Experts - A Proven History of Meeting and Exceeding Customer Expectations A Trusted Partner - Original Equipment Supplier to the World s Major Automobile Manufacturers - A Commitment to Customer Satisfaction Schaeffler Group USA Inc Wegman Drive Valley City, OH Phone Fax schaeffler-aftermarket.us Customer Service Phone Fax [email protected]
44 Schaeffler Group USA Inc Wegman Drive Valley City, OH Phone Fax LIT077
Schaeffler Automotive Aftermarket INA Overrunning Alternator Pulleys REMATEC 2009 June 9th.
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